An analysis of an ethanol-based, whole-crop refinery system in China

doi:10.1016/j.cjche.2016.05.036

Abstract

Abstract: Bio-fuel can be used to help transition froma petroleum-based society to a bio-based society. Ever since the China Development and Reform Commission suspended the approval of crop processing programs, second-generation bio-ethanol research and industrialization processes have attracted significant attention. In 2020, bio-ethanol production is predicted to reach 10 million tons. Currently, there are a few domestic enterprises that have established different scaled pilot or demonstration bases for cellulosic ethanol, which reduce the cost of ethanol by continuously improving pretreatment and hydrolysis techniques. In the next three years, these enterprises will realize large-scale commercial production. Given the practical problems in cellulosic ethanol plant construction and operation (e.g., marketing price variation and difficulties in feedstock collection), this paper began with the concept of a "whole-crop refinery" and presented a solution to the integration of industry and agriculture as well as multi-crop refining. This paper then took the whole-crop refining system of corn as an example and presented an analysis of the logistics, energy flow, and economical efficiency of the system. The results demonstrated that the integrated system could properly reduce the required fixed investments in production equipment, shared utilities, and wastewater treatment facilities, as well as reduction of energy consumption. Although the proposed system has several problems, it brings the long-term goal of large-scale commercial application closer than ever.

Key words: Whole-crop refinery, Cellulosic ethanol, Biomass, Corn stover

摘要： Bio-fuel can be used to help transition froma petroleum-based society to a bio-based society. Ever since the China Development and Reform Commission suspended the approval of crop processing programs, second-generation bio-ethanol research and industrialization processes have attracted significant attention. In 2020, bio-ethanol production is predicted to reach 10 million tons. Currently, there are a few domestic enterprises that have established different scaled pilot or demonstration bases for cellulosic ethanol, which reduce the cost of ethanol by continuously improving pretreatment and hydrolysis techniques. In the next three years, these enterprises will realize large-scale commercial production. Given the practical problems in cellulosic ethanol plant construction and operation (e.g., marketing price variation and difficulties in feedstock collection), this paper began with the concept of a "whole-crop refinery" and presented a solution to the integration of industry and agriculture as well as multi-crop refining. This paper then took the whole-crop refining system of corn as an example and presented an analysis of the logistics, energy flow, and economical efficiency of the system. The results demonstrated that the integrated system could properly reduce the required fixed investments in production equipment, shared utilities, and wastewater treatment facilities, as well as reduction of energy consumption. Although the proposed system has several problems, it brings the long-term goal of large-scale commercial application closer than ever.

关键词: Whole-crop refinery, Cellulosic ethanol, Biomass, Corn stover

Zhiqiang Zhang, Shanying Hu, Dingjiang Chen, Bing Zhu. An analysis of an ethanol-based, whole-crop refinery system in China[J]. Chin.J.Chem.Eng., 2016, 24(11): 1609-1618.

Zhiqiang Zhang, Shanying Hu, Dingjiang Chen, Bing Zhu. An analysis of an ethanol-based, whole-crop refinery system in China[J]. Chinese Journal of Chemical Engineering, 2016, 24(11): 1609-1618.

References

[1] D.-j. Chen, S.-y. Hu, F.-g. Du, Develop circular economic pattern for biomass-based energy and chemical industry, Mod. Chem. Ind. 27(7) (2007) 5-8.
[2] H. Yu, L. Zhou, P. Yuan, Development of fuel ethanol industry in China, Cereal Food Ind. 16(4) (2009) 18-21.
[3] W.-s. Feng, F.-g. Du, Current developing situation of fuel ethanol industry in China, and problems and counter measures, Mod. Chem. Ind. 30(4) (2010) 8-12.
[4] M.R. Schmer, K.P. Vogel, R.B. Mitchell, R.K. Perrin, Net energy of cellulosic ethanol from switchgrass, PNAS 105(2) (2008) 464-469.
[5] Y. Bi, C. Gao, Y. Wang, Estimation of straw resources in China, Trans. CSAE 25(12) (2009) 211-217.
[6] S. Jin, F. Zhang, L.'a. Zhang, An analysis of straw available for fuel ethanol production in China, Int. Pet. Econ. (2008).
[7] L. Duan, Commercialization and economic analysis of cellulose ethanol, Chem. Ind. Eng. Prog. 27(6) (2008) 867-873.
[8] H.-b. Liu, Developing of cellulosic ethanol production from nonfood-based biomass in China:challenges and strategies, Chin. J. Bioprocess Eng. 6(1) (2008) 7-12.
[9] B. Yang, C.E.Wyman, Pretreatment:the key to unlocking low-cost cellulosic ethanol, Biofuels Bioprod. Biorefin. 2(2008) 26-40, http://dx.doi.org/10.1002/bbb.49.
[10] C.N. Hamelinck, G. van Hooijdonk, A.P.C. Faaij, Ethanol from lignocellulosic biomass:techno-economic performance in short-, middle-and long-term, Biomass Bioenergy 28(2005) 384-410.
[11] T. Scheper, L. Olsson, Advances in Biochemical Engineering, University of Hannover, Germany, 2007http://dx.doi.org/10.1007/978-3-540-73651-6.
[12] Z.H. Wang, Novozymes teams up with Cofco, Sinopec on bioenergy, China Daily, 2010-9-9[2015-72], http://http://www.chinadaily.com.cn/bizchina/2010-09/09/content_11278870.htm.
[13] J.L. Gaddy, Biological production of ethanol from waste gases with Clostridium ljungdahlii:US,6136577P, 2000.
[14] L. Rosgaard, S. Pedersen, J. Langston, Evaluation ofmini-MaL Trichoderma reesi cellulase mixtures on differently pretreated barley straw substrates, Biotechnol. Prog. 23(2007) 1270-1276.
[15] D.J. Gregg, A. Boussaid, J.N. Saddler, Techno-economic evalution of a generic woodto-ethanol process:effect of increased cellu-lose yields and enzyme recycle, Bioresour. Technol. 63(1998) 7-12.
[16] M.B. Tu, R.P. Chandra, J.N. Saddler, Recycling cellulases during the hydrolysis of steam exploded and ethanol pretreated Lodgepole Pine, Biotechnol. Prog. 23(2007) 1130-1137.
[17] A. Aden, M. Ruth, K. Ibsen, Lignocellulosic biomass to ethanol process design and economics utilizing co-current dilute acid prehydrolysis and enzymatic hydrolysis for corn stover, National Renewable Energy Laboratory report, 2002(TP-510-32438).
[18] B. Kamm, P.R. Gruber, M. Kamm, Biorefineries-Industrial Processes and Products, WILEY-VCHVerlag GmbH & Co. KGaA, Weinheim,Germany, 2006.
[19] M. Narodoslawsky, Renewable resources-new challenges for process integration and synthesis, Chem. Biochem. Eng. Q. 17(1) (2003) 55-64.
[20] A.McAloon, F. Taylor,W. Yee, K. Ibsen, R.Wooley, Determining the cost of producing ethanol from corn starch and lignocellulosic feedstocks, Report No.:NREL/TP-580-28893. Contract No.:DE-AC₃6-99-GO10337, A Joint Study Sponsored by:U.S. Department of Agriculture and U.S. Department of Energy, Oct. 2000.
[21] G. Cao, X. Zhang, F. Zheng, Estimating the quantity of crop residues burnt in open field in China, Resour. Sci. 25(4) (2003) 62-67.
[22] J. Li, D. Ren, X. Zhuang, Systemic evaluation method of renewable energy resources and its practical application, J. Nat. Resour. 7(4) (2001) 373-380.
[23] H. Zhong, Y. Yue, J. Fan, Characteristics of crop straw resources in China and its utilization, Resour. Sci. 25(4) (2003) 62-67.
[24] A.E. Farrell, R.J. Plevin, B.T. Turner, A.D. Jones,M. O'Hare, D.M. Kammen, Ethanol can contribute to energy and environmental goals, Science 311(2006) 506-508.
[25] National Agricultural Ministry, Plans for the Development of Biomass (2007-2015), Biotechnology & Business 1(2007) 3.
[26] National Bureau of Statistics of the People's Republic of China, Yearbook of agricultural statistics 2003-2008 Available from:http://www.stats.gov.cn/tjfw/.
[27] L. Luo, E. van der Voet, G. Huppes, An energy analysis of ethanol from cellulosic feedstock-corn stover, Renew. Sustain. Energy Rev. 13(2009) 2003-2011.
[28] P. Dwivedi, J.R.R. Alavalapati, P. Lal, Cellulosic ethanol production in the United States:conversion technologies, current production status, economics, and emerging developments, Energy Sustain. Dev. 13(2009) 174-182.
[29] A. Song, T. Ren, B. Zhang, Economic analysis for production of fuel ethanol with corn straw, Trans. CSAE 26(6) (2010) 283-286.
[30] S. Li, C. Chan-Halbrendt, Ethanol production in (the) People's Republic of China:Potential and technologies, Appl. Energy 86(Supp. 1) (2009) S162-S169.
[31] B.D. Solomon, J.R. Barnes, K.E. Hal-vorsen, Grain and cellulosic ethanol:History, economics, and energy policy, Biomass Bioenergy 31(6) (2007) 416-425.
[32] T. Patzek, Thermodynamics of the corn-ethanol biofuel cycle, Crit. Rev. Plant Sci. 23(2004) 519.
[33] D. Pimentel, T. Patzek, Ethanol production using corn, switchgrass, and wood:Biodiesel production using soybean and sunflower, Nat. Resour. Res. 14(2005) 65.
[34] M.E.D. De Oliveira, B.E. Vaughan, E.J. Rykiel, Ethanol as fuel:Energy, carbon dioxide balances and ecological footprint, Bioscience 55(2005) 593.
[35] H. Shapouri, A. McAloon, The 2001 Net Energy Balance of Corn Ethanol, U.S. Department of Agriculture, Washington, DC, 2004(Also available at www.usda.gov/oce/oepnu).
[36] M. Graboski, Fossil Energy Use in the Manufacture of Corn Ethanol, National Corn Growers Association, Washington, DC, 2002(Also available at www.ncga.com/ethanol/main).
[37] M. Wang, Development and Use of GREET 1.6 Fuel-cycle Model for Transportation Fuels and Vehicle Technologies, Tech. Rep. ANL/ESD/TM-163, Argonne National Laboratory, Argonne, IL, 2001(Also available at www.transportation.anl.gov/pdfs/TA/153.pdf).
[38] E. Gnansounou, A. Dauriat, Energy balance of bioethanol:A synthesis, European Biomass Conference, Paris, France, 2005(Oct. Also available at http://eners.ch/downloads/eners_0510_ebce_paper.pd).