Using agricultural waste, instead of food crops, to make biofuels and bioplastics is a subject that's been discussed often in Design News' comment boards. One of the biggest -- and also one of the first -- commercial-scale cellulosic biorefineries in the world is targeted for completion next year by DuPont, and it will make cellulosic ethanol from corn stalks and leaves.
The corn stalks and leaves that will serve as feedstock are known as corn stover.
DuPont has recruited more than 500 local farmers near the site of its Nevada, Iowa facility, where it recently broke ground, to provide this material. The facility, which the company expects to complete in 2014, will generate 30 million gallons per year.
Next year DuPont plans to complete one of the first and biggest commercial-scale cellulosic biorefineries in the world, which will make biofuel from corn stalks and leaves at this Nevada, Iowa construction site. (Source: DuPont)
DuPont, which is involved in agricultural science as well as plastics, has been testing and optimizing its biofuel production process and technology in a Tennessee pilot plant, but the effort began more than 10 years ago. "Nearly a decade ago, DuPont set out to develop innovative technology that would result in low capital and low-cost cellulosic ethanol production," said James C. Collins, president of DuPont Industrial Biosciences, in a press release. "By leveraging DuPont Pioneer corn production expertise and designing an integrated technology platform, we've built an affordable and sustainable entry point into this new industry."
In planning the process and the facility, DuPont has worked closely with the state of Iowa, Iowa State University, and growers to make renewable fuels a commercial reality, Collins said. As a state, Iowa leads the US in renewable fuel production, said its governor, Terry Branstad, at the groundbreaking ceremony.
DuPont estimates it will need 375,000 dry tons per year of corn stover to meet the annual goal of 30 million gallons. That will require corn stalks and leaves to be harvested from about 190,000 acres. To supply those quantities, DuPont will contract with more than 500 local farmers to gather, store, and deliver the corn residue. Although growers often leave a little stover on the field as a mulch to protect against erosion, there's a lot more than they need and disposing of it is a big headache. It interferes with corn planting and maintenance, pulls nitrogen out of the soil that could be used by crops, and can house insects and diseases that damage corn plants.
In addition to corn waste, DuPont is working on adapting its process to other feedstocks, such as switchgrass. Currently, the company is processing switchgrass in its testing facility near Knoxville, Tenn., which it owns jointly with the University of Tennessee. DuPont says several local businesses and academic institutions are interested in using the resulting biofuel to reduce some of the energy they get from burning coal.
We've written before about the need for finding usable biofuel feedstocks that don't use food crops and also don't grow non-food crops on land that could be growing food, even if it isn't used for that now. We've also reported on converting non-recycled plastic trash and other waste that would otherwise go into landfills into fuel. But I haven't seen a company and a research project on this scale that set out to do a high-quality job of making fuel from the huge amounts of agricultural waste. DuPont is a company with a lot of resources and a stated dedication to sustainability. They've spent a lot of time, effort, and research dollars on this project, and have done the homework needed to make it succeed. The proof will be in the product, but meanwhile, I say kudos and more power to them.
Kudos to DuPont for their new ethanol facility in Iowa. However, Methanol (wood alcohol) is clearly easier to produce from cellulose than Ethanol. Methanol has been used as a fuel in auto racing since before most of us were wearing diapers.
Robert Zubrin has proposed that new automobiles be fitted with corrosion resistant flex-fuel systems which could utilize Methanol. In fact, Mr. Zubrin has converted his own car to run on Methanol. The production of Methanol could become a decentralized, cottage industry throughout the country as various entrepreneurs utilized local supplies of waste wood products, manure, etc to produce affordable, renewable motor fuels.
Perhaps this is the greatest flaw in Mr. Zubrin's plan - it would create competition for the mega-corporations that currently maintain a stranglehold on motor fuel production, refining and distribution?
The economy is global, yes, but I believe your post was concerning ethanol production in the US using crop waste. I doubt the US will ever be able to compete as an exporter of ethanol, so any ethanol we produce will likely be used domestically. Whether other countries agree or disagree with food-crop based bio fuels produced and consumed in the US is largely irrelevant. In regards to the post you referenced, the EC wants a "magic" fuel that costs little to produce, doesn't impact food production and doesn't emit significant greenhouse gases. The only thing that comes close is hydrogen. All bio fuels will emit greenhouse gases when used. Alcohols contain less stored energy than gasoline or diesel, so when compared on a gallon to gallon basis, we will consume significantly more ethanol than the fossil fuels it replaces and it is likely that switching from gasoline to ethanol will result in a higher production of greenhouse gases. Bio fuels are not the answer to the question of how to reduce greenhouse gases. They are just renewable alternatives to fossil fuels. The EC's efforts to encourage the development of bio fuels that significantly reduce greenhouse gases is a waste of time. Development of hydrogen as a fuel source is the best we can do for now.
Not as "well off" as the US?!! Considering our monumental and ever growing national debt? Nobody is worse off than we are. We're just kidding ourselves if we think otherwise.
There is a fundamental problem with using corn (grain) to make alcohol fuel. The total fossil fuel energy required to produce the corn and make it into ehtnaol is greater that the calorific value of the alcohol. Thus it is both an environmental and a thermodynamic loser. See "Thermodynamics of the Corn Ethanol Cycle" from U. of Calif. Cellulose as a feedstock at least theoretically overcomes this problem.
Also, since photosynthesis converts <1% of solar energy into plant-based enthalpy, it compares very poorly with photovoltaic efficiencies which run about 15%. Thus if you have a field and want to use it as an energy source, PV is a much better choice. Of course the product will be electricity, rather than a liquid fuel.
Please note that I have no objection to corn alcohol as a fuel, so long as I burn it in the Krebs cycle rather than the Otto cycle. (just kidding)
NiteOwl, many different people and countries completely disagree with growing food crops for making ethanol, or with growing non-food crops to make biofuel on land that could be used for growing food, whether that's here in the US or elsewhere. The economy is now global, and much of the rest of the world is simply not as well off as the US, so what may make economic "sense" here for a small minority does not make that sense for the rest, or even when considering that small minority in context. The literature is vast and the regulations are many. We have covered the subject briefly here: http://www.designnews.com/author.asp?section_id=1392&doc_id=253371
I grew up on a farm in IL. My father raised quite a bit of corn. We never disposed of corn stalks. Cattle will eat some of them and the rest can easily be mulched and used to fortify the soil as well as protect it from erosion. I don't understand where the issue of disposing of corn residue is coming from. If there is enough profit from harvesting corn stalks as a product to cover the production costs and additional cost for fertilizer to replace the removed stalks, then DePont's biofuel project may be viable. I seriously doubt it, though. The cost for fuel and fertilizer are significant.
The push to produce ethanol from non-food crops may very well be a waste of time. If the US is serious about producing ethanol as a renewable fuel, then we will use farm land to grow fuel crops. Using corn as a fuel crop makes sense. Not only can it be used to make fuel, it can be used for food. Wherever the demand is highest. Plus, the fermented corn mash waste can be used as a food component for pigs. We should not be concerned about corn being used for producing fuel. We should be concerned about using food producing land to grow fuel-only crops. Using food-crop residue makes sense, but only if it's cost effective. The push to stop using food-crops to make ethanol is a reaction to higher corn prices, which are the result of higher demand for corn. Plain and simple. As corn prices increase, so will corn production to the point where the price drops. We have thousands of acres of farm land enrolled in the Federal Feed-Grain program, which pays farmers to NOT produce grain on that land. If food production ever becomes an issue, that farm land can be put back into production. The reason farmers opt-in for the Feed-Grain program is because it makes economic sense. The Feed-Grain program was created to reduce grain production and support higher grain prices. If grain prices are getting too high, then that program is no longer needed.
As usual, well put, Ann. Motivation is probably one of the biggest factors, here. If someone wants to do something enough, they will find a way to do it cost-effectively, excuses be damned. I do hope this effort has legs.
I think Elizabeth's point is well taken. The examples Lou gives are of failures, not successes. And there have been successes. In addition, I learned growing up next to Silicon Valley that, if you've got enough time, money and innovation you can solve almost any technical problem and make it financially worthwhile to do so. But you have to be motivated, and innovative enough to figure out the best way to make it work. From what I can see, DuPont has all of those going for it.
Lou, the feedback--granted, given by DuPont and participating farmers--is that it costs them to have the stover hauled away. Presumably, they'd have to bundle it for that, too, so having DuPont pay them for it was worth the cost. There's also the cost of diseases and pests the un-removed stover harbors to be factored in. Perhaps whether it's financially worth it depends on the size of the farm, and of the crop. The farmers are being recruited from those in a radius of 30 miles, though, and 500 in that area sounds like a lot to me.
New versions of BASF's Ecovio line are both compostable and designed for either injection molding or thermoforming. These combinations are becoming more common for the single-use bioplastics used in food service and food packaging applications, but are still not widely available.
The 100-percent solar-powered Solar Impulse plane flies on a piloted, cross-country flight this summer over the US as a prelude to the longer, round-the-world flight by its successor aircraft planned for 2015.
GE Aviation expects to chop off about 25 percent of the total 3D printing time of metallic production components for its LEAP Turbofan engine, using in-process inspection. That's pretty amazing, considering how slow additive manufacturing (AM) build times usually are.
A $1,500, hand-operated, bench-model, plastic injection machine crowdsource-funded via Kickstarter can be used to mold small, quality, plastic parts inexpensively, on demand.
The federal government is launching competitions to kickstart three more manufacturing innovation institutes, including one focused on Lightweight and Modern Metals Manufacturing Innovation.
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