Improved Uses and Values for the Byproducts of the Developing Biofuels Industry

Transcription

1 Iowa State University From the SelectedWorks of Kurt A. Rosentrater August 25, 2008 Improved Uses and Values for the Byproducts of the Developing Biofuels Industry Kurt A. Rosentrater, United States Department of Agriculture Available at:

2 The DDG Consortium Pursuing Improved Uses and Values for Byproducts of the Biofuels Industry Kurt A. Rosentrater, Ph.D. Lead Scientist, Bioprocess Engineer USDA ARS North Central Agricultural Research Laboratory Brookings, South Dakota, USA 1

3 Overview Biofuels industry Relevance Partnerships Accomplishments Future directions 2

4 Exciting Times in US Agriculture In the midst of many changes DDGS Ethanol Many opportunities for rural America Not only biofuels But also byproducts/coproducts DDGS (million metric tons) Ethanol (million gallons) Corn Cellulosic Year Boon vs. bane? Fuel vs. food vs. feed? 3

5 Ethanol Coproducts Condensed Distillers Solubles Distillers Dried Grains with Solubles Dryer Distillers Wet Grains DDGS 2000: 3.5 million metric tons 2007: 16 million metric tons Sales = Key to economic viability ~ 15 to 40% of income stream 460% growth over 7 years 4

6 Biofuel Research in ARS Major thrusts 1) Feedstock development 2) Feedstock production 3) Conversion / coproducts Starch-based ethanol coproducts Conduct research that Is nationally relevant Meets local customer needs More information found at: 5

7 What are Customers Needs? Focus group meeting Held on June 2, 2005 At USDA-ARS NCARL in Brookings, SD Purposes To determine current needs of Companies that produce distillers grains Customers that utilize distillers grains Identify Current constraints Research needs Future directions 50 participants Government agency officials (local, state, federal) SD Congressional delegation Livestock producers Ethanol industry Processors Marketers Research & development University research faculty More information found in: Rosentrater, K. A. and K. E. Dashiell Improving the Value and Utilization of Distillers Grains A Focus Group Discussion North Central ASAE/CSBE Conference, Brookings, SD. ASAE Paper No. SD St. Joseph, MI: ASAE. Presented September 30,

8 Coproducts Key Issues Mountains of distillers grains Standardized grading system Livestock feed Current generation products Next generation products Processed feeds New species Antibiotic residues Sulfur / phosphorous Aflatoxin contamination Energy consumption / cost Optimizing quality w/ ethanol New / evolving coproducts Consistency / variability Transportation Domestic International Other value-added uses Human foods Industrial products 7

9 DDG Consortium Research To meet these needs Established a multi-disciplinary research endeavor Research objectives 1) Improve storage and logistics of coproducts 2) Convert coproducts into value-added a) Feeds b) Food ingredients c) Industrial products Anticipated outcomes Augment viability of fuel ethanol industry Improve manufacturing economics Better methods for storing and handling DDGS New markets for DDGS Improve use by livestock industry 8

10 Vision Improve the Value and Utilization of Distillers Grains Can achieve this by Addressing industry s challenges Creating new opportunities & markets More information found in: Rosentrater, K. A Ethanol processing coproducts a review of some current constraints and potential directions. International Sugar Journal 109(1307):

11 How? Synergy Customers Stakeholders USDA-ARS NCARL SDSU Processes DDGS Research Pipeline Products Industry Needs Publications/ Tech Transfer National Programs MBI More information found in: Visser, J. and K. A. Rosentrater Partnership in undergraduate research experience. Paper No. AC ASEE Annual Conference & Exposition, Honolulu, Hawaii. Presented June,

12 Major Discoveries to Date Flowability Feeds Industrial products DWG 11

13 Major Discoveries to Date Flowability Importance 1296/9400 livestock operations in Midwest used coproducts in 2006 (NASS, 2007) 13.8% Much DDGS is shipped out of the corn belt 10-20% of all railcars are hard unload 1.6 million tons in 2007 would not discharge from rail car hoppers Significant economic losses And frustration Need to know Why does DDGS have flowability problems? How to prevent from happening? Tools to remediate this problem? 12

