on the road to a new sweet sorghum industry in the usa gillian eggleston 1 and matthew heckemeyer 2...
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On the Road to a New Sweet Sorghum Industry in the USA
Gillian Eggleston1 and Matthew Heckemeyer2
Heckemeyer Mill
1Lead ScientistSugar & Energy CRIS Project
USDA-ARS-SRRCNew Orleans, LA, USA
2CEOHeckemeyer Mill
Sikeston, MO, USA
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Presentation Outline
Largest operational sweet sorghum biorefinery in USA: Heckemeyer Mill, Sikeston, Missouri, USA
Overcoming processing problems with help of USDA scientists
Key value added products from sugar feedstocks – the “Sugar Platform”
Advantages of sweet sorghum over other crops
USDA-ARS New Orleans research on sweet sorghum
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Sugar Platform
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Biomass Conversion Technologies
BIOCHEMICAL
Sugar Fermentation Platform
THERMOCHEMICAL
Gasification Platform
Fuels,
Chemicals,
Energy &
Co-products
CHEMICAL
Oleochemical/Chemical Platform
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C6 or C5 Sugars
Key Value Added Products from Sugar Feedstocks “Sugar Platform”
– From Chemical or Biocatalytic Processes
Lactic acid → PLA Biodegradable plastic1,2-Propanediol3-Hydroxy Propionic acidAcrylic acid
C3
C2Ethanol → Liquid fuelAcetic acid → Wood glueGlyoxylic acid → skin care products
C6Citric acid → Food preservativeGluconic acid → Food acidulentLysine → animal feedHMF → plasticsGlucaric acidSorbitol
C5Furfural → Industrial solventsLevulinic acid → Rubber/resinsXylitol → low calorie sweetenerGlutamic acidItaconic acid
C4Butanol → Liquid fuelSuccinic acid → Polymers/ surfactants/adhesivesAspartic acidButanediol
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The Development of the Sugar Platform Will Depend On:
Application of chemical and bio-catalysts to transform sugars into useful biobased chemical intermediates and downstream products
Successful scaling up of biocatalysts from “proof-of- concept” experiments on a laboratory scale to commercial industrial process scale - only beginning to emerge
Availability of economic, readily-available source or sources of sugar feedstocks (expected to transition to ligno-cellulosic derived sugars)
At present mainly focused on corn, cassava starch, and sugarcane molasses
Availability of stable, transportable, and storable feedstocks for year-round use
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Sweet Sorghum
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Advantages of Sweet Sorghum over Other Crops for Biofuels and Bioproducts
Can be used in existing ethanol factories
• Much easier to ferment than corn with higher ethanol output potential
Genetic improvement potential is HUGE
• Hybrid and tailor made sweet sorghum cultivars
Adapts well to adverse environments
• Requires relatively low inputs
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
1 - 2 crops per year (Temperate)• Improves economics immensely
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Skip Text Links
70o
60o
52o
Sugarcane
SweetSorghum
Sugar beet
World Map Depicting Approximate Areas Where Sweet Sorghum, Sugarcane, and Sugar Beet can be Grown
Limit for grains
Adapted from Debor (2009).
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Parameter* Sweet Sorghum Corn Sugarcane
Crop duration (months) 3-5 4 12-18
Relative energy efficiency
1:8 1:16 1:9
Water requirement/crop (cm)
33 81 36
Grain yield (t/ha) 4.9 3.6 n/a
Stalk yield (t/ha) 74 45 76
Juice purity (%) ~75 n/a 82-88
Advantages and Disadvantages of Sweet Sorghum as aFeedstock Compared to Other Crops
* Average values
Grain
Huge Biofuel and Bioproducts
Potential
LiquidSugar
BiomassSweetSorghum
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USDA-ARS Sweet Sorghum ResearchObjectives of the New Sugar & Energy CRIS
Project2014-2019
All objectives and sub-objectives are focused on solving industry problems after discussions with numerous industrial stakeholders
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Interrelationships of New Project Objectives :
Sugarcane for Sugar Manufacture Sweet Sorghum and Energy Beets for Advanced Biofuels and Bioproducts
Manufacture
Objective 1. Develop commercially -viable technologies that reduce undesirable effects of starch and color on processing and end –product quality
Objective 2. Develop commercially-viable technologies that reduce or eliminate undesirable effects of high viscosity on sugar processing and end-product quality.
Objective 3. Develop commercially- viable technologies to increase the stability and lengthen storage of sugar feedstocks.
Objective 4. Develop commercially-viable technologies for the biorefining of sugar crop feedstocks into advanced biofuels and bioproducts.
Objective 5. Identify and characterize field sugar crop trai ts that affect sugar crop refining/ biorefining efficiency, and collaborate with plant breeders in the development of new cultivars/ hybrids.
Objective 6. Develop, in collaboration with commercial partners, technologies that enable production of marketable products from residues and by-product streams.
Develop Technologies That Enable Growth and Profitability in the Commercial Conversion of Sugarcane, Sweet Sorghum, and Energy
Beets into Sugar, Advanced Biofuels, and Bioproducts
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Lead Scientist
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Largest Sweet Sorghum Biorefinery in USA
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Sikeston, Missouri, USA
Heckemeyer Mill (2015)
Poultry
Cattle
Timber
Row crop sweet sorghum
x
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Heckemeyer Mill
2015
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Heckemeyer Mill
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Heckemeyer Mill
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Heckemeyer Mill
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Heckemeyer Mill
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Row-cropped sweet sorghum
Heckemeyer Mill
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• Multiple Cultivars: e.g., M81E, Honey Drop, Dale, and KN Morris
• Plant late May/Early June
• Stagger the rotation for timely harvest
• Process from Mid August (depends on Juice Brix)
• Modified Forage Harvesting - up to 2.5 inch billets
Heckemeyer Mill
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Double Tandem 4 ft Wide Roller Mill
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Overcoming Processing Problems with Help of USDA
Scientists
Aim: Large, Commercial Scale Manufactureof Food Grade and Non-Food Grade Syrup
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August to October, 2014
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Major Starch Problem
Eggleston et al (2015.). Sugar Tech.
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Heated, De-aeratedSweet Sorghum Juice
Scum formed on surface
Formation of Flocs (Light Color) which are Starting to Precipitate
Clarified (Clean) Juice 92% Turbidity Removal over 1 hr
Eggleston Clarification Process
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New Late Season Problem
Microbubbles
Light Green Scum Formation on Surface of Clarification Tank
7.93 ± 0.52% proteinon a dry wt basis
Has to be skimmed off or filter pressed
Highlights seasonal variations that warrant further investigation
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Syrup (Long-Term) Storage
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Extraction De-aeration Heating Clarification EvaporationSettling
Overall Process and Supply Chain for Syrup Production at Heckemeyer Mill
ensiledbagasse mud
High Value Cattle Feed
V. minimalwaste
processing
sediment
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QualityControl
Stabilizationof Juice
Assuranceof Supply
BusinessContinuity
Extraction De-aeration Heating Clarification EvaporationSettling
2015 Process and Supply Chain for Syrup Production at Heckemeyer Mill
Capacity of Mill is 90 tons/hr which is approx. 120 acres/day or 24,000 gals of 80 Brix syrup/day
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Thank You