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Stover Update 3
- 1. Machinery Innovations toMeet Biomass Harvesting Demands in Expanding United States Markets Dr. Matt Darr, Iowa State University
- 2. First Generation BiorefineryScale • 30 MGPY of liquid fuel production • 80 gallons of liquid ethanol fuel per ton of biomass • 900,000 large square bales per year (3ft x 4ft x 8ft) • 1 bale processed every 30 seconds • 25,000 semi trucks of bales delivered • 45,000 tons of ash byproduct Agricultural and Biosystems Engineering
- 3. Iowa State’s Rolewith Biorefinery Development • Support biorefineries with key technical information on all aspects of a corn stover biomass supply chain. • Support producers in understanding the management of corn stover production. • Support growth in key service areas to enable job creation and supply chain efficiencies. Agricultural and Biosystems Engineering
- 4. Corn Stover SupplyChain Agricultural and Biosystems Engineering
- 5. Innovations to EmpowerStep Changes in Supply Chain Costs 1. 2. 3. 4. 5. Increased harvest rate through baler machinery innovations. Increased unit package density through technology enhancements and operational excellence. New machine forms which eliminate passes through the field. High capacity transportation systems. Telematics business rule integration to ensure efficiency gains. Agricultural and Biosystems Engineering
- 6. Feedstock Quality Increase ThroughRefined Windrow Design Agricultural and Biosystems Engineering
- 7. New Machine Forms: SinglePass Harvesting Benefits • Direct baling of corn stover eliminate soil contamination and reduces ash content from ~10% to less than 4%. • Windrowing pass is eliminated and baling operator and tractor are also eliminated. Challenges • High feedstock moisture content requires special handling. • Reduces peak grain harvest capacity of the combine. Agricultural and Biosystems Engineering
- 8. New Machine Forms: WindrowingCorn Headers Benefits • Creates a windrow with the combine and allows higher collection efficiency of cobs. • Reduces ash content from ~10% to ~7%. • Eliminates windrowing pass and maximizes harvest collection rate. Challenges • High feedstock moisture content requires special handling. • Requires close coupling of baling systems to collect feedstock in a timeline manner. • Complicates grain unloading logistics. Agricultural and Biosystems Engineering
- 9. High Capacity Transportation Systems Agriculturaland Biosystems Engineering
- 10. High Quality FeedstockStorage Agricultural and Biosystems Engineering
- 11. Agronomic Impacts of CornStover Harvest Agricultural and Biosystems Engineering
- 12. Direct Impacts ofTelemetry in a Production Supply Chain • Supply Chain Benefits – Directly reduce feedstock production costs. – Directly reduced capital equipment requirements. – Guide new production crews towards improved operating efficiencies. – Provide informed decisions on crew performance. – Provide traceability of feedstocks and improved inventory management. Telematics Features • • • • • • ISOBUS Interface GPS Interface Cellular Modem Wifi Data Logging Direct Business Rule Software Agricultural and Biosystems Engineering
- 13. Multiyear Case StudyResearch on Biomass Production Costs • 100,000 ac corn stover harvest conducted in partnership with DuPont Cellulosic Ethanol. • 160,000 tons of corn stover production monitored for feedstock quality and machinery productivity analysis. • Key Results: – In depth technoeconomic model – Selection of optimized harvest equipment configurations – Implementation of technology to directly target cost reduction strategies Agricultural and Biosystems Engineering
- 14. Cost of BiorefineryGate Delivered Corn Stover ~30% for Transportation ~30% for Harvesting ~21% ~$122/std. Mg Annual Working Capital: ~$45.6 millions/yr Agricultural and Biosystems Engineering
- 15. Sensitivity Analysis: CornStover Supply Chain Costs Top 4 highest supply chain cost influencer related to baling operation 10 out of 15 top supply chain cost influencers related to feedstock supply operations (i.e., Production-specific parameters) decrease by ~$22/std. Mg Bale density alone can decrease supply chain cost by ~$8/std. Mg increase by ~$29/std. Mg Bale density alone can increase supply chain cost by ~$9/std. Mg Agricultural and Biosystems Engineering
- 16. Cumulative Supply ChainImpact Excluding Nutrients: ~$91/std. Mg Strategy 1: Reducing Stover Collection Area, Cost Savings: ~$11/std. Mg Durations Efficiencies Strategy 2: Reducing Bale Supply Quantity, Cost Savings: ~$16.5/std. Mg Strategy 3: Reducing Quantities of In-Field Machineries, Cost Savings: ~$11.5/std. Mg • Final Cost: ~$52/std. Mg • and Biosystems Engineering AgriculturalTotal Cost Savings: ~$39/std. Mg • Cost Reduced by ~43%
- 17. Questions Department of Agriculturaland Biosystems Engineering