14 Major Discoveries to Date Flowability Particle consolidation Why does DDGS have flowability problems? Sometimes vs. always? Potential factors: DDGS dryer DDGS cooler Soluble addition Moisture content State of sugars Microbial exudates Chemical reactions Temperature Processing Storage Environmental Humidity Compaction Vibration Cure time Storage time Processes Products Conditions 13

15 Major Discoveries to Date Flowability Accomplishments Determined Physical Properties of DDGS Defined DDGS Relationships with Water Quantified DDGS Flowability Shear Strength (kg/cm 2 ) T=25 C 0.4 T=45 C Linear (T=45 C) 0.2 Linear (T=25 C) Pressure (Pa) FLOW INDEX CDS LEVEL (%) MOISTURE (%) FLOW INDEX More information found in: Shear Strength (kg/cm 2 ) Pressure (Pa) t=5 days t=15 days Linear (t=15 days) Linear (t=5 days) FLOOD INDEX CDS LEVEL (%) FLOOD INDEX MOISTURE (%) Ganesan, V., K. Muthukumarappan, and K. A. Rosentrater Effect of moisture content and soluble level on the physical, chemical, and flow properties of distillers dried grains with solubles (DDGS). Cereal Chemistry 85(4):

16 Major Discoveries to Date Feeds Accomplishment Pelleted 100% DDGS Importance Feedlots; range Flowability ~30% bulk density increase Next steps Various die geometries Various sources of DDGS Pelleting hot vs. cold DDGS Multiple production scales Range cubes Cost More information found in: Rosentrater, K. A Can you really pellet DDGS? Distillers Grains Quarterly 2(3):

17 Major Discoveries to Date Feeds - Beef Objectives Use of coproducts to enhance efficiency of beef production Methods to increase the use of coproducts Accomplishments At inclusions >10% diet (accounts for CP needs), DGS has 88% the energy value of corn 22% DDGS diets lower (P<.01) consumer panel acceptance of ground beef; but tend (P=.06) to improve tenderness of steaks In vitro: Glycerol levels <13% do not depress forage DMD; Levels up to 24% cause a net increase (P<.05) in apparent DMD 16

18 Major Discoveries to Date Feeds - Dairy Objectives Replacement of starch from corn with non-forage fiber from distillers grains Long-term feeding of distillers grains on productivity and health of dairy cows Effect of distillers products on milk fatty acid composition Optimal dietary ruminally undegradable protein (RUP) and ruminally degradable protein (RDP) content of diets containing distillers grains Accomplishments Non-forage fiber from DG can partially substitute for starch (up to 1/3 of starch removed from diet) Distillers grains may be fed at 15% diet DM throughout the lactation and gestation cycle without negative consequences Health or productivity Feeding ethanol coproducts increases CLA and TVA in milk fat Replacing soybean protein as a source of RUP with DDGS at 11 and 22% of the diet increased milk and component yields 17

19 Major Discoveries to Date Feeds - Aqua Accomplishment Developed DDGS-Based Tilapia Diets Up to 60% of the diet Importance Much potential to use DDGS Other types of animals Aquaculture feeds; pet foods Could displace expensive, animal-based proteins Alternative protein source for aquaculture $180/ton vs. $1000/ton Research currently very limited Feeding Need a complete ration Not just DDGS Processing Lack of starch; high protein/fiber Difficult to stick together Difficult to produce floating feeds 18

20 Major Discoveries to Date Feeds - Aqua Diets (%) Ingredient Control DDGS Soy flour Corn Fish meal Cod liver oil Soybean oil Vitamin mix Mineral mix Proximate Composition (%) Total moisture Crude protein Crude fat Crude fiber Ash Energy (kcal/kg) 2,176 2,296 2,475 2,397 20% DDGS equivalent to Control Protein efficiency ratio Weight gain (g) C C Feed conversion ratio Muscle ratio (%) C C DDGS Inclusion (%) 19

21 Major Discoveries to Date Industrial Products Accomplishment Developed Biodegradable Plastic Composites using DDGS Up to 90% DDGS/10% phenolic resin Compression molding Importance Little investigated in the industrial products arena DDGS contains high fiber, amendable to bio-based composites Next steps Bio-based/bio-degradable polymers Moisture / hydrophobicity Chemical behavior / modification Other processes More information found in: Tatara, R. A., S. Suraparaju, and K. A. Rosentrater Compression molding of phenolic resin/corn-based DDGS blends. Journal of Polymers and the Environment 15(2):

22 Major Discoveries to Date DWG Accomplishment Predicting Stability of Distillers Wet Grains (DWG) using Color Analysis Color parameters can predict microorganism activity L a b y = x x R 2 = Hunter Value (-) y = x x R 2 = y = x x R 2 = Time (days) More information found in: Rosentrater, K. A. and R. M. Lehman Physical and chemical properties of corn distillers wet grains. Applied Engineering in Agriculture 24(1):

23 Current Research Focus Current coproducts of corn-to-ethanol manufacturing Essential to address these issues Will be important to continue to address these problems DDG Consortium Unique effort / research program As we move into the future Biofuels industry is evolving Must examine additional research directions Next-generation coproducts 22

24 New Research Directions Next Generation Fractionation offers exciting opportunities Separate component streams Oil biodiesel Fiber cellulosic ethanol Protein new animal feeds Fiber 1 st stage in lignocellulosic ethanol Ethanol DDGS High Protein / High Fiber DDGS High Protein DDGS Corn oil Biodiesel 23

25 New Research Directions Collaboration with MBI MBI ARS SDSU Lab/pilot biorefining R&D - Substrates - DDGS - Corn fiber - AFEX pretreatment - Fermentability - Xylan development Next-gen Biorefinery Byproducts Coproducts Value-added R&D - Physical/chemical properties - Storability, flowability - Value-added processing - Foods (humans) - Feeds (aqua) - Bioproducts (bioplastics) Next-gen Biorefinery Byproducts Coproducts Utilization R&D - Physical/chemical properties - Feed applicability/digestibility - Value-added uses trials - Feeds (beef, dairy, aqua) - Foods (humans) Other collaborators Main products - Ethanol - Industrial chemicals (succinic acid) - Biodiesel - Others? Other collaborators Next-gen coproducts - DDGS (traditional) - Deoiled DDGS - Defibered DDGS - Glycerol (soy diesel) Other collaborators Next-gen coproducts - DDGS (traditional) - Deoiled DDGS - Defibered DDGS - Glycerol (soy diesel) 24

26 New Research Directions Collaboration with MBI Accomplishments Ammonia Fiber Expansion (AFEX) Increase enzyme digestibility of corn fiber in DDGS Blank Sample 1 Sample 2 Gas (psi) 21 Sample 3 Sample 4 Sample 5 19 Sample 6 Cellulose Hemicellulose Fiber /27/2008 9:50 2/27/ :26 2/27/ :02 2/27/ :38 2/28/2008 0:14 2/28/2008 3:50 2/28/2008 7:26 2/28/ :02 Pretreatment Fermentation Ethanol Byproduct Accumulated gas production (psi) curves for 24 h incubation In vitro true DM digestibility (%) at 6, 24 and 48 h incubation DDG # 6 h St dev 24 h St dev 48 h St dev

27 New Research Directions Next Generation Coming wave for biofuels Many questions Processes/products Collection and storage? Conversion processes? Commercialization / scale-up? What about the byproducts? What are they? Properties? Remaining nutrients? Feed value? Soil amendments? Biomass energy gasification/pyrolysis Multiple scales including farm scale Chemical structure modifications? Corn-to-Ethanol DDGS Stover-to- Ethanol Residues Switchgrass-to- Ethanol Residues 26

28 Acknowledgements Many thanks to those who have contributed to the DDG Consortium s efforts MBI SDSU Ag Engineering; Dairy Science; Animal Science; Food Science; Fisheries, Engineering Technology, Experiment Station Private Industry Research partners USDA-ARS Technical staff Graduate students Undergraduate students 27

29 Improve the Value and Utilization of Distillers Grains Thank you Questions? Comments? Kurt Rosentrater USDA-ARS NCARL 2923 Medary Ave Brookings, SD (605)