Biofuel co-products as livestock feed - Opportunities and challenges

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Utilizing co-products of the sweet sorghum-based biofuel industry as livestock feed in decentralized systems 231 Linkage between centralized model anddecentralized models of the sweet sorghumsupply chainmaterial supply. Examples of such centralized plants includeRusni Distilleries Ltd, Sangareddy, Medak District, AndhraPradesh, India; Tata Chemicals Ltd, Nanded, Maharashtra,India; and ZTE Ltd, Inner Mongolia, China.Decentralizedmodel(200 farmers)Decentralizedmodel(200 farmers)Decentralizedmodel(200 farmers)Ethanol distilleryCentralized model(1000 farmers)Decentralizedmodel(200 farmers)Decentralizedmodel(200 farmers)The decentralized modelFigure 1 illustrates the overlap of the two models, showinglinkages of hundreds of farmers to decentralized crushingunits (DCU), while thousands connect to a central distillery.The finer details reflect productivity, capacity utilizationand other factors. In simple terms a DCU comprises thecrusher and boiling unit, and essentially crushes the stalksto extract juice. The extracted juice is either concentratedto syrup or fermented in situ to alcohol. The forward andbackward linkages of DCU are illustrated in Figure 2. Sweetsorghum is a seasonal crop that in India can be cultivatedin three seasons a year (rainy, post-rainy and summer) tosupply raw material for 3 to 4 months annually for ethanolproduction (Kumar et al., 2010). The grain and sugar yieldsare best in the rainy and summer seasons, whereas in thepost-rainy season the grain yield is high, but with less stalkand sugar yield. A commercial ethanol distillery requires Decentralized model. A village enterprise to crush stalks and produce syrup, linked with a centralized unitto produce ethanol from syrupBackward linkagesCluster of villagesFarmersInput linkages –seed, fertilizer, pesticide,technical supportCapacity buildingEnhance stalk productivityand supply to DCUPartner/ICRISATForward linkagesBuy-back agreementwith distilleries for syrupSyrup supply to distilleries(centralized model)Micro enterprises:Juice extracted at DCUin the village andconverted into syrupEthanolBy product of bagasse:for cattle feed or vermicompost
232Biofuel co-products as livestock feed – Opportunities and challengesfeedstock year round – for at least 10 months annually –for economical operation. However, in regions with shortharvest windows, smaller acreages or with low plantationdensities, a typical centralized model with a 30 kilolitres perday (KLPD) processing plant dedicated to sweet sorghumethanol production could operate only seasonally, requiringa high capital investment that might not be cost effective.In areas with low plantation densities, the transportationcosts associated with supplying the plant with sweetsorghum feedstock become prohibitive. Transportationcosts are a significant cost factor in all sweet sorghummodels studied, with costs ranging from US$ 34 toUS$ 107 per tonne of fermentable carbohydrates (Bennettand Anex, 2009). Larger plant sizes may not benefit fromtraditional economies of scale because of the increasedtransportation costs associated with longer travel distances.Due to these limitations, alternative processing optionshave been investigated. In view of the need for regularsupply of feedstock to the distillery, it is widely believedthat DCUs help in sustainability of the supply chain. Thejuice obtained after crushing the stalks is boiled in pansto produce concentrated syrup (~60 percent Brix) (Photo1), which is supplied to a distillery for ethanol production(Reddy et al., 2009).Alternatively, extracted juice can also be fermentedin situ, resulting in a fermentation mash containing6–10 percent ethanol. Studies have shown that non-sterilefermentation in the field is possible, with very good ethanolconversion efficiencies, as demonstrated by a researchgroup at the University of Oklahoma, USA (Kundiyana etal., 2006). As an alternative to fermentation of the sweetsorghum liquids, several groups have investigated thesolid-phase fermentation of sweet sorghum for productionof ethanol as it (i) has greater ethanol production per unitvolume of the fermenter, (ii) has reduced fermentationcapacity requirement, (iii) has no nutrient supplementationrequirement, (iv) has lower production costs, (v) leavessmaller volumes of stillage for disposal, and (vi) needs lessenergy for distillation (Gibbons, Westby and Dobbs, 1986).In these systems, shredded sweet sorghum is injected intoa solid-phase fermenter, inoculated with yeast, and mixedduring fermentation. Fermenters have been of varied sizesand configurations, including rotary drums and screwaugers (Gibbons, Westby and Dobbs, 1986). Solid-phasefermentations typically result in higher ethanol yield thanfermentation of the juice alone (78 percent of theoreticalethanol yield in solid state versus 75 percent in juicefermentation) (Bryan, Monroe and Caussanel, 1985), butmay have higher capital costs and lower throughput. Othervariations to the system have included operating in a semicontinuousrather than batch mode, and application ofimmobilized yeast in the system, both of which improvedsystem performance.Potential advantages of small-scale, decentralized ethanolprocessing are: Promotes biodiversity by using more diverse feedstock. Enhances food security and food system resilience byensuring that geographically diverse farms have accessto locally-produced renewable fuel for food production. Promotes resource cycling by keeping nutritious co-productsof ethanol production close to their farm source,where they can be returned to farms for feed or fertilizer.ABCPhoto 1Decentralized sweet sorghum crushing unit. A. Crushing.B. Bagasse. C. Boiling the juice to produce syrup
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BIOFUEL CO-PRODUCTS AS LIVESTOCK FE
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Recommended citationFAO. 2012. Biof
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vco-products to swine - Feeding cru
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viiCHAPTER 22Use of Pongamia glabra
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ixPrefaceHumans are faced with majo
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xiiCBMCBSCCDSCCKCDOCDSCFCFBCFRCGECI
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xivHCHOHClHCNHisH-JPKMHMCHPDDGHPDDG
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xviPPbPCVPDPEMPFADPhePJPKCPKEPKMPKO
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xviiiWBPWCGFWDGWDGSWDGSHWPCWTWWWNSK
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2Biofuel co-products as livestock f
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10Biofuel co-products as livestock
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35Chapter 3Impact of United States
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Impact of United States biofuels co
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101Chapter 6Hydrogen sulphide: synt
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Hydrogen sulphide in cattle fed co-
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155Chapter 8Utilization of crude gl
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Utilization of crude glycerin in be
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Sustainable and competitive use of
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291Chapter 16Scope for utilizing su
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Scope for utilizing sugar cane baga
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303Chapter 17Camelina sativa in pou
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Camelina sativa in poultry diets: o
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311Chapter 18Utilization of lipid c
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Utilization of lipid co-products of
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351Chapter 21Use of detoxified jatr
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Use of detoxified jatropha kernel m
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379Chapter 22Use of Pongamia glabra
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Use of Pongamia glabra (karanj) and
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403Chapter 23Co-products of the Uni
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Co-products of the United States bi
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467Chapter 26An assessment of the p
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An assessment of the potential dema
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483Chapter 27Biofuels: their co-pro
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Biofuels: their co-products and wat
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501Chapter 28Utilization of co-prod
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Utilization of co-products of the b
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523Contributing authorsSouheila Abb
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Contributing authors 525for the Fee
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Contributing authors 527Friederike
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Contributing authors 529Sustainable
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Contributing authors 531During the
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Contributing authors 533(Hons.) and
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Biofuel co-products as livestock feed - Opportunities and challenges

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