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Douglas G. Tiffany - One of the best experts on this subject based on the ideXlab platform.

  • Life cycle assessment of a Corn stover torrefaction plant integrated with a Corn Ethanol plant and a coal fired power plant.
    Biomass & Bioenergy, 2014
    Co-Authors: Nalladurai Kaliyan, R. Vance Morey, Douglas G. Tiffany
    Abstract:

    Abstract A life cycle assessment (LCA) study was conducted to understand and assess potential greenhouse gas (GHG) emissions reduction benefits of a biomass torrefaction business integrated with other industrial businesses for the use of the excess heat from the torrefaction off-gas volatiles and biocoal. A torrefaction plant processing 30.3 Mg h −1 of Corn stover at 17% wet basis (w.b.) moisture content was modeled. The torrefaction plant produced 136,078 Mg y −1 of biocoal at 1.1% w.b. moisture content and 28.1 MW of excess heat energy in the torrefaction off-gas volatiles. At the torrefaction plant gate, the life-cycle GHG emission for the production of biocoal (including Corn stover logistics emissions) is 11.35 g MJ −1 carbon dioxide equivalent (dry basis) (i.e., 229.5 kg Mg −1 carbon dioxide equivalent of biocoal at 1.1% w.b. moisture content). The excess heat from the torrefaction plant met 42.8% of the process steam needs of a U.S. Midwest dry-grind Corn Ethanol plant producing 0.38 hm 3  y −1 of denatured Ethanol, which results in about 40% reduction in life-cycle GHG emissions for Corn Ethanol compared to gasoline. Co-firing 10%, 20%, and 30% (energy basis) of biocoal at a coal-fired power plant reduced the life-cycle GHG emissions of electricity generated by 8.5%, 17.0%, and 25.6%, respectively, compared to 100% coal-fired electricity. A sensitivity analysis showed that adding a combined heat and power (CHP) system at the torrefaction plant to meet 100% electricity demand of the torrefaction plant (2.5 MW) could further reduce the GHG emissions for biocoal, Corn Ethanol, and co-fired electricity.

  • Understanding the evolution of environmental and energy performance of the US Corn Ethanol industry: evaluation of selected metrics
    Biofuels Bioproducts and Biorefining, 2013
    Co-Authors: Helena L. Chum, R. Vance Morey, Douglas G. Tiffany, Yimin Zhang, Jason Hill, Alison Goss Eng, Zia Haq
    Abstract:

    Throughout the past two decades, numerous studies characterized the greenhouse gas (GHG) emissions and net energy balance of Corn Ethanol production in the USA. A wide range of reported values resulted from differences in the vintage of the data used to evaluate the Ethanol conversion technology and the agricultural practices of Corn production, which evolved substantially during the rapid growth phase of the industry. Methodological differences in life cycle assessments also caused the reported values to vary widely. With Corn dry mills growing from 30% of total installed Ethanol production capacity in 1990 to 80–90% from 2006 to 2011, we document the evolution of this industry using vintage-specific data to analyze selected energy and environmental metrics, including GHG emissions, fossil energy use, direct land use, and GHG emissions reduction per hectare of land harvested for Ethanol production. Our estimates indicate that production and use of Corn Ethanol emitted 44% fewer GHG emissions, consumed 54% less fossil energy and required 44% less land in 2010 compared to 1990 (on a life cycle basis). Our review and analysis point to strategies for reducing the carbon footprint of the Corn dry mill industry by building on the progress already achieved. Using biomass (e.g. residues from Corn production) for process heat or combined heat and power is one such strategy. Additional environmental benefits are projected from the adoption of integrated gasification combined cycle technology (using Corn residues), which leads to energy-self-sufficient mills or net electricity producers depending on the power system configuration. © 2013 Society of Chemical Industry and John Wiley & Sons, Ltd

  • Life cycle assessment of Corn stover torrefaction plant integrated with a Corn Ethanol plant and a coal fired power plant
    2013 Kansas City Missouri July 21 - July 24 2013, 2013
    Co-Authors: Nalladurai Kaliyan, R. Vance Morey, Douglas G. Tiffany
    Abstract:

    Abstract. A life cycle assessment (LCA) study was conducted to understand and assess potential greenhouse gas (GHG) emissions reduction benefits of a biomass torrefaction business integrated with other industrial businesses for the use of the excess heat from the torrefaction off-gas volatiles and biocoal. A torrefaction plant processing 30.3 t/h (33.4 ton/h) of Corn stover at 17% wet basis (w.b.) moisture content was modeled. The torrefaction plant produced 136,078 t/year (150,000 ton/year) of torrefied material (i.e., biocoal) at 1.1% (w.b.) moisture content and 28.1 MW th (96 million Btu/h) of excess heat energy in the torrefaction off-gas volatiles. At the torrefaction plant gate, the life-cycle GHG emission for the production of biocoal from Corn stover (including Corn stover logistics GHG emissions) is 11.35 g CO 2 e/MJ biocoal dry matter (229.5 kg CO 2 e/t biocoal at 1.1% w.b. moisture content). The excess heat from the torrefaction plant met about 42.8% of the process steam needs (excluding the co-products dryer heat demand) of a 379 million liter per year (100 million gallon per year) natural gas-fueled dry-grind Corn Ethanol plant, which results in about 40% reduction in life-cycle GHG emissions for Corn Ethanol compared to gasoline. Co-firing 10%, 20%, and 30% (energy basis) of biocoal at a coal-fired power plant reduced the life-cycle GHG emissions of electricity generated by 8.5%, 17.0%, and 25.6%, respectively, compared to 100% coal-fired electricity. A sensitivity analysis showed that adding a combined heat and power (CHP) system at the torrefaction plant to meet 100% electricity demand of the torrefaction plant (i.e., 2.5 MW e ) would result in lower GHG emissions for biocoal, Corn Ethanol, and co-fired electricity than for the case where the torrefaction plant purchased electricity from the grid.

  • reducing life cycle greenhouse gas emissions of Corn Ethanol by integrating biomass to produce heat and power at Ethanol plants
    Biomass & Bioenergy, 2011
    Co-Authors: Nalladurai Kaliyan, Vance R Morey, Douglas G. Tiffany
    Abstract:

    Abstract A life-cycle assessment (LCA) of Corn Ethanol was conducted to determine the reduction in the life-cycle greenhouse gas (GHG) emissions for Corn Ethanol compared to gasoline by integrating biomass fuels to replace fossil fuels (natural gas and grid electricity) in a U.S. Midwest dry-grind Corn Ethanol plant producing 0.19 hm3 y−1 of denatured Ethanol. The biomass fuels studied are Corn stover and Ethanol co-products [dried distillers grains with solubles (DDGS), and syrup (solubles portion of DDGS)]. The biomass conversion technologies/systems considered are process heat (PH) only systems, combined heat and power (CHP) systems, and biomass integrated gasification combined cycle (BIGCC) systems. The life-cycle GHG emission reduction for Corn Ethanol compared to gasoline is 38.9% for PH with natural gas, 57.7% for PH with Corn stover, 79.1% for CHP with Corn stover, 78.2% for IGCC with natural gas, 119.0% for BIGCC with Corn stover, and 111.4% for BIGCC with syrup and stover. These GHG emission estimates do not include indirect land use change effects. GHG emission reductions for CHP, IGCC, and BIGCC include power sent to the grid which replaces electricity from coal. BIGCC results in greater reductions in GHG emissions than IGCC with natural gas because biomass is substituted for fossil fuels. In addition, underground sequestration of CO2 gas from the Ethanol plant’s fermentation tank could further reduce the life-cycle GHG emission for Corn Ethanol by 32% compared to gasoline.

  • Reducing Life-Cycle Greenhouse Gas Emissions of Corn Ethanol
    2010 Pittsburgh Pennsylvania June 20 - June 23 2010, 2010
    Co-Authors: Nalladurai Kaliyan, R. Vance Morey, Douglas G. Tiffany
    Abstract:

    A life-cycle assessment (LCA) of Corn Ethanol was conducted to determine the reduction in the life-cycle greenhouse gas (GHG) emissions of Corn Ethanol compared to gasoline by integrating biomass fuels in a 190 million liter (50 million gallon) per year dry-grind Corn Ethanol plant to replace fossil fuels (natural gas and grid electricity). The biomass fuels studied are Corn stover and Ethanol co-products [dried distillers grains with solubles (DDGS), and syrup (solubles portion of DDGS)]. The biomass conversion technologies/systems considered are process heat (PH) only systems, combined heat and power (CHP) systems, and biomass integrated gasification combined cycle (BIGCC) systems. The key inventory components of the LCA are Corn production, stover production, Ethanol production, fertilizer inputs, truck transport, co-product credits, Ethanol transport to blending, biomass fuel conversion systems, and combustion of anhydrous Ethanol (E100). The life-cycle GHG emission reduction for Corn Ethanol compared to gasoline (97.7 g CO2e/MJ gasoline) is 42.5% for PH with natural gas, 61.3% for PH with Corn stover, 82.2% for CHP with Corn stover, 81.6% for IGCC with natural gas, 127.7% for BIGCC with Corn stover, and 119.1% for BIGCC with syrup and stover. These GHG emission estimates do not include indirect land use change effects. GHG emission reductions for CHP, IGCC, and BIGCC include power sent to the grid which replaces electricity from coal. BIGCC results in greater reductions in GHG emissions than IGCC with natural gas because biomass is substituted for fossil fuels. In addition, underground sequestration of CO2 gas from the Ethanol plant’s fermentation tank could further reduce the life-cycle GHG emission of Corn Ethanol by 31.5% compared to gasoline.

Nalladurai Kaliyan - One of the best experts on this subject based on the ideXlab platform.

  • Life cycle assessment of a Corn stover torrefaction plant integrated with a Corn Ethanol plant and a coal fired power plant.
    Biomass & Bioenergy, 2014
    Co-Authors: Nalladurai Kaliyan, R. Vance Morey, Douglas G. Tiffany
    Abstract:

    Abstract A life cycle assessment (LCA) study was conducted to understand and assess potential greenhouse gas (GHG) emissions reduction benefits of a biomass torrefaction business integrated with other industrial businesses for the use of the excess heat from the torrefaction off-gas volatiles and biocoal. A torrefaction plant processing 30.3 Mg h −1 of Corn stover at 17% wet basis (w.b.) moisture content was modeled. The torrefaction plant produced 136,078 Mg y −1 of biocoal at 1.1% w.b. moisture content and 28.1 MW of excess heat energy in the torrefaction off-gas volatiles. At the torrefaction plant gate, the life-cycle GHG emission for the production of biocoal (including Corn stover logistics emissions) is 11.35 g MJ −1 carbon dioxide equivalent (dry basis) (i.e., 229.5 kg Mg −1 carbon dioxide equivalent of biocoal at 1.1% w.b. moisture content). The excess heat from the torrefaction plant met 42.8% of the process steam needs of a U.S. Midwest dry-grind Corn Ethanol plant producing 0.38 hm 3  y −1 of denatured Ethanol, which results in about 40% reduction in life-cycle GHG emissions for Corn Ethanol compared to gasoline. Co-firing 10%, 20%, and 30% (energy basis) of biocoal at a coal-fired power plant reduced the life-cycle GHG emissions of electricity generated by 8.5%, 17.0%, and 25.6%, respectively, compared to 100% coal-fired electricity. A sensitivity analysis showed that adding a combined heat and power (CHP) system at the torrefaction plant to meet 100% electricity demand of the torrefaction plant (2.5 MW) could further reduce the GHG emissions for biocoal, Corn Ethanol, and co-fired electricity.

  • Modelling of superheated steam drying for combined heat and power at a Corn Ethanol plant using Aspen Plus software
    Biosystems Engineering, 2014
    Co-Authors: R. V. Morey, Huixiao Zheng, Nalladurai Kaliyan, Matthew V. Pham
    Abstract:

    A superheated steam drying (SSD) model was developed in Aspen Plus software to determine energy and water recovery for drying the co-products in a Corn Ethanol plant. The SSD was integrated into a biomass integrated gasification combined cycle (BIGCC) heat and power production model developed for a 190 million litre per year Corn Ethanol plant. The BIGCC system was fuelled with either Corn stover or a mixture of syrup and Corn stover at a rate of 110 MW. Results were compared to estimates for steam tube drying (STD). Energy consumed for the SSD was 759–804 kJ kg −1 of water removed compared to 2660–2690 kJ kg −1 for the STD. Approximately 1.3 l of water were recovered per litre of Ethanol produced with the SSD, with none for the STD. Less power was generated in the BIGCC system with SSD due to its smaller heat sink than for the BIGCC system with STD.

  • Life cycle assessment of Corn stover torrefaction plant integrated with a Corn Ethanol plant and a coal fired power plant
    2013 Kansas City Missouri July 21 - July 24 2013, 2013
    Co-Authors: Nalladurai Kaliyan, R. Vance Morey, Douglas G. Tiffany
    Abstract:

    Abstract. A life cycle assessment (LCA) study was conducted to understand and assess potential greenhouse gas (GHG) emissions reduction benefits of a biomass torrefaction business integrated with other industrial businesses for the use of the excess heat from the torrefaction off-gas volatiles and biocoal. A torrefaction plant processing 30.3 t/h (33.4 ton/h) of Corn stover at 17% wet basis (w.b.) moisture content was modeled. The torrefaction plant produced 136,078 t/year (150,000 ton/year) of torrefied material (i.e., biocoal) at 1.1% (w.b.) moisture content and 28.1 MW th (96 million Btu/h) of excess heat energy in the torrefaction off-gas volatiles. At the torrefaction plant gate, the life-cycle GHG emission for the production of biocoal from Corn stover (including Corn stover logistics GHG emissions) is 11.35 g CO 2 e/MJ biocoal dry matter (229.5 kg CO 2 e/t biocoal at 1.1% w.b. moisture content). The excess heat from the torrefaction plant met about 42.8% of the process steam needs (excluding the co-products dryer heat demand) of a 379 million liter per year (100 million gallon per year) natural gas-fueled dry-grind Corn Ethanol plant, which results in about 40% reduction in life-cycle GHG emissions for Corn Ethanol compared to gasoline. Co-firing 10%, 20%, and 30% (energy basis) of biocoal at a coal-fired power plant reduced the life-cycle GHG emissions of electricity generated by 8.5%, 17.0%, and 25.6%, respectively, compared to 100% coal-fired electricity. A sensitivity analysis showed that adding a combined heat and power (CHP) system at the torrefaction plant to meet 100% electricity demand of the torrefaction plant (i.e., 2.5 MW e ) would result in lower GHG emissions for biocoal, Corn Ethanol, and co-fired electricity than for the case where the torrefaction plant purchased electricity from the grid.

  • Aspen Plus simulation of biomass integrated gasification combined cycle systems at Corn Ethanol plants
    Biomass and Bioenergy, 2013
    Co-Authors: Huixiao Zheng, Nalladurai Kaliyan, R. Vance Morey
    Abstract:

    Abstract Biomass integrated gasification combined cycle (BIGCC) systems and natural gas combined cycle (NGCC) systems are employed to provide heat and electricity to a 0.19 hm 3 y −1 (50 million gallon per year) Corn Ethanol plant using different fuels (syrup and Corn stover, Corn stover alone, and natural gas). Aspen Plus simulations of BIGCC/NGCC systems are performed to study effects of different fuels, gas turbine compression pressure, dryers (steam tube or superheated steam) for biomass fuels and Ethanol co-products, and steam tube dryer exhaust treatment methods. The goal is to maximize electricity generation while meeting process heat needs of the plant. At fuel input rates of 110 MW, BIGCC systems with steam tube dryers provide 20–25 MW of power to the grid with system thermal efficiencies (net power generated plus process heat rate divided by fuel input rate) of 69–74%. NGCC systems with steam tube dryers provide 26–30 MW of power to the grid with system thermal efficiencies of 74–78%. BIGCC systems with superheated steam dryers provide 20–22 MW of power to the grid with system thermal efficiencies of 53–56%. The life-cycle greenhouse gas (GHG) emission reduction for conventional Corn Ethanol compared to gasoline is 39% for process heat with natural gas (grid electricity), 117% for BIGCC with syrup and Corn stover fuel, 124% for BIGCC with Corn stover fuel, and 93% for NGCC with natural gas fuel. These GHG emission estimates do not include indirect land use change effects.

  • reducing life cycle greenhouse gas emissions of Corn Ethanol by integrating biomass to produce heat and power at Ethanol plants
    Biomass & Bioenergy, 2011
    Co-Authors: Nalladurai Kaliyan, Vance R Morey, Douglas G. Tiffany
    Abstract:

    Abstract A life-cycle assessment (LCA) of Corn Ethanol was conducted to determine the reduction in the life-cycle greenhouse gas (GHG) emissions for Corn Ethanol compared to gasoline by integrating biomass fuels to replace fossil fuels (natural gas and grid electricity) in a U.S. Midwest dry-grind Corn Ethanol plant producing 0.19 hm3 y−1 of denatured Ethanol. The biomass fuels studied are Corn stover and Ethanol co-products [dried distillers grains with solubles (DDGS), and syrup (solubles portion of DDGS)]. The biomass conversion technologies/systems considered are process heat (PH) only systems, combined heat and power (CHP) systems, and biomass integrated gasification combined cycle (BIGCC) systems. The life-cycle GHG emission reduction for Corn Ethanol compared to gasoline is 38.9% for PH with natural gas, 57.7% for PH with Corn stover, 79.1% for CHP with Corn stover, 78.2% for IGCC with natural gas, 119.0% for BIGCC with Corn stover, and 111.4% for BIGCC with syrup and stover. These GHG emission estimates do not include indirect land use change effects. GHG emission reductions for CHP, IGCC, and BIGCC include power sent to the grid which replaces electricity from coal. BIGCC results in greater reductions in GHG emissions than IGCC with natural gas because biomass is substituted for fossil fuels. In addition, underground sequestration of CO2 gas from the Ethanol plant’s fermentation tank could further reduce the life-cycle GHG emission for Corn Ethanol by 32% compared to gasoline.

R. Vance Morey - One of the best experts on this subject based on the ideXlab platform.

  • Life cycle assessment of a Corn stover torrefaction plant integrated with a Corn Ethanol plant and a coal fired power plant.
    Biomass & Bioenergy, 2014
    Co-Authors: Nalladurai Kaliyan, R. Vance Morey, Douglas G. Tiffany
    Abstract:

    Abstract A life cycle assessment (LCA) study was conducted to understand and assess potential greenhouse gas (GHG) emissions reduction benefits of a biomass torrefaction business integrated with other industrial businesses for the use of the excess heat from the torrefaction off-gas volatiles and biocoal. A torrefaction plant processing 30.3 Mg h −1 of Corn stover at 17% wet basis (w.b.) moisture content was modeled. The torrefaction plant produced 136,078 Mg y −1 of biocoal at 1.1% w.b. moisture content and 28.1 MW of excess heat energy in the torrefaction off-gas volatiles. At the torrefaction plant gate, the life-cycle GHG emission for the production of biocoal (including Corn stover logistics emissions) is 11.35 g MJ −1 carbon dioxide equivalent (dry basis) (i.e., 229.5 kg Mg −1 carbon dioxide equivalent of biocoal at 1.1% w.b. moisture content). The excess heat from the torrefaction plant met 42.8% of the process steam needs of a U.S. Midwest dry-grind Corn Ethanol plant producing 0.38 hm 3  y −1 of denatured Ethanol, which results in about 40% reduction in life-cycle GHG emissions for Corn Ethanol compared to gasoline. Co-firing 10%, 20%, and 30% (energy basis) of biocoal at a coal-fired power plant reduced the life-cycle GHG emissions of electricity generated by 8.5%, 17.0%, and 25.6%, respectively, compared to 100% coal-fired electricity. A sensitivity analysis showed that adding a combined heat and power (CHP) system at the torrefaction plant to meet 100% electricity demand of the torrefaction plant (2.5 MW) could further reduce the GHG emissions for biocoal, Corn Ethanol, and co-fired electricity.

  • Understanding the evolution of environmental and energy performance of the US Corn Ethanol industry: evaluation of selected metrics
    Biofuels Bioproducts and Biorefining, 2013
    Co-Authors: Helena L. Chum, R. Vance Morey, Douglas G. Tiffany, Yimin Zhang, Jason Hill, Alison Goss Eng, Zia Haq
    Abstract:

    Throughout the past two decades, numerous studies characterized the greenhouse gas (GHG) emissions and net energy balance of Corn Ethanol production in the USA. A wide range of reported values resulted from differences in the vintage of the data used to evaluate the Ethanol conversion technology and the agricultural practices of Corn production, which evolved substantially during the rapid growth phase of the industry. Methodological differences in life cycle assessments also caused the reported values to vary widely. With Corn dry mills growing from 30% of total installed Ethanol production capacity in 1990 to 80–90% from 2006 to 2011, we document the evolution of this industry using vintage-specific data to analyze selected energy and environmental metrics, including GHG emissions, fossil energy use, direct land use, and GHG emissions reduction per hectare of land harvested for Ethanol production. Our estimates indicate that production and use of Corn Ethanol emitted 44% fewer GHG emissions, consumed 54% less fossil energy and required 44% less land in 2010 compared to 1990 (on a life cycle basis). Our review and analysis point to strategies for reducing the carbon footprint of the Corn dry mill industry by building on the progress already achieved. Using biomass (e.g. residues from Corn production) for process heat or combined heat and power is one such strategy. Additional environmental benefits are projected from the adoption of integrated gasification combined cycle technology (using Corn residues), which leads to energy-self-sufficient mills or net electricity producers depending on the power system configuration. © 2013 Society of Chemical Industry and John Wiley & Sons, Ltd

  • Life cycle assessment of Corn stover torrefaction plant integrated with a Corn Ethanol plant and a coal fired power plant
    2013 Kansas City Missouri July 21 - July 24 2013, 2013
    Co-Authors: Nalladurai Kaliyan, R. Vance Morey, Douglas G. Tiffany
    Abstract:

    Abstract. A life cycle assessment (LCA) study was conducted to understand and assess potential greenhouse gas (GHG) emissions reduction benefits of a biomass torrefaction business integrated with other industrial businesses for the use of the excess heat from the torrefaction off-gas volatiles and biocoal. A torrefaction plant processing 30.3 t/h (33.4 ton/h) of Corn stover at 17% wet basis (w.b.) moisture content was modeled. The torrefaction plant produced 136,078 t/year (150,000 ton/year) of torrefied material (i.e., biocoal) at 1.1% (w.b.) moisture content and 28.1 MW th (96 million Btu/h) of excess heat energy in the torrefaction off-gas volatiles. At the torrefaction plant gate, the life-cycle GHG emission for the production of biocoal from Corn stover (including Corn stover logistics GHG emissions) is 11.35 g CO 2 e/MJ biocoal dry matter (229.5 kg CO 2 e/t biocoal at 1.1% w.b. moisture content). The excess heat from the torrefaction plant met about 42.8% of the process steam needs (excluding the co-products dryer heat demand) of a 379 million liter per year (100 million gallon per year) natural gas-fueled dry-grind Corn Ethanol plant, which results in about 40% reduction in life-cycle GHG emissions for Corn Ethanol compared to gasoline. Co-firing 10%, 20%, and 30% (energy basis) of biocoal at a coal-fired power plant reduced the life-cycle GHG emissions of electricity generated by 8.5%, 17.0%, and 25.6%, respectively, compared to 100% coal-fired electricity. A sensitivity analysis showed that adding a combined heat and power (CHP) system at the torrefaction plant to meet 100% electricity demand of the torrefaction plant (i.e., 2.5 MW e ) would result in lower GHG emissions for biocoal, Corn Ethanol, and co-fired electricity than for the case where the torrefaction plant purchased electricity from the grid.

  • Aspen Plus simulation of biomass integrated gasification combined cycle systems at Corn Ethanol plants
    Biomass and Bioenergy, 2013
    Co-Authors: Huixiao Zheng, Nalladurai Kaliyan, R. Vance Morey
    Abstract:

    Abstract Biomass integrated gasification combined cycle (BIGCC) systems and natural gas combined cycle (NGCC) systems are employed to provide heat and electricity to a 0.19 hm 3 y −1 (50 million gallon per year) Corn Ethanol plant using different fuels (syrup and Corn stover, Corn stover alone, and natural gas). Aspen Plus simulations of BIGCC/NGCC systems are performed to study effects of different fuels, gas turbine compression pressure, dryers (steam tube or superheated steam) for biomass fuels and Ethanol co-products, and steam tube dryer exhaust treatment methods. The goal is to maximize electricity generation while meeting process heat needs of the plant. At fuel input rates of 110 MW, BIGCC systems with steam tube dryers provide 20–25 MW of power to the grid with system thermal efficiencies (net power generated plus process heat rate divided by fuel input rate) of 69–74%. NGCC systems with steam tube dryers provide 26–30 MW of power to the grid with system thermal efficiencies of 74–78%. BIGCC systems with superheated steam dryers provide 20–22 MW of power to the grid with system thermal efficiencies of 53–56%. The life-cycle greenhouse gas (GHG) emission reduction for conventional Corn Ethanol compared to gasoline is 39% for process heat with natural gas (grid electricity), 117% for BIGCC with syrup and Corn stover fuel, 124% for BIGCC with Corn stover fuel, and 93% for NGCC with natural gas fuel. These GHG emission estimates do not include indirect land use change effects.

  • Reducing Life-Cycle Greenhouse Gas Emissions of Corn Ethanol
    2010 Pittsburgh Pennsylvania June 20 - June 23 2010, 2010
    Co-Authors: Nalladurai Kaliyan, R. Vance Morey, Douglas G. Tiffany
    Abstract:

    A life-cycle assessment (LCA) of Corn Ethanol was conducted to determine the reduction in the life-cycle greenhouse gas (GHG) emissions of Corn Ethanol compared to gasoline by integrating biomass fuels in a 190 million liter (50 million gallon) per year dry-grind Corn Ethanol plant to replace fossil fuels (natural gas and grid electricity). The biomass fuels studied are Corn stover and Ethanol co-products [dried distillers grains with solubles (DDGS), and syrup (solubles portion of DDGS)]. The biomass conversion technologies/systems considered are process heat (PH) only systems, combined heat and power (CHP) systems, and biomass integrated gasification combined cycle (BIGCC) systems. The key inventory components of the LCA are Corn production, stover production, Ethanol production, fertilizer inputs, truck transport, co-product credits, Ethanol transport to blending, biomass fuel conversion systems, and combustion of anhydrous Ethanol (E100). The life-cycle GHG emission reduction for Corn Ethanol compared to gasoline (97.7 g CO2e/MJ gasoline) is 42.5% for PH with natural gas, 61.3% for PH with Corn stover, 82.2% for CHP with Corn stover, 81.6% for IGCC with natural gas, 127.7% for BIGCC with Corn stover, and 119.1% for BIGCC with syrup and stover. These GHG emission estimates do not include indirect land use change effects. GHG emission reductions for CHP, IGCC, and BIGCC include power sent to the grid which replaces electricity from coal. BIGCC results in greater reductions in GHG emissions than IGCC with natural gas because biomass is substituted for fossil fuels. In addition, underground sequestration of CO2 gas from the Ethanol plant’s fermentation tank could further reduce the life-cycle GHG emission of Corn Ethanol by 31.5% compared to gasoline.

Steven M Heilmann - One of the best experts on this subject based on the ideXlab platform.

  • industrial symbiosis Corn Ethanol fermentation hydrothermal carbonization and anaerobic digestion
    Biotechnology and Bioengineering, 2013
    Co-Authors: Brandon M Wood, Lindsey R Jader, Frederick J Schendel, Nicholas J Hahn, Kenneth J Valentas, Patrick J Mcnamara, Paige M Novak, Steven M Heilmann
    Abstract:

    The production of dry-grind Corn Ethanol results in the generation of intermediate products, thin and whole stillage, which require energy-intensive downstream processing for conversion into commercial animal feed products. Hydrothermal carbonization of thin and whole stillage coupled with anaerobic digestion was investigated as alternative processing methods that could benefit the industry. By substantially eliminating evaporation of water, reductions in downstream energy consumption from 65% to 73% were achieved while generating hydrochar, fatty acids, treated process water, and biogas co-products providing new opportunities for the industry. Processing whole stillage in this manner produced the four co-products, eliminated centrifugation and evaporation, and substantially reduced drying. With thin stillage, all four co-products were again produced, as well as a high quality animal feed. Anaerobic digestion of the aqueous product stream from the hydrothermal carbonization of thin stillage reduced chemical oxygen demand (COD) by more than 90% and converted 83% of the initial COD to methane. Internal use of this biogas could entirely fuel the HTC process and reduce overall natural gas usage. Biotechnol. Bioeng. 2013;110: 2624–2632. © 2013 Wiley Periodicals, Inc.

  • Industrial symbiosis: Corn Ethanol fermentation, hydrothermal carbonization, and anaerobic digestion
    Biotechnology and Bioengineering, 2013
    Co-Authors: Brandon M Wood, Lindsey R Jader, Frederick J Schendel, Nicholas J Hahn, Kenneth J Valentas, Patrick J Mcnamara, Paige M Novak, Steven M Heilmann
    Abstract:

    The production of dry-grind Corn Ethanol results in the generation of intermediate products, thin and whole stillage, which require energy-intensive downstream processing for conversion into commercial animal feed products. Hydrothermal carbonization of thin and whole stillage coupled with anaerobic digestion was investigated as alternative processing methods that could benefit the industry. By substantially eliminating evaporation of water, reductions in downstream energy consumption from 65% to 73% were achieved while generating hydrochar, fatty acids, treated process water, and biogas co-products providing new opportunities for the industry. Processing whole stillage in this manner produced the four co-products, eliminated centrifugation and evaporation, and substantially reduced drying. With thin stillage, all four co-products were again produced, as well as a high quality animal feed. Anaerobic digestion of the aqueous product stream from the hydrothermal carbonization of thin stillage reduced chemical oxygen demand (COD) by more than 90% and converted 83% of the initial COD to methane. Internal use of this biogas could entirely fuel the HTC process and reduce overall natural gas usage.

K. G. Karthikeyan - One of the best experts on this subject based on the ideXlab platform.

  • Phosphorus flow and characterization in dry-grind Corn Ethanol plants.
    Journal of Environmental Quality, 2012
    Co-Authors: A. Alkan-ozkaynak, K. G. Karthikeyan
    Abstract:

    Both the high phosphorus (P) content and P bioavailability of the animal feed coproducts of the Corn-Ethanol industry could potentially contribute to increased manure and soil P levels and associated environmental issues (e.g., eutrophication). Therefore, a detailed modeling of total P mass flow to the coproducts (i.e., dry distillers grains with solubles, DDGS) was performed. Distribution of P between inorganic P and phytase-hydrolyzable P forms was quantified for selected coproducts (thin stillage, DDGS, modified DDGS [mDDGS]). The P mass balance indicated that although Corn is the major P contributor to the coproducts (80.2%), a substantial portion (19.4%) comes from yeast addition. Of the two components constituting DDGS, wet distillers grains and condensed solubles, the latter contributes to only one-third of the mass but, importantly, yields 70.9% of P. The phytase enzyme used, , was very effective in hydrolyzing the nonorthophosphate P components of thin stillage, DDGS and mDDGS. Our results would help track P movement during various dry-grind processing steps and formulate strategies for phytase enzyme supplementation to various postfermentation coproducts from Corn-Ethanol plants.

  • anaerobic digestion of thin stillage for energy recovery and water reuse in Corn Ethanol plants
    Bioresource Technology, 2011
    Co-Authors: A Alkanozkaynak, K. G. Karthikeyan
    Abstract:

    Recycling of anaerobically-digested thin stillage within a Corn-Ethanol plant may result in the accumulation of nutrients of environmental concern in animal feed coproducts and inhibitory organic materials in the fermentation tank. Our focus is on anaerobic digestion of treated (centrifugation and lime addition) thin stillage. Suitability of digestate from anaerobic treatment for reuse as process water was also investigated. Experiments conducted at various inoculum-to-substrate ratios (ISRs) revealed that alkalinity is a critical parameter limiting digestibility of thin stillage. An ISR level of 2 appeared optimal based on high biogas production level (763 mL biogas/g volatile solids added) and organic matter removal (80.6% COD removal). The digester supernatant at this ISR level was found to contain both organic and inorganic constituents at levels that would cause no inhibition to Ethanol fermentation. Anaerobic digestion of treated-thin stillage can be expected to improve the water and energy efficiencies of dry grind Corn-Ethanol plants.