Iowa State University, Ag Engineering/Agronomy, Central Iowa, and BioCentury Research Farms ISRF16-16, 30

BioCentury Research Farm Summary

RFR-A16140 - Thermochemical research that included biomass gasification, pyrolysis, and solvent Andrew Suby, manager liquefaction processes - Educational support Introduction - Infrastructure and equipment The BioCentury Research Farm (BCRF) had a - Grants, appropriations, donations, and diversity of users in 2016. Iowa State awards University (ISU) faculty and staff from the Departments of Agricultural and Biosystems Algae. Various production systems, including Engineering (ABE); Agronomy; flat panel bioreactors, two raceway pond Biochemistry; Chemical and Biological systems, a novel revolving algal biofilm Engineering (CBE); Civil, Construction, and (RAB) system, and various lab-scale reactors Environmental Engineering (CCEE); and located in the BCRF Algae Facility are being Food Science and Human Nutrition (FSHN), used to grow algae. The major focus for these as well as the Bioeconomy Institute (BEI), algal growth systems is removal of nutrients Center for Crops Utilization Research (nitrogen and phosphorus) and toxic metals (CCUR), College of Agriculture and Life from municipal and industrial wastewaters. A Sciences (CALS), and Extension and mobile pilot-scale RAB system was developed Outreach conducted research, teaching, and/or in 2015 to treat wastewater on site at outreach at the BCRF. Private industry users municipalities and industrial processors. of the BCRF included ARGO, Deere & Offsite projects in Fort Dodge and Dallas Company, DuPont Cellulosic Ethanol, Phillips Center, Iowa, and numerous demonstrations 66, and many others. By the end of 2016, the employed this mobile unit in 2016. BCRF had more than 80 full- and part-time users with projects in all available space. Additionally, newer belt designs were added and further research was conducted on The BCRF Advisory Council was established component materials and processes. Projects in the first quarter of 2016. The first meeting with municipal and industrial groups was held May 17–18. The council discussed continued throughout the year to include the BCRF's strengths and weaknesses to help private companies and the City of Chicago, identify short- and long-term goals and (Illinois) water treatment plant. The developed an action plan for future work. researchers led by Zhiyou Wen, FSHN, can produce 1.3 to 4.5 kg of dried algae Research, Education, and Equipment biomass/week in the BCRF facility. A great deal of project activity occurred in the following areas: The diverse algae species grown in the facility are suited for different end uses. Algae with - Algae research and production methods high lipid levels are best for producing - Biochemical research biodiesel, and algae with high protein levels - Biomass feedstock logistics research and good amino acid profiles are used for - Biomass preparation livestock feed. Algae biomass grown on - Biopolymer research wastewater is being studied as an organic fertilizer.

10 Iowa State University, Ag Engineering/Agronomy, Central Iowa, and BioCentury Research Farms ISRF16-16, 30

Biochemical. Work expanded in this area in spp. rhizomes with a semi-automated planter 2016. Bench-scale projects continued on at three locations in Iowa. This project, the campus and there is the potential for scaling Long-Term Assessment of Miscanthus these up at the BCRF in 2017. In February, a Productivity and Sustainability (LAMPS), is project to grow a single cell microbe was designed to answer several questions about completed in the 500-liter fermentor for an Miscanthus  giganteus production. The industrial client. In the fourth quarter, work overarching goal for LAMPS is to answer the began on several week-long fermentations in questions farmers are asking about the 1,000-liter fermentor for another industrial Miscanthus, especially those concerning client. This work continued into 2017. Steam fertility rates and quantifying yields using tube drying testing was completed in August. commercial harvesting equipment.

Biomass feedstock logistics. Multiple projects LAMPS has several partners and sponsors to continued in this area in 2016 with the most accomplish its project goals. ISU and the notable ones related to the DuPont Cellulosic University of Iowa assisted with planting Ethanol (DCE) and POET-DSM Advanced costs; Repreve Renewables, LLC provided Biofuels research led by Matt Darr and Stuart plant material and planting equipment; New Birrell, ABE. Holland Agriculture provided equipment leases; and the Bioeconomy Institute, For the DCE project, work continued in the Department of Agronomy, Iowa Energy area of corn stover bale collection and quality Center, and Leopold Center for Sustainable assessment, and added bale processing at the Agriculture provided funding and support. inlet of the plant. The BCRF received numerous bales for observation, stack testing, Biomass preparation. The BCRF prepared ash and moisture content sampling, and other biomass feedstocks for several internal and attribute testing. Over 11,000 bale samples external clients (e.g., universities, national were processed during the 2016 harvest. This laboratories). The farm’s biomass preparation is a typical number of samples processed. lab was used to fine grind, screen, and size the feedstocks. Biomass drying projects also were The DCE plant continued to be commissioned completed. In separate projects, 10 different with a projected date of operation of mid-year entities received processed material totaling 2017. over 19 tons of various feedstocks milled with 0.5 to 19 millimeter screens. Agricultural product development and research support for and from several major In one particular project, the BCRF milled 15 agricultural equipment manufacturers such as tons of corn stover and switchgrass for an off- AGCO, John Deere, New Holland campus industry client. The material was Agriculture, and Vermeer continued in 2016. milled using a round bale processor adapted to In particular, New Holland Agriculture milling square bales. The biomass was used continued to provide ISU with equipment for by the client to test processing equipment quantifying the efficiency of harvesting performance. biomass crops. Drying projects were completed throughout The New Holland equipment enabled the the year and used several different methods. BCRF to continue helping Emily Heaton’s Biomass materials such as wood chips, corn research group (Agronomy) plant Miscanthus stover, and switchgrass were dried using a

11 Iowa State University, Ag Engineering/Agronomy, Central Iowa, and BioCentury Research Farms ISRF16-16, 30 combination of different drying methods such from ABE, Agronomy, FSHN, and Plant as oven, belt conveyor, and rotary steam tube Pathology and Microbiology, as well as the dryers. CyBiz Program, visited the farm.

Biopolymer research. The Bio-Polymer The BCRF also supported several capstone Processing Facility was completed and projects that included development of a low- dedicated August 26, 2015. The project was temperature grain drying system, a led by Eric Cochran (CBE) and Chris Miscanthus single pass harvester, a zipline Williams (CCEE) in collaboration with Argo retrieval system, and a baler bearing wear Genesis Chemical, LLC, an affiliated measurement test program. company of Seneca Petroleum, Crestwood, Illinois. System commissioning, cold weather Infrastructure and equipment. The DuPont repairs, and an extensive process safety review soil separator was delivered to the BCRF in were completed in 2016. Research will begin mid-year 2016. Concrete footings were in 2017. installed in late 2016 and the system will be reassembled in 2017. Thermochemical. Robert Brown’s (BEI, Mechanical Engineering) fast pyrolysis unit Grants, appropriations, donations, and located at the BCRF was used for bio-oil awards. The BCRF has been well supported production from red oak and corn stover for by private industry donations. In 2016, internal and external projects. This work was DuPont Cellulosic Ethanol (DCE) donated a done to explore possible uses for individual one-of-a-kind soil separator processing plant fractions, including a path to fermentable valued at $219,000. This addition allows the sugars and generation of pilot-plant data for BCRF to provide stover at ash content rates system scale up. Excellent progress was made below typically harvested material. in increased throughput using autothermal pyrolytic processes, sustainable corn stover In 2010, the BCRF was recognized by processing, and alternative collection stage Biofuels Digest as the Institutional Research design. Facility of the Year. In 2016, the Association of Public and Land-grant Universities BEI’s research continued in the area of designated Iowa State as an Innovation and gasification gas cleanup for syngas Economic Prosperity University citing the fermentation. Simulated contaminants were BCRF as one of its noteworthy removed from bottle gas using a slipstream- accomplishments. scale scrubbing column test rig. The gasifier process development unit is ready for the next Outreach, Visitors, and Tours potential project in 2017. Information dissemination and promotion was accomplished through tours, conferences, and The solvent liquefaction pilot plant became symposia. Tours were provided for 103 groups fully operational in late 2015. Work on a with approximately 1,505 visitors in 2016. battery of tests began near the end of the first Since the dedication in 2009, BCRF has quarter and continued to the end of the year hosted 787 tours with 13,073 visitors. and will continue through summer 2017. This is a BEI and Chevron collaborative project. The 2016 tours included visits by American Association of State Highway and Educational support. The BCRF hosted many Transportation Officials, Ames Chamber of ISU class tours. In 2016, over 200 students Commerce, Australian farmers, Boone

12 Iowa State University, Ag Engineering/Agronomy, Central Iowa, and BioCentury Research Farms ISRF16-16, 30

Chamber of Commerce Leadership Group, - Roquette Boone County Disaster Assistance - Valent Biosciences Committee, Des Moines Engineering Club, Farm Progress Show, Hebei Province (China), The BCRF also gave numerous tours to IEEE, International Farmers Aid Association, students and teachers from K-12 schools as Iowa Economic Development Authority, Iowa well as the following groups and workshops: Farm Bureau, Iowa Governor Terry Branstad, Iowa Lieutenant Governor Kim Reynolds, - CBiRC Biorenewables Workshop for former Iowa Lieutenant Governor and U.S. Elementary Teachers Senate candidate Patty Judge, KWQC-TV, - CBiRC Summer Academy Kyrgyz Republic group, SBIR/STTR National - FFA Students Road Tour, U.S. Congressman David Young, - Waterloo West High School U.S. Department of Commerce, U.S. Senators - Waukee APEX students Charles Grassley and Pat Roberts, and a West Africa group. Tours were given for students and professors from DMACC, Iowa Central, University of Several companies and other organizations Michigan, and foreign universities in Belarus, also visited including the following: Brazil, Costa Rica, India, Korea, and Thailand. - Annikki GmbH - Arvegenix The BCRF participated in two conferences. In - AVEKA, Inc. August, the Biofuels: Science and - Bayer Crop Science Sustainability Tour group of approximately 50 - Biova congressional aides and federal agency - Context staffers visited. In September, groups from the - Deere and Company Petroleum Marketers and Convenience Stores - Doerfer of Iowa Energy Conference were given guided - Dreamfield Ventures tours. - DuPont - Emerson The BCRF was an exhibitor at the 2016 Iowa - Enginity Renewable Fuels Summit and Trade Show - Fraunhofer-Gesellschaft January 19 in Altoona, Iowa. Many attendees - General Mills visited the exhibit and were able to see - Grain Processing Corp. samples of materials produced at the BCRF - Harima Chemicals Group including algae, ground feedstocks, bio-oil, - Kemin Industries biochar, and torrefied corn stover pellets. - Nationwide Insurance - Nelson Engineering Through close cooperation with the ISU - New Holland Research Farms, ISU Center for Crops - PepsiCo Utilization Research, Ames Convention and - Phillips 66 Company Visitors Bureau, BEI, and ISU Foundation, - Quaker Oats many public organizations, private companies, - Renewable Energy Group international organizations, and citizens of - Renmatix Iowa have visited the BCRF. - Roeslein

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