Effect of starch-based natural and synthetic binders on densification of sugar cane trash

doi:10.21203/rs.3.rs-3562353/v1

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Effect of starch-based natural and synthetic binders on densification of sugar cane trash

https://doi.org/10.21203/rs.3.rs-3562353/v1

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The growing demand of energy and the concurrent uplift in greenhouse gas emissions is attributed to the global waning of fossil fuels. In this regard, densification of biomass presents a viable and eco-friendly approach for producing solid fuels. Sugarcane trash is one of the promising biomasses used for energy production. This study aims to analyze and evaluate the effect of pretreatment and binder’s concentration on the densification of sugarcane trash. For this purpose, sugarcane trash is pretreated with hot water at 80°C in a 1:15 solid-to-liquid ratio (S/L) and densified by adding two different starch-based binders named as natural binder (low-grade broken rice) (NB) and synthetic binder (Maya) (SB) with three different concentrations i.e., 10%, 20% and 30%, followed with the palletization. After densification, the pellets are characterized by physical, mechanical, thermal, and structural properties. The results indicated that pellets with 10%SB presented optimum properties. Pellets with 10%SB pellets showed higher heating values (4301.17 Cal/g) (HHV), a crucial property for the design calculations or simulations of thermal conversion for biomass. The pellet strength is suggested to be linked with the composition of binder and biomass which is linked with the binding of binder and biomass material in the densified biomass. It is evident from the results that sugarcane trash pellets can fulfill energy requirements as per the needs of the present era keeping in view the green and sustainable environment. Thus, rather than burning the sugarcane trash which causes pollution, densified pellets are of great significance for bioenergy production.

Greenhouse gases emission

Sugar Cane trash

natural binder

synthetic binder

densification

The increased energy demand and the progression of living standards have posed several challenges in meeting the energy requirements. Not only in Pakistan, the global inclination of renewable energy resources for energy production has been increasingly driven with the rapid depletion of fossil fuels and the raising awareness of clean energy. In addition to fossil fuels depletion, there is also an implied issue of ecological effect with the use of fossil fuels [1]. Fossil fuel burning produces, greenhouse gasses (GHG) and carbon dioxide (CO₂) emissions to about 35.341 billion metric tons (2021) [2]. Only 50% of the produced CO₂ is being eradicated by natural processes, while the rest of the amount remains in the atmosphere which in turn causing a rise in the earth’s temperature [3]. Reducing GHG and other harmful pollutants emissions is crucial. Most developed countries have signed treaties to improve citizen life, maintain social equality, and preserve natural resources [4]. Renewable energy production is the only solution to energy, pollution, and economic problems [5].

Renewable energy sources like solar, wind, hydroelectric power, geothermal, and biomass are widely used in many countries, contributing to clean energy production and meeting energy needs, though some are climate-dependent and require specific planning [6]. Nowadays, biomass energy has gained much attraction due to its zero carbon emission [7] and efficient waste management [8]. Biomass is present in vast quantities and can be used for energy production [5]. Energy from waste not only aids in the energy generation for power plants but also plays a role in waste management and in the reduction of negative environmental impact associated with these wastes. Biomass waste includes agricultural waste, human waste, animal waste, food processing, and forestry waste [9]. Biomass due to its vast range category has eminent potential to increase energy supplies in populated countries. For power generation and heating processes, biomass can be directly burned [10].

The importance of biomass in the generation of power from the conversion of waste to energy is increasing due to its carbon-neutral properties and renewable characteristics [6]. Biomass of agricultural waste includes bagasse, dry sugarcane leaves, rice husk, rice straw, wheat straw, and corncobs. These residues are burnt on field sides in an open atmosphere due to lower heat content and irregular shape which in turn causes air pollution [11]. Problems that are associated with the usage of raw biomass material are its low bulk density, high moisture content, and hydrophilic character, presence of dust particles, low volumetric energy content, lower heating values, and irregular shape which make its handling and transportation difficult [12]. In this regard, densification of biomass is stated to be the best practice. Pelletization of biomass not only provides improved combustion and physical properties but also facilitates uniformity in material along with low moisture content which makes transportation easier [13].

Sugarcane is cultivated abundantly in many countries. Sugar is the main product of sugarcane, along with it produces several by products which can be utilized as energy source [14]. Bagasse is considered as the main waste by-product with a strong energy potential [15]. After the processing and densification process, bagasse became a valuable source of energy and also a substitute source of carbon-neutral renewable energy [16]. On the other hand, leaves and stem also considered as the wastes. The leaves and stems are undesirable products during the milling process so during harvesting they are detached from the stalk. Sugarcane stems and leaves are collectively known as sugarcane trash. Every ton of harvested sugarcane produced around 140 to 180 kg of sugarcane trash [17]. Sugarcane trash can be efficiently converted into solid biofuel through the formation of pellets. Pellets of sugarcane trash can be used as a source of energy in power plants for electricity generation. However, pellets without pretreatment cause operational problems such as fouling, slagging, agglomeration, and corrosion in furnaces and boilers due to the presence of inorganic constituents [18]. In addition to that when these inorganic constituents are combusted they cause air pollution by emitting oxides of sulfur and nitrogen whereas ash content gives rise to the emission of particulate matter. In return emissions caused by these compounds have a severe influence on the environment and especially on human health [19].

The efficient conversion of biomass into energy resources along with the densification technique includes the pretreatment method. The purpose of the pretreatment method is to remove inorganic constituents, making biomass energy efficient and making its transportation easy [20]. Among all pretreatment techniques, chemical pretreatment is the most effective for the reduction of inorganic components and ash content. It includes the demineralization, leaching, washing, and valorization methods. Studies revealed that washing treatment using acid and water is the most efficient pretreatment technique for the removal of inorganic components and reduction in ash content in biomass [21].

The acidic and basic treatment removes ash content to a higher level [22]. For the efficient usage of biomass in power plants, water washing fractionation is determined as the suitable treatment as it is low-cost and environmentally friendly. Various water washing parameters and conditions have an impact on overall pretreatment results. These parameters include material and process conditions such as solid-to-liquid ratio, temperature, and process duration. A lot of pretreatment methods were present such as acidic, basic, and water treatment [23]. Investigation of the thermal behavior of water washing shows an improvement in burn-out temperature and ignition with a slight decrease in reactivity [24]. During biofuels production biomass water treatment had shown improvement in enzymatic hydrolysis at the elevated temperature range from 150–240°C in 1h time duration. This act is accomplished by the disruption of the cellular matrix. Liquid hot water treatment results in an improvement in energy density. This happens due to the reduction in ash content and removal of hemicellulose from biomass after washing [25]. A lot of pretreatment methods were present such as acidic, basic, and water treatment. Among all the hot water treatment was selected for this research as it is the most economical and environment-friendly method [23].

Lack of binding potential of cellulosic biomass results in a low-grade dusty pelletized product which is still unstable for handling. Researchers and industrial stakeholders have made significant efforts to enhance the effectiveness of inter-particle binding in biomass pellets. Thus, binding purposes, organic and inorganic binding agents are used to have better strength and durability of binders [13]. The selection of binder plays a significant role in getting the required qualities of pellets. In this research, low-grade broken rice based natural binder (LGBRB) and laundry starch based synthetic binder (LSBSB, Maya) binders [16] at three different concentrations are used to improve pellet characteristics.

This research aims to evaluate the effect of hot water pretreatment, types of binders, and binder concentration on the densification of sugarcane trash for pellet formation to have a product with improved properties for commercial usage and offers greater future possibilities for bioenergy and a sustainable environment.

The experimental work is divided into four stages as mentioned below (1) preparation of feed, (2) binders selection and preparation, (3) pellet formation and (4) characteristics of pellets as shown in Fig. 1.

2.1 Preparation of the feed

The preparation of the feed starts with the collection of sugarcane trash as a source of biomass followed by the washing, grinding, and hot water pretreatment process.

2.1.1 Selection of biomass

Pakistan is an agricultural country, contains a vast variety of biomass feedstock waste materials. Firstly, the selection of suitable biomass raw material was done. Among all those easily available feedstocks, sugar cane waste was the most suitable as it contains 20.1% of ash content which is considered to be lower when comparing with other biomass materials. Sugarcane is Pakistan’s one of the major crops, thus sugarcane trash is easily available. Secondly, the raw sugarcane leaves and stems were collected from the sugarcane field of the Sargodha, Pakistan, as shown in Fig. 2(a). These sugarcane leaves and stems were then dried in direct sunlight for about 2 to 3 weeks (Fig. 2(b)).

2.1.2 Washing of sugarcane trash

Biomass was washed manually to remove pollutants as the material was collected directly from the field. Most of the dust was removed from the surface of the sugarcane trash during the washing process followed with the raw materials drying under the direct sunlight for about 2 weeks.

2.1.3 Grinding of sugarcane trash

After the washing process, the dried sugarcane trash was then crushed and grinded in an ultrafine grinder to reduce its size. For crushing purposes, a 2 mm screen opening-sized local ultrafine grinder was used. The crushed sugarcane trash was then sieved to obtain the standard size for pellet formation. For the sieving process, standard size gauzes having opening sizes 1 mm and 0.5 mm were used. During the sieving process, the material that passed through the 1 mm opening and remained at 0.5 mm was collected and considered standard-sized. However, some of the material remained at a 1 mm opening and was considered as oversized. Similarly, the material that passes straight through the 0.5 mm opening was considered as undersize. The material that was considered as standard size ranges from 0.5–0.9 mm. This material was then stored in air-tight polythene bags. The whole grinding process is shown in Fig. 3.

2.1.4 Hot water treatment, filtration, and absorption of moisture

The stored sugar cane trash was treated with hot water in the laboratory for the removal of inorganic constituents. Different S/L ratios were present to perform the experiment but 1:15 S/L was considered as it shows better results [26]. For the washing process, the whole biomass was divided to form a 1:15 S/L ratio i.e., 6 g of the sample and 90 mL of water. The hot water washing was performed at 80°C temperature for 20 min at 100 rpm mixing speed using a magnetic stirrer as shown in Fig. 4.

After the washing process, the biomass was then filtered using filter paper to remove excess water and other dust particles. Filtration was done overnight and then the material was manually pressed to further squeeze the remaining water from the biomass. The biomass after the filtration process was then dried for 6 h in the oven at 105 ± 2°C. The biomass obtained was fully dried, so it was then placed openly for a few hours to absorb some moisture. After the absorption of moisture, the biomass was then packed in transparent plastic polythene bags for preservation and further use.

2.2 Binder’s selection and preparation

In pellets formation particles of biomass forms a better linking in the presence of a binding agent. For good sugar cane trash pellets formation two types of binders were selected and prepared (1) LGBRB and (2) LSBSB. The NB was prepared by boiling 250 g of cheap low-grade broken rice in 1.5 L of water. After boiling the mixture including pitch was grinded and a thick paste was prepared as shown in Fig. 5(a). This thick mixture was then used as a binder in pellet formation. The Synthetic binder was formed by boiling 0.6 g of starch (Maya) in 250 mL of water. The mixture was kept on heating until the formation of a thick paste along with continuous stirring, the obtained mixture is shown in Fig. 5(b). The mixture was then used as a binder in pellet formation [16].

2.3. Pellets Formation

We have formed pellets using varying binder’s concentrations and analyzed their qualities to ensure higher-quality pellets with HHV [27]. Three concentrations (10%, 20%, and 30%) of NB and SB were mixed manually with the pretreated sugar cane trash to form pellets. The mixing process was performed until a homogeneous mixture was formed, followed with the pelletization process. The pelleting process was performed using a properly shaped die and hydraulic press as shown in Fig. 6(a) until the formation of pellets as shown in Fig. 6(b). After formation, the pellets were then dried in sunlight for a week and stored in polythene bags.

2.4. Characteristics of pellets

The pellets’ moisture content was determined using Moisture Analyzer (OHAUS MB45). Moisture analyzer provides fast, simple, and cheap analysis [28]. In the moisture analyzer, the pellet’s moisture content was determined by setting some parameters such as temperature, time, and mass of biomass. The pellets’ size was determined using a Vernier caliper. For pellets’ bulk density, at first 1L empty cylinder and then a 1 L cylinder filled with pellets were weighed [29].

For mechanical properties, the impact resistance test was conducted. This test was performed by taking three samples of pellets with the same binder concentration which were dropped from the height of 1.83 m onto a floor [30]. The experiment was repeated two time an average values were used. The pieces having a weight less than 5% of the pellet’s original weight were not included in the estimate. The impact resistance was calculated by using the formula

Impact Resistance Test =\(\frac{(100\times total number of drops )}{\left(total number of pieces after drop\right)}\)

The heating values of each pellet were determined using a Bomb Calorimeter. The internal and external structural properties of pellets such as the presence of voids and cracks, bonding of particles, and surface structure of pellets were observed using Scanning Electron Microscopy (SEM, ZEISS, Germany).

3.1. Analysis of physical properties

3.1.1. Moisture content analysis

The moisture content for both NB and SB pellets lie in the optimum range i.e., upto 10% [31]. Pellets with NB had a higher moisture content value (6.65%) than SB (4.28%) as shown in Table S1 & Fig. 7. However, for both NB and SB pellets a decreasing trend in moisture content is witnessed. The water molecules act as a lubricant and a binding agent which enhances the area of contact present among the particles by developing van der Waals’ forces [5], thus it also aids in pelletization. Previous studies reported the moisture content values of raw sugarcane trash in between 9.18% − 8.9% [32] An increase in moisture content up to an optimum value facilitates an increase in the durability and strength of densified material. It is also witnessed that high moisture content reduces the release of natural binders from the particles and complete flattening due to the incompressible nature of water [33].

3.1.2. Pellets size analysis

The results of pellet length and diameter for all NB and SB pellets are mentioned Table S2 & Fig. 8. An increased trend was witnessed for NB pellets whereas for SB pellets, a decreasing trend was witnessed with increased binder concentration, attributed to the increased durability of SB pellets. This might be due to the bonding capability of sugar cane trash lignocellulosic particles that the particles forms better bonding with SB than NB and as a result smaller size pellets are produced. Biomass typically contains macromolecules like cellulose, hemicellulose, and lignin as well as low molecular weight organic and inorganic components. Lignocellulosic biomass mostly contains cellulose, hemicellulose, lignin, protein, fat, starch, ash, water, and other extractives when it comes to chemical compositions. Comprehending the compositional changes that transpire throughout the processing of biomass is crucial as it provides insight into the compaction behavior [34]. A pellet's size impacts its strength because a bigger-sized pellet breaks more readily when it hits with a smaller force. Compared to thicker pellets, thinner biomass pellets allow for more constant combustion. The pellets with smaller sizes keep the gasification reactors and stoves operating continuously [35].

3.1.3. Analysis of pellets bulk density

Pellet density is a crucial factor in determining significant storage provision, line-up, and handling systems. It also influences the efficiency of transport, storage, and handling [36]. When the bulk density of the pellet is high, less storage space is required, and in return, the transport efficiency improves. Figure 9 & Table S3 show the bulk density for both NB and SB pellets. Interestingly, NB pellets showed higher bulk density as compared with SB for all compositions. With the increase in binder concentration, an increasing bulk density has been observed for both SB and NB i.e., 156 to 206 and 209 to 226 for SB and NB, respectively.

3.2. Analysis of mechanical properties

The results of drop resistance test (IRI) for all NB and SB pellets are shown in Fig. 10 & Table S4. All SB pellets passed the impact resistance test, whose target was IRI = 50. However, for NB pellets only pellets having 10%NB pass the IRI test. This point might be due to increased pellets size which is the effect of loose bonding of sugar cane trash particle with NB. The IRI value for SB pellets increases with the increase in binder concentration and 30% SB pellets possess the highest IRI value of 320. This result shows that SB pellets possess higher strength and durability than NB pellets. IRI is used to measure the strength and durability of biomass pellets and the forces involved in the unloading of densified pellets from trucks onto the ground or from chutes into bins [37]. An IRI was performed to check the safest height of pellet production [38].

3.3. Structural analysis

The structural analysis of pellets was performed to study the existence of cracks and voids which induce the timely destruction at the surface of the material through which the strength and durability of bonding between adjacent particles can be determined [39]. SEM images (Fig. 11) showed that binder addition had a high impact on the bonding of sugar cane trash fibrous particles. In the case of NB, the fibrous particles of sugarcane trash failed to form a homogeneous structure for a compact durable shape. For NB pellets cracks were dominant at the surface and increased with an increase in pellet concentration (Figures S1-S3). However, SB pellets showed smooth and crack-free surfaces which provided a stronger bonding between adjacent particles, as shown in Figures S4-S6. For SB pellets, the increase in binder concentration aids in a more compact and void-free structure. The pellet strength is suggested to be linked with the composition of binder and biomass which is linked with the binding of binder and biomass material in the densified biomass. The difference in structural results for NB and SB pellets might be due to the presence of organic and inorganic constituent’s in sugar cane trash which causes SB to form compact and strong pellets while for NB pellets binder failed to form strong bonding with particles. As literature suggested that wood residue [40] and bagasse [16] pellets show better results for NB (LGBRB) instead of SB (LSBSB). In SB pellets a different type of bonding mechanism was identified due to the formation of lignin bridge and mechanical interlocking [41]. 10% and 20% SB pellets possess smooth surfaces but few voids were present at the surface while 30% SB pellets possess void-free smooth surfaces.

3.4. Thermal analysis

Figure 12 indicates that 10% SB pellets have the HHV of 4301.17 Cal/g, indicating that these pellets possess greater energy density and ought to be chosen. Overall characteristic analysis had showed that all SB pellets possess better results for physical, mechanical, structural properties but according to thermal properties 10% SB pellets have better results. So based on thermal characteristics results 10% SB pellets are considered better than 20% and 30% as it is a crucial property for the design calculations or simulations of thermal conversion for biomass [42].

3.5. Comparison of pellets characteristics and future recommendations

Biomass is a renewable energy source that cannot be used directly without any pretreatment or conversion. Mainly biomass from agricultural waste causes operational issues like slagging, fouling, corrosion, and agglomeration in furnaces and boilers due to the presence of inorganic compounds and ash content [43]. In this research work sugar cane trash pellets without pretreatment were also made and evaluated to see the effect which resulted in pellets possessing poor characteristics. The results of pellets without pretreatment are not upto the required standard and thus not included in this work.

Furthermore, the comparison of pellets with natural and synthetic binders at (10%, 20%, and 30%) concentrations also shows variations. The physical, mechanical, and structural analysis shows that for synthetic binder pellets the increasing binder concentration results in improved physical, mechanical, and structural characteristics. However, for NB pellets results obtained from physical, mechanical, and structural analysis shows that NB pellets did not hold better results. The thermal analysis have shown that overall synthetic binder pellets are found to have HHV as compared to pellets with NB and 10%SB pellets possess HHV(4301.17). So, to use sugarcane trash as an alternate source for power generation 10%SB is considered better according to the characteristics analysis.

From the overall analysis, it might be considered that NB didn’t form an effective bond with sugarcane trash as compared with SB for 10%, 20% and 30% binder concentration. This is suggested to be linked with the bonding of binder with the sugar cane trash particles indirectly linked with the presence of organic and inorganic constituents in sugar cane trash. Overall it is witnessed that better results are obtained at (10%, 20%, and 30%) SB concentration but for more enhanced results analysis of SB pellets between 5–15% concentration is recommended. Further work will be done to determine the value of Carbon, volatile matter, and ash content through proximate analysis and its effect on bonding mechanism so that more effectiveness of the pretreatment method is evaluated. Biomass pellets are not easily available for commercial usage due to conversion and other factors related to biomass so cost-benefit estimation and energy analysis of the pellets will be presented in the next report.

Sugarcane trash is produced in bulk quantity and is usually burnt directly in an open atmosphere, creating environmental pollution. Furthermore, there are some problems associated with this waste being directly used in the power sector as a fuel such as low heating value. The densification of sugar cane trash can lead to improved properties. Densification is effected by pretreatment and binding agents. Sugarcane Trash is densified using hot water pre-treatment and starch based natural and synthetic binders. Pellets having 10%SB are found to be possesses better physical, thermal, mechanical and structural properties. Pellets with 10%SB were found to have the highest heating value 4301.17Cal/g. This research work shows that proper densification of sugarcane trash offers greater future possibilities for bioenergy and a sustainable environment.

Author Contributions

The original idea, experimentation, writing, and revision are attributed to Muhammad Irfan, Rohya Fatima, and Tanveer Iqbal. Editing was done by Hira Fatima available literature.

Acknowledgments

The authors are thankful to the Center for Energy, Research and Development and Chemical, Polymer and Composite Materials Engineering Department, University of Engineering and Technology, New Campus, Lahore for all support and assistance during experimentation and characterization.

Conflict of Interest

The author declares no conflict of interest in publishing this manuscript.

Data Availability

The sets of data generated during and/or analyzed during the current study are available from the corresponding author upon reasonable request.

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Table 1: Moisture content of pellets (Target Mass=1g, Temp=100°C, Time=5mint)

Binder	Mass of Material	Moisture Content
%	g	%
10% NB	0.964g	6.65%
10% SB	0.958g	4.28%
20% NB	0.972g	6.07%
20% SB	0.975g	4.51%
30% NB	0.958g	4.18%
30% SB	0.968g	4.13%

Table 2: Size of pellets

Binder

Dimension

10%NB

10%SB

20%NB

20%SB

30%NB

30%SB

Pellet 1

Length

19.05

20.00

20.10

19.75

20.90

18.60

Dia.

37.20

38.75

38.38

38.00

38.75

37.06

Pellet 2

Length

18.89

20.05

19.55

19.75

20.19

18.69

Dia.

36.95

38.77

37.88

38.43

38.05

37.20

Pellet 3

Length

19.15

20.25

20.35

19.65

20.98

18.66

Dia.

37.35

39.15

38.44

38.28

38.89

37.15

Average

Length

19.03

20.1

20.00

19.71

20.69

18.65

Dia.

37.16

38.89

38.23

38.24

38.56

37.14

Length

0.11

0.33

0.04

0.35

0.04

Dia.

0.16

0.18

0.25

0.18

0.36

0.06

Table 3: Pellets bulk density

Pellet	Bulk Density (g/cm³)	Bulk Density (kg/m³)
10% NB	0.209	209
10% SB	0.156	156
20% NB	0.212	212
20% SB	0.183	183
30% NB	0.226	226
30% SB	0.206	206

Table 4: Pellets impact resistance

No. of Drops / No. of pieces
Pellets	Test 1	Test 2	Test 3	IRI	Target IRI= 50 Pass/Fail
10%NB	1/3	3/2	1/2	71	P
10%SB	3/1	4/2	2/2	180	P
20%NB	1/2	1/3	1/3	37	F
20%SB	4/1	4/2	3/1	275	P
30%NB	1/3	1/3	1/3	33	F
30%SB	6/2	5/1	5/2	320	P

Table 5: Gross heating values of pellets

Pellet	Heating Values
Pellet	Cal/g
10% NB	4143.66
10% SB	4301.17
20% NB	4137.69
20% SB	4210.63
30% NB	4093.78
30% SB	3802.63

Graph is available in Supplementary Files section.

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Effect of starch-based natural and synthetic binders on densification of sugar cane trash

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Abstract

Figures

1. Introduction

2. Materials and methods

2.1 Preparation of the feed

2.1.1 Selection of biomass

2.1.2 Washing of sugarcane trash

2.1.3 Grinding of sugarcane trash

2.1.4 Hot water treatment, filtration, and absorption of moisture

2.2 Binder’s selection and preparation

2.3. Pellets Formation

2.4. Characteristics of pellets

3. Results and discussions

3.1. Analysis of physical properties

3.1.1. Moisture content analysis

3.1.2. Pellets size analysis

3.1.3. Analysis of pellets bulk density

3.2. Analysis of mechanical properties

3.3. Structural analysis

3.4. Thermal analysis

3.5. Comparison of pellets characteristics and future recommendations

4. Conclusion

Declarations

References

Tables

Graph

Supplementary Files

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