Advanced BioFuels USA

by Alayna DeMartini (Ohio State University College of Engineering)  Although the stalks and leaves of a corn plant can be turned into ethanol, the high cost of collecting, storing, and transporting the material has limited its use in producing the fuel. Ajay Shah, an agricultural engineer at The Ohio State University, is testing a method that could cut the cost of collecting and delivering corn plant material for making ethanol by up to 20%.

Shah just received a $1 million grant from the U.S. Department of Agriculture to test the effectiveness of a new method that harvests and transports corn plants intact, the ears together with the stalks. Shah’s strategy has the potential to spur the lagging industry of so-called cellulosic ethanol—ethanol produced from the inedible parts of plants, most commonly corn plants in the United States.

“We have an opportunity to significantly cut the cost of taking agricultural waste and turning it into a sustainable fuel,” said Shah, an assistant professor in the Department of Food, Agricultural and Biological Engineering (FABE).

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The system still would gather about half of the corn plant, leaving the remaining dry corn stalks in the field to prevent erosion and return organic material and its associated nutrients to the soil.

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“We’re working on improving the efficiency of everything from harvest to processing at a biorefinery,” Shah said. “We are focused on reducing the cost and environmental impacts of logistics.”

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The system Shah is testing involves harvesting the corn plant so the ears and a portion of the stalks are not separated in the field but are sent as a single package to the biorefinery. Separating the corn kernels from the rest of the plant requires a combine, which is expensive and currently used in the field only a few months of the year. 

If, instead, the farmer were to collect the cobs and stalks at the same time, he or she could then have them baled and stored on the farm or at a centralized storage location. A stationary machine that separates the grain from the rest of the plant could operate throughout the year, maximizing its use.

Additional cost savings can result from the delivery of the bales. Baling the corn plant material has been a challenge because it is difficult to compact into dense bales, resulting in additional costs to transport it. The bed of a truck may be filled before its weight capacity is met. So Shah has been testing various ways to compact and bale the whole corn plant, including the ears with grain, so that the bales are more dense. The more densely packed the bales, the cheaper it is to transport them.  READ MORE