On the Road to a New Large-Scale Sweet Sorghum Industry in the USA
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1 On the Road to a New LargeScale Sweet Sorghum Industry in the USA Gillian Eggleston Lead Scientist Sugar & Energy CRIS Project USDAARSSRRC New Orleans, LA, USA
2 Presentation Outline Relevant USDAARS research Advantages of sweet sorghum over other crops Largest operational sweet sorghum biorefinery in USA: Heckemeyer Mill, Sikeston, MO, USA
3 1. Quality and Utilization of Agricultural Products (NP306) 2. Bioconversion, Biofuels & Biobased Products (NP213)
4 Quality and Utilization of Agricultural Products
5
6 Sugar and Energy Project (New Orleans) Develop Technologies That Enable Growth and Profitability in the Commercial Conversion of Sugarcane, Sweet Sorghum, and Energy Beets into Sugar, Advanced Biofuels, and Bioproducts Sugarcane for Sugar Manufacture Sweet Sorghum and Energy Beets for Advanced Biofuels and Bioproducts
7
8 Supply Chain Components for Sweet Sorghum and Energy Beets and Integration of Project Objectives and Subobjectives System Performance Metrics Feedstock Logistics Sweet Sorghum Feedstock Development 5A, 5B Energy Beets Harvesting Grower Payment Feedstock Production System 5A 5C Harvesting Tandem Roller Mills 6C Diffusion (Both Crops) 6C Direct Mash Fermentation 4B Sugar stabilization, concentration, transport, and storage for different endproducts 3B, 3C, 6D Advanced Biofuels and Bioproducts Conversion 4A to C Sweet Sorghum bagasse VAP 3C, 6B VAP=value added products
9 Biomass Conversion Technologies CHEMICAL Oleochemical/Chemical Platform THERMOCHEMICAL Gasification Platform Fuels, Chemicals, Energy & Coproducts BIOCHEMICAL Sugar Fermentation Platform
10 The Development of the Sugar Platform Will Depend On: Application of chemical and biocatalysts to transform sugars into useful biobased chemical intermediates and downstream products Successful scaling up of biocatalysts from proofofconcept experiments on a laboratory scale to commercial industrial process scale only beginning to emerge Availability of economic, readilyavailable source or sources of sugar feedstocks (expected to transition to lignocellulosic derived sugars) At present mainly focused on corn, cassava starch, and sugarcane molasses Availability of stable, transportable, and storable feedstocks for yearround use
11 Sweet Sorghum
12 Advantages of Sweet Sorghum over Other Crops for Biofuels and Bioproducts Adapts well to adverse environments Requires relatively low inputs Easily fermentable sugars Much easier to ferment than grains 1 2 crops per year NonGMO Very high energy balance Comparable efficiency as sugarcane Can be processed with a dual feed stock Makes it a low cost seasonal crop Sugarcane and sugar beet Genetic improvement potential is HUGE Hybrid and tailormade sweet sorghum cultivars
13 World Map Depicting Approximate Areas Where Sweet Sorghum, Sugarcane, and Sugar Beet can be Grown Limit for grains 70 o 60 o 52 o Sugar beet Sugar cane Skip Text Links Sweet Sorghum Adapted from Debor (2009).
14 Sweet Sorghum Versatile in use: Foodgrade syrup Biobased chemicals Use in Premium Spirits Livestock sweet forage Biobased products from bagasse Nutritional grain Partly from: Brent Crafton
15 For Sweet Sorghum to Succeed as an Advanced Fuel or Bioproduct: Grower behavior must be driven thru economics Sweet sorghum must be more efficient than corn Need year round production & processing technologies
16 Advantages and Disadvantages of Sweet Sorghum as a Biofeedstock Compared to Sugarcane and Corn Parameter* Sweet Sorghum Sugarcane Crop duration (months) Juice purity (%) ~ N/A * Average values This could change with application of high temp stable amylases Corn Relative energy efficiency 1:8 1:9 1:1.6 Water requirement/crop (cm) Grain yield (t/ha) 4.9 n/a 3.6 Stalk yield (t/ha) Ethanol from grain (L/ha) Ethanol from juice (L/ha) ~ Relative deterioration rate Medium Fast Medium Fast N/A Yusupov (2009) Proc. SSEA, Orlando, FL Eggleston et al (2010) In: Industrial Crops and Uses, CABI International
17 Several private sector companies in the USA are pursuing the development of sweet sorghum as a new domestic industrial sugar feedstock, including Florida Southeast Renewables (Lake Okechobee) Highland Envirofuels LLC (Riverview)
18 Largest Sweet Sorghum Biorefinery in the USA
19 Heckemeyer Mill Sikeston, Missouri, USA Poultry Cattle x Timber Row crop sweet sorghum
20 Heckemeyer Mill
21 Heckemeyer Mill Cultivars: M81E, Honey Drip, Dale, Top 766, KY 1810 Plant late May/Early June Stagger the rotation for timely harvest Process from Mid August (depends on Juice Brix) Combine (Billeted) Harvesting 6 to 9 inch billets
22 Process Flow Chart in 2012/2013 (Not Operational) Milling Bagasse Evaporation Open Pan Foodgrade syrup Dilution water Projected liquid ethanol Fermentation Distillation Chemicals Vinasse
23 Digital Micrographs Juice Stained with Filtered Iodine Solution Honey Drip Raw Juice ~1.0 to 20.0 µm M81E Raw Juice ~1.0 to 28.4 µm 8,979 ppm/brix Total Starch 7,228 ppm/brix Total Starch Both starch concentration & granule size contribute to sweet sorghum processing problems in the largescale biorefinery
24 Settling of Raw Juice ~3.8 to 23.7 μm (small to medium sized starch granules) settled
25 Improved Settling of Raw Juice with Deaeration Vacuum Tank
26 Sweet Sorghum Juice Clarification Andrzejewski et al (2013a,b). Industrial Crops & Products Eggleston et al (2014). Industrial Crops & Products. 80 C; ph 6.5 with milk of lime; polyanionic flocculant 5 ppm cane juice particle coagulated colloids calcium phosphate forms Ca 2+ flocculant added Ca 2+ Ca 2+ Heat Ca 2+ Ca 2+ PO 4 3 Ca 2+ Ca 2+ Ca 2+ Lime + phosphate in juice 3 PO Ca 2+ 4 Ca 2+ larger flocs Ca 2+ adsorbed colloidal particles, i.e., proteins, polysaccharides Ca 2+ Precipitation in clarifier tank Ca 2+ Ca 2+ Heated Floc Calcium Phosphate Bridging Large Cultivar Effect
27 Scum formed on surface Heated, Deaerated Sweet Sorghum Juice Formation of Flocs (Light Color) which are Starting to Precipitate Clarified Juice 92% Turbidity Removal over 1 hr
28 Clarified Juice large granules mostly removed solubilization of starch 305 NTU Clarification Mud < 1 hr Settling Clarification Mud > 1 hr Settling Medium to large starch granules: ~1.0 to 44.5 μm More Medium to large starch granules: ~1.0 to 52.2 μm
29 Clarification also Stabilizes Sweet Sorghum Juice Top 766 cultivar Eggleston et al (2015). Industrial Crops & Products.
30 Overall Process and Supply Chain for Syrup Production at Heckemeyer Mill December 2014 Extraction Deaeration Settling Heating Clarification Evaporation ensiled bagasse sediment High Value Cattle Feed mud V. minimal waste processing Quality Control Stabilization of Juice Assurance of Supply Business Continuity
31 Since December 2014
32 Overall Process and Supply Chain for Syrup & Whiskey Production at Heckemeyer Mill 2016 Extraction Deaeration Settling Clarification 15 Bx Clarified Juice Storage TripleEffect Evaporation Pan Seeds 10% Ensiled Bagasse 44.1% Sediment 9.2% Mud 7% Reverse Osmosis 65 Bx Syrup Storage High Value Cattle Feed 28 Brix Fermentation diln
33 Heckemeyer Mill 2016 Targets (Sept to Nov) 200 acres 16 tons/acre; (can go up to 22) Brix 200 gal of 80 Brix syrup per acre 30,000 gal (capacity 40,000 gal) of 80 Brix syrup Food grade syrup & whiskey
34 Sweet Sorghum Syrup Storage Need to stabilize and concentrate juice to a stable syrup for efficient and effective yearround supply, transport, and storage 6065 Brix syrups preferred due to handling, piping High Brix syrups susceptible to fungal deterioration (surface), lower Brix syrups (less than ~40 Brix) susceptible to lactic acid bacteria Vegetable oils, e.g., soy bean oil, can act as surface sealants and allow storage of sweet sorghum syrup up to 1 year. Large scale trials later this year Eggleston et al (2015) Biomass Bioenergy
35 ReIntroduction of Sweet Sorghum Syrup as a Large Scale, Commercial Liquid Sweetener Replacement for high fructose corn syrup Not high in fructose Natural Non GMO Glutenfree Can be produced free of additives and preservatives Antioxidants Unique flavor profile (studies) Possible source of nonanimal protein
36 Thank You
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