Industrial sugar beets to biofuel: Field to fuel production system and cost estimates

Specialized varieties of sugar beets (Beta vulgaris L.) may be an eligible feedstock for advanced biofuel designation under the USA Energy Independence and Security Act of 2007. These non-food industrial beets could double ethanol production per hectare compared to alternative feedstocks. A mixed-integer mathematical programming model was constructed to determine the breakeven price of ethanol produced from industrial beets, and to determine the optimal size and biorefinery location. The model, based on limited field data, evaluates Southern Plains beet production in a 3-year crop rotation, and beet harvest, transportation, and processing. The optimal strategy depends critically on several assumptions including a just-in-time harvest and delivery system that remains to be tested in field trials. Based on a wet beet to ethanol conversion rate of 110 dm³ Mg⁻¹ and capital cost of 128 M$ for a 152 dam³ y⁻¹ biorefinery, the estimated breakeven ethanol price was 507 $ m⁻³. The average breakeven production cost of corn (Zea mays L.) grain ethanol ranged from 430 to 552 $ m⁻³ based on average net corn feedstock cost of 254 and 396 $ m⁻³ in 2014 and 2013, respectively. The estimated net beet ethanol delivered cost of 207 $ m⁻³ was lower than the average net corn feedstock cost of 254–396$ m⁻³ in 2013 and 2014. If for a mature industry, the cost to process beets was equal to the cost to process corn, the beet breakeven ethanol price would be $387 m^-3 (587 $ m⁻³ gasoline equivalent).     

Lignocellulosic ethanol production employing immobilized Saccharomyces cerevisiae in packed bed reactor

Most of ethanol production processes are limited by lower ethanol production rate and recyclability problem of ethanologenic organism. In the present study, immobilized co-fermenting Saccharomyces cerevisiae GSE1618 was employed for ethanol fermentation using rice straw enzymatic hydrolysate in a packed bed reactor (PBR). The immobilization of S. cerevisiae was performed by entrapment in Ca-alginate for optimization of ethanol production by varying alginic acid concentration, bead size, glucose concentration, temperature and hardening time. Remarkably, extra hardened beads (EHB) immobilized with S. cerevisiae could be used up to repeated 40 fermentation batches. In continuous PBR, maximum 81.82 g L⁻¹ ethanol was obtained with 29.95 g L⁻¹ h⁻¹ productivity with initial glucose concentration of 180 g L⁻¹ in feed at dilution rate of 0.37 h⁻¹. However, maximum ethanol concentration of 40.33 g L⁻¹ (99% yield) with 24.61 g L⁻¹ h⁻¹ productivity was attained at 0.61 h⁻¹ dilution rate in fermentation of un-detoxified rice straw enzymatic hydrolysate (REH). At commercial scale, EHB has great potential for continuous ethanol production with high productivity using lignocellulosic hydrolysate in PBR.     

Techno-economic assessment of pellets produced from steam pretreated biomass feedstock

Minimum production cost and optimum plant size are determined for pellet plants for three types of biomass feedstock – forest residue, agricultural residue, and energy crops. The life cycle cost from harvesting to the delivery of the pellets to the co-firing facility is evaluated. The cost varies from 95 to 105 $ t⁻¹ for regular pellets and 146–156 $ t⁻¹ for steam pretreated pellets. The difference in the cost of producing regular and steam pretreated pellets per unit energy is in the range of 2–3 $ GJ⁻¹. The economic optimum plant size (i.e., the size at which pellet production cost is minimum) is found to be 190 kt for regular pellet production and 250 kt for steam pretreated pellet. Sensitivity and uncertainty analyses were carried out to identify sensitivity parameters and effects of model error.     

Cost estimates of post harvest forest biomass supply for Canada

This study estimates the potential physical amounts and financial costs of post-harvest forest residue biomass supply in Canada. The analyses incorporate the locations of harvest activities in Canada, the geographical variation of forest productivity patterns and the costs associated with the extraction and transportation of residue feedstock to bioenergy facilities. We estimated the availability of harvest residues within the extent of industrial forest management operations in Canadian forests. Our analyses focused on the extraction of biomass from roadside harvest residues that involve four major cost components: pre-piling and aggregation, loading, chipping and transportation. The estimates of residue extraction costs also included representation of basic ecological sustainability and technical accessibility constraints. Annual supply of harvestable residual biomass with these ecological sustainability constraints were estimated to be approximately 19.2–23.3 Tg_*year⁻¹ and 16.5–20.0 Tg_*year⁻¹ in scenarios that included both ecological and technical accessibility limitations. These estimates appear to be less than other similar studies, due to the higher level of spatial details on inventories and ecological and operational constraints in our analyses. The amount of residual biomass available in baseline scenarios at a supply cost of $60 ODT⁻¹ and $80 ODT⁻¹ were 1.08 and 1.38 Tg year⁻¹ and 7.82 and 10.14 Tg year⁻¹ respectively. Decreasing residue extraction costs by 35% increased the amount of residues available at a $60 ODT⁻¹ and $80 ODT⁻¹ supply price by ∼5.5–5.7 and ∼1.5–1.6 times respectively. The assessment methodology is generic and could be extended to examine residue supplies for specialized biomass markets such as lignocellulosic ethanol production.     

Logistics cost analysis of rice straw pellets for feasible production capacity and spatial scale in heat utilization systems: A case study in Nanporo town,Hokkaido, Japan

Rice straw is a promising renewable energy source because it is abundantly available in Asia. This study conducted a case study of logistics cost analysis for rice straw pellets by considering all stages in the supply chain to define the main factors affecting the selling price of rice straw pellets: collection (job-commission or employment of part-time workers), transportation, storage (vinyl greenhouses or storage buildings with larger capacity), pelletizing, and delivery to users with biomass boilers. The selling price was found to be strongly dependent on the production capacity because the investment cost for the pellet production facility had a significant effect of economies of scale. A production capacity of larger than 1500 t y⁻¹ is required for rice straw pellets to compete with wood pellets and fossil fuels in the studied Japanese context if the subsidy rate for the investment is 50%, part-time workers conduct the collection, and rice straw is stored in the storage buildings. Our sensitivity analysis also showed an economically feasible spatial scale: for example, rice straw should be collected within a 20 km radius and the users should be within a 38 km radius when the production capacity is 1500 t y⁻¹. In addition, other critical factors related to the collection of rice straw from the paddy fields and transportation of rice straw rolls to storage were identified as planning factors to further reduce the total logistics cost of rice straw pellets.     

Effect of nutrient supplementation on ethanol production in different strategies of saccharification and fermentation from acid pretreated rice straw

The effect of nutrient supplementation on ethanol production by recently selected thermotolerant yeast (Kluyveromyces marxianus NRRL Y-6860) was investigated in different strategies of saccharification and fermentation employing rice straw pretreated by dilute acid. Among the evaluated strategies, similar ethanol yields (Y_P/S ∼ 0.23 g g⁻¹) were obtained with or without nutrient addition. However, considering the whole process time, the strategy based on simultaneous saccharification and fermentation (SSF), without pre-hydrolysis, was assigned as the most suitable configuration due to the highest ethanol volumetric productivity (1.4 g L⁻¹ h⁻¹), about 2-fold higher in relation to the others. The impact of enzymatic preparation employed in this study was also evaluated on glucose fermentation in semi-synthetic medium. The enzymatic preparation affected both glucose consumption and ethanol production by K. marxianus NRRL Y-6860, but just in the absence of nutrients. Therