Technologies for Utilisation of Crop Residues

PowerPoint Presentation: 

Dr. R. T. Patil Director, Central Institute of Post Harvest Engineering and Technology, Ludhiana Bioprocessing Technologies in Utilization of Crop Residues – An Overview

PowerPoint Presentation: 

Availability of Agricultural Biomass in India Food grains-over 200 million tons Biomass @60%-120 million tons Processing by products @20%-16 million tons Fruits & Vegetables-over 150 MT Biomass @50%-75 million tons Chemical extracts Pyrolysis co-products Bioprospecting (medical, enzymes) Natural pesticides Bio fuels Bio-polymers

PowerPoint Presentation: 

Low bulk density High moisture content Increased transportation costs Lower energy value Lower heating value (20% lower than coal) High oxygen content – have to remove to convert to hydrocarbons Solids more difficult to handle & transport Challenges to Biomass Utilization

Thermal Gasification of Crop Residues: 

Thermal Gasification of Crop Residues Conversion of biomass to most volatile carbon monoxide, hydrogen, carbon dioxide and methane and its fermentation to ethanol Thermal gasification followed by conversion to distillates (green diesel) Thermal gasification of the biomass followed by methanol synthesis, dehydration and catalytic conversion to dimethyl ether, a higher-reaction-temperature, higher-cetane compound that is an excellent diesel fuel substitute Conversion of biomass to bio-oils by pyrolysis

Solid State Fermentation: 

Solid State Fermentation Effective for production of enzymes, Single Cell Proteins (SCP) Simple, Convenient and results in higher yields Crop residues can serve as a good substrate for solid state fermentation Problems of heat transfer and scale up

Converting Lignocellulosic Materials to Bio-polymers : 

Converting Lignocellulosic Materials to Bio-polymers Advantages: 1) All components of feedstock material are totally utilized in this process. 2) The bio-polyols (liquefied mixture) including liquefying chemicals can be directly used as polymer building blocks. No complicated and costly processes are necessary for purification and fractionation. 3) No toxic substances are involved and no pollutants are emitted in the process. 4) Polymers from the biopolyols should be biodegradable. 5) Low investment and operation cost can be expected because of mild operation conditions.

Bioprocessing Technologies for Crop Residues: 

Bioprocessing Technologies for Crop Residues Efficient process for production of ethanol (Need for efficient microbial strains) Production of enzymes such as cellulase, xylanase, pectinase and protease Production of industrially important products such as citric acid Single Cell Protein ( SCP ) production Utilization of crop residues for cattle feed, composting, mushroom production etc after fermentation

Technologies for Crop Residue Management: 

Technologies for Crop Residue Management Densification and pelletization (Low bulk density of residual material) Pretreatment for delignification (Hard lignocellulosic complex) Conversion of pretreated biomass into fermentable sugars (Role of hydrolysis and enzymes)

Major Hindrances to Crop Residue Management: 

Major Hindrances to Crop Residue Management Cellulosic ethanol production is costly and energy intensive process Thermal gasification needs very high temperatures and a lot of infrastructure Fermented residues might contain mycotoxins which need to be addressed. Composting is a time consuming process in absence of efficient cellulose degraders.

Physical Treatment: Grinding & Pelleting: 

Physical Treatment: Grinding & Pelleting Increases surface area for fast microbial action Helps in breaking the complex bonds to a certain extent Energy intensive process

Pre Treatment Processes: 

Pre Treatment Processes

Steam Treatment: 

Steam Treatment Good for horticultural residues because of low degree of polymerization Releases some hemicellulosic fraction sugars into the hydrolysate Simple and Economical but not very effective

Acid Hydrolysis : 

Acid Hydrolysis Hydrolysates contain inhibitory compounds which restrict the fermentation process Requires additional step of detoxification High acid concentration is corrosive and difficult to handle

Alkali/ Ammonia Hydrolysis: 

Alkali/ Ammonia Hydrolysis Significant delignification and solubilization of cellulosic biomass Loss of important hemicellulosic fraction High loss in weight of the pretreated substrate Requires lot of neutralization

Novel Pretreatment Methods: 

Novel Pretreatment Methods Microwave treatment (with/ without chemicals) Extrusion processing (with/without chemicals) Super critical carbon dioxide treatment

Application of Hydrolysed Material: 

Application of Hydrolysed Material Silica from rice straw and or wheat straw can be used in cement industry, for clarification of oils, as an adsorbent. Lignin has a plenty of uses in tanning industry, as an adhesive, binder and dispersant Ligno-chemicals such as syringic acid/ syringaldehyde and vanillic acid/ vanilldihyde have a lot of uses in perfumes and flavours

Utilization of Fermented Residue: 

Utilization of Fermented Residue Cattle/ poultry/ fish feed supplement especially in case of horticultural residues Preparation of fine quality compost Mushroom cultivation

Enzyme Production: 

Enzyme Production

Enzyme Production: 

Enzyme Production Powder production Technology ferment liquid acquire clear liquid through Flat-frame filtration or Ceramic membrane filtration. Use the ferment liquid directly, mixing followed by spray drying, and then separate the rough powder, fine power and residue by sifter. Main equipment: ferment liquid storage tank, filtration equipment(optional), spray dryer or airflow dryer.

Enzyme Production: 

Enzyme Production Granular production technique Sprayed powder is mixed through stated proportion and carrier and excipient, and then enter to swaying granulator to make the granulate. At last, separate them by sifting equipment. Main equipment: mixer, swaying granulator, aerator, multi-function granulator, sifting equipment.

Enzyme Production: 

Enzyme Production Coated enzyme production technique Sprayed powder is mixed in a certain proportion with carrier. Enters extrusion granulator, and then goes to the Aerator to make pill, then into the boiling dryer granulator to obtain a pill core, pill core is  coated in the coating machine and separated by sifter. Main equipment: mixer, extrusion granulator, Aerator, multi-function granulator(with coating function), sifting equipment.

Enzyme Production: 

Enzyme Production Liquid enzyme production technique ferment liquid passed through flat-frame filtration, centrifugal machine or ceramic membrane filtration. Main equipment: centrifugal machine or flat –frame filtration machine, Ceramic membrane filtration system, producing tank,ready products storage tank

Bottlenecks in Enzyme Production: 

Bottlenecks in Enzyme Production Available microbial strains do not have high potential of enzyme production Enzyme concentration and purification is an energy intensive and expensive process as it requires a lot of paraphernalia. Molecular biology techniques are expensive and time consuming

Biotech-engineering Interventions: 

Biotech-engineering Interventions Strain improvement using simple protoplast fusion and mutagenesis especially for developing recombinants for fermentation Developing microbes which can produce fairly large amount of product in less time and generating less wastes Making the process fast and economically feasible through emerging process technologies

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