Compatibility of High-Moisture Storage for Biochemical Conversion of Corn Stover: Storage Performance at Laboratory and Field Scales

Effect of nitrogen management in cultivation on the stability and microbial community of post-harvest Monoraphidium sp. algae biomass

Long-term storage is necessary to mitigate for seasonal variation in algae productivity, to preserve biomass quality and to guarantee a constant biomass supply to a conversion facility. While ensiling has shown promise as a solution, biomass attributes for successful storage are poorly understood. Storage studies of Monoraphidium sp. biomass indicate a strong correlation between nitrogen management in algae cultivation and stability of post-harvest algae biomass. Algae cultivated with periodic nitrogen addition were stored poorly (>20% loss, dry basis) compared to biomass from nitrogen depleted cultivation (8% loss, dry basis). A follow-up study compared the post-harvest stability of Monoraphidium biomass cultivated in nitrogen-deplete or nitrogen-replete conditions. Replete biomass experienced the largest degradation (24%, dry basis), while deplete biomass experienced the least (10%, dry basis). Dry matter loss experienced among blends of each correlated positively with nitrogen-replete biomass content. The composition of the post-storage algae microbial community was also affected by cultivation conditions, with Clostridia species being more prevalent in stored biomass obtained from nitrogen-replete cultivations. Nitrogen management has long been known to influence algae biomass productivity and biochemical composition; here, we demonstrate that it also strongly influences the stability of post-harvest algae biomass in anaerobic storage.

Impacts of Biological Heating and Degradation during Bale Storage on the Surface Properties of Corn Stover

The variability of chemical, physical, and mechanical properties of lignocellulosic biomass feedstocks has a major impact on the efficiency of biomass processing and conversion to fuels and chemicals. Storage conditions represent a key source of variability that may contribute to biomass quality variations from the time of harvest until delivery to the biorefinery. In some cases, substantial microbial degradation can take place during storage. In this work, we investigate how degradation during storage affects the surface texture, surface energy, and porosity of different corn stover anatomical fractions (e.g., leaf, stalk, and cob). Understanding any potential changes in surface properties is important because interparticle interactions during bioprocessing cause aggregation and blockages that lead to at least process inefficiency and at most complete equipment failure. The surface roughness and texture parameters of corn stover with variable degrees of microbial degradation were calculated directly from stereomicroscopy and scanning electron microscopy micrographs. Surface energy and porosity were measured by inverse gas chromatography. The results show differing trends in the impact of increasing biological heating and degradation depending on the specific corn stover tissue type that was analyzed. These results also indicate that biomass surface properties are scale-dependent and that the scale, which is most industrially relevant, may depend on the specific unit operation within the biorefinery being considered.

Chemical and Structural Changes in Corn Stover After Ensiling: Influence on Bioconversion

Production of biofuels, bioproducts, and bioenergy requires a well-characterized, stable, and reasonably uniform biomass supply and well-established supply chains for shipping biomass from farm fields to biorefineries, while achieving year-round production targets. Preserving and stabilizing biomass feedstock during storage is a necessity for cost-effective and sustainable biofuel production. Ensiling is a common storage method used to preserve and even improve forage quality; however, the impact of ensiling on biomass physical and chemical properties that influence bioconversion processes has been variable. Our objective in this work was to determine the effects of ensiling on lignocellulosic feedstock physicochemical properties and how that influences bioconversion requirements. We observed statistically significant decreases (p < 0.05) in the content of two major structural carbohydrates (glucan and xylan) of 5 and 8%, respectively, between the ensiled and non-ensiled materials. We were unable to detect differences in sugar yields from structural carbohydrates after pretreatment and enzymatic hydrolysis of the ensiled materials compared to non-ensiled controls. Based on this work, we conclude that ensiling the corn stover did not change the bioconversion requirements compared to the control samples and incurred losses of structural carbohydrates. At the light microscopy level, ensiled corn stover exhibited little structural change or relocation of cell wall components as detected by immunocytochemistry. However, more subtle structural changes were revealed by electron microscopy, as ensiled cell walls exhibit ultrastructural characteristics such as wall delimitation intermediate between non-ensiled and dilute-acid-pretreated cell walls. These findings suggest that alternative methods of conversion, such as deacetylation and mechanical refining, could take advantage of lamellar defects and may be more effective than dilute acid or hot water pretreatment for biomass conversion of ensiled materials.

Microbial Heat and Organic Matter Loss in an Aerobic Corn Stover Storage Reactor: A Model Validation and Prediction Approach Using Lumped-Parameter Dynamical Formulation

Corn stover dry matter loss effects variability for biofuel conversion facility and technology sustainability. This research seeks to understand the dynamic mechanisms of the thermal system, organic matter loss, and microbial heat generation in corn stover storage operations through system dynamics, a mathematical modeling approach, and response analysis to improve the system performance. This study considers epistemic uncertainties including cardinal temperatures of microbial respiratory activity, specific degradation rate, heat evolution per unit substrate degraded, and thermal conductivity in corn stover storage reactors. These uncertainties were managed through calibration, a process of improving the agreement between the computational and benchmark experimental results by adjusting the parameters of the model. Model calibration successfully predicted the temperature of the system as quantified by the mean absolute error, 0.6°C, relative to the experimental work. The model and experimental dry matter loss after 30 days of storage were 5.1% and 4.9 ± 0.28%. The model was further validated using additional experimental results to ensure that the model accurately represented the system. Model validation obtained a temperature mean absolute relative error of 0.9 ± 0.3°C and dry matter loss relative error of 3.1 ± 1.5%. This study presents a robust prediction of corn stover storage temperature and demonstrates that an understanding of carbon sources, microbial communities, and lag-phase evolution in bi-phasic growth are essential for the prediction of organic matter preservation in corn stover storage systems under environment's variation.

Evaluation of the effect of feruloyl esterase-producing Lactobacillus plantarum and cellulase pretreatments on lignocellulosic degradation and cellulose conversion of co-ensiled corn stalk and potato pulp

The effects of feruloyl esterase-producing Lactobacillus plantarum A1, cellulase, or their combination on the fermentation characteristics, carbohydrate composition, and enzymatic hydrolysis of mixed corn stalk and potato pulp silage were investigated. Two mixture ratios were used: a weight ratio of rehydrated corn stalk to potato pulp of 35:1 (HD) and a weight ratio of dry corn stalk to potato pulp of 5:11 (LD). No advantage was observed with the addition of strain A1 alone for lignocellulosic degradation and cellulose conversion, while its combination with cellulase enhanced the lignocellulosic degradation and preserved more fermentable carbohydrates in co-ensiled corn stalk and potato pulp. The enzymatic hydrolysis results indicated a potential benefit of pretreatment for biogas production, as the co-ensiled HD ratio mixture without additive treatment showed high glucose yield after enzymatic hydrolysis following 60 d of fermentation.

Effects of Storage Moisture Content on Corn Stover Biomass Stability, Composition, and Conversion Efficacy

Variable moisture content of biomass during storage is known to compromise feedstock stability, yet a great deal of uncertainty remains on how to manage or mitigate the issue. While moisture contents above 20% risk unacceptable losses in aerobic feed and forage storage, no quantitative relationship exists between corn stover moisture content and rates or extents of degradation for bioenergy use. This work quantifies the relationship between initial moisture content of aerobically stored corn (Zea mays L.) stover biomass and dry matter loss through time. Corn stover with 20% to 52% moisture was stored under aerobic conditions in laboratory reactors while dry matter loss was measured in real time, reaching extents of 8% to 28% by the end of storage. Rates and extents of degradation were proportional to moisture content but were not linearly related. A moisture content “threshold” exists between 36% and 52% above which rates and extents of degradation increase rapidly. Compositional changes included glucan and lignin enrichment resulting from hemicellulose component (xylan and acetyl) biodegradation. Moisture desorption characteristics of the post-storage materials suggest chemical and/or physical changes that increase biomass hydrophilicity. Monomerization of carbohydrates though dilute acid pretreatment and enzymatic hydrolysis resulted in only minor changes, suggesting that degradation does not negatively influence conversion potential of the remaining biomass. Total dry matter preservation remains one of the most significant challenges for a biorefinery.

Total and Sustainable Utilization of Biomass Resources: A Perspective

Feedstock cost is a major variable cost component in conversion to biofuels and chemicals. Consistent feedstock quality is critically important to achieve high product yield and maximum onstream time. Traditionally, raw biomass materials are delivered directly to the biorefineries where they are preprocessed to feedstock prior to being converted to products. Since many types of biomass materials-including agricultural residues, energy crops, and logging residues-are harvested according to growth cycles and optimal harvesting time, just-in-time steady supply of raw biomass to the biorefineries is not possible. Instead, biomass materials are stored, then delivered to the biorefineries as needed. Experience to date indicates that this approach has caused many issues related to logistics, biomass losses due to microbial degradation and fire, and inconsistent feedstock quality due to variability in the properties of as-delivered biomass. These factors have led to high feedstock cost, low throughput, and low product yield for the biorefineries. Idaho National Laboratory has developed a new strategy to address the problems encountered in the traditional approach in biomass feedstock supply, storage, and preprocessing mentioned above. The key components of this strategy are (1) preservation and preconditioning of biomass during storage, (2) utilization of all the biomass, including minor components that are normally considered wastes or contaminants, and (3) maximization of the value of each component. This new approach can be accomplished using feedstock preprocessing depots located near the biomass-production sources.

Review on Bioenergy Storage Systems for Preserving and Improving Feedstock Value

Long-term storage is a necessary unit operation in the biomass feedstock logistics supply chain, enabling biorefineries to run year-round despite daily, monthly, and seasonal variations in feedstock availability. At a minimum, effective storage approaches must preserve biomass. Uncontrolled loss of biomass due to microbial degradation is common when storage conditions are not optimized. This can lead to physical and mechanical challenges with biomass handling, size reduction, preprocessing, and ultimately conversion. This review summarizes the unit operations of dry and wet storage and how they may contribute to preserving or even improving feedstock value for biorefineries.

Preservation of Microalgae, Lignocellulosic Biomass Blends by Ensiling to Enable Consistent Year-Round Feedstock Supply for Thermochemical Conversion to Biofuels

Seasonal variation in microalgae productivity is a significant barrier to economical production of algae biofuels and chemicals. Summer production can be 3–5 times higher than in the winter resulting in uneven feedstock supplies at algae biorefineries. A portion of the summer production must be preserved for conversion in the winter in order to maintain a biorefinery running at capacity. Ensiling, a preservation process that utilizes lactic acid fermentation to limit microbial degradation, has been demonstrated to successfully stabilize algae biomass (20% solids) and algae-lignocellulosic blends (40% algae-60% lignocellulosic biomass, dry basis) for over 6 months, resulting in fuel production cost savings with fewer emissions. Preservation of algae as blends could be beneficial to biorefineries that utilize thermochemical approaches to fuel production as co-processing of algae and lignocellulosic biomass has been observed to enhance biocrude yield and improve oil quality. This study conducts a resource assessment of biomass residues in the southern United States to identify materials available during peak algae productivity and in sufficient quantity to meet the algae storage needs of an algae biofuel industry. Eight feedstocks met the quantity threshold but only three, distillers grains, haylage, and yard waste, were also available in season. Storage experiments utilizing both freshwater and marine strains of microalgae – Scenedesmus acutus, Chlorella vulgaris, Chlorella zofingiensis, Nannochloropsis gaditana, and Porphyridium purpureum – and yard waste were conducted for 30 days. Storage losses were less than 10% in all but one case, and the pH of all but one blend was reduced to less than 4.7, indicating that yard waste is a suitable feedstock for blending with algae prior to storage. To better understand whether the benefits to conversion realized by processing blends might be affected by storage, elemental analysis and bomb calorimetry of pre- and post-storage algae-yard waste blends were conducted to characterize changes occurring during storage. Storing algae biomass as blends with lignocellulosic biomass could be an effective method of mitigating seasonal variability in algae biomass production while retaining the synergistic effect of co-processing algae blends in thermochemical conversion.

Ensilability of Biomass From Effloresced Flower Strips as Co-substrate in Bioenergy Production

Flower strips are grown to an increasing degree in order to enhance the ecological value of agricultural landscapes. Depending on their profitable life span and the crop sequence, the strips' biomass must be mulched after flowering to enable repeated tillage. A promising alternative is the use of the flower strips' biomass as a co-substrate for biomethanisation - thereby contributing to the climate-friendly generation of energy. This potential bioenergy substrate occurs only seasonally and is commonly produced only in limited quantities at a farm scale. To realize the additional benefit of flower strips as energy suppliers, stock piling of the strips' biomass is required. However, information about the ensilability of flower strip biomass is still rare. We conducted a 2-year study to analyze the ensilability of pure biomass from effloresced flower strips and mixtures of flower strip biomass with 33 and 67% whole crop maize, respectively. Ensiling took place in 3 l model silos at laboratory scale after chopping the substrate. Before ensiling several chemical characteristics of the biomass stock were determined to assess the substrate's biochemical ensilability potential (dry matter content, water-soluble carbohydrates, buffering capacity, nitrate content). The process-engineered ensiling success after 90 days was determined based on fermentation patterns. The ensilability potential of the pure flower strip substrates reached modest levels (fermentability coefficients according to Weißbach vary around the threshold of 45). Nevertheless, acceptable silage qualities were achieved under the laboratory conditions (pH ranging from 4.2 to 4.7). Compared to pure flower strip biomass, the addition of maize noticeably improved both the substrate's biochemical ensilability potential and the quality of real fermented silage. We conclude that a mixture of 33% biomass from flower strips with 67% whole crop maize can be regarded as a recommendable ratio if proper ensiling technology is applied.

Collection of ear corn residue and its utilization as a bulking agent for cow manure composting

This study examined the collection, storage, and utilization of ear corn residue as a bulking agent for composting. Ear corn residue left in fields was collected by a sequence of windrowing and round baling operations, which showed a collection efficiency of 53%-56%. More than 70% of the corn stalks had lengths shorter than 15 cm. The moisture content of corn residue collected in late October was approximately 58%; it decreased to 23% during storage. Dried corn residue was mixed with raw manure in two different ways, namely using complete mixing (CM) treatment or creating a bottom layer of residue, and a total of 3.4 t of the manure and ear corn residue mixture were composted using a pilot-scale composting apparatus. The results showed that the CM treatment resulted in higher temperature generation and produced less odorous and well-degraded compost after 2 months of composting, while the odorous compounds in the compost with corn residue as the bottom layer remained similar to those of the initial compost. To sufficiently utilize the advantages of the ear corn residue, thorough mixing of the corn residue with raw manure is preferable; this procedure produced well-degraded and safety compost in a shorter time period.

Ensiled Wet Storage Accelerates Pretreatment for Bioconversion of Corn Stover

Organic acids produced during ensiled wet storage are beneficial during the storage process, both for biomass preservation, and to aid in mild in-situ pretreatment. However, there is concern these acids could later have negative impacts on downstream processes, especially microbial fermentation. Organic acids can inhibit microbial metabolism or growth, which in turn could affect biofuel productivity or yield. This study investigated the interaction of organic acids produced during ensiled storage with subsequent pretreatment of the resulting corn stover silage, as well as the potential for interference with downstream ethanol fermentation. Interaction with pretreatment was observed by measuring xylan and glucan removal and the formation of inhibitors. The results indicated that organic acids generally do not impede downstream processes and in fact can be beneficial. The levels of organic acids produced during 220 days of storage jar tests at 23°C or 37°C, and their transformation during pretreatment, remained below inhibitory levels. Concentrations of individual acids did not exceed 6 g per liter of the pretreated volume, and < 5% on a dry matter basis. Whereas, unensiled corn stover required 15 min of 190°C pretreatment to optimize sugar release, ensiled corn stover could be treated equally effectively at a lower pretreatment duration of 10 min. Furthermore, the different organic acid profiles that accumulate at various storage moisture levels (35-65%) do not differ significantly in their impact on downstream ethanol fermentation. These results indicate biorefineries using ensiled corn stover feedstock at 35-65% moisture levels can expect as good or better biofuel yields as with unensiled stover, while reducing pretreatment costs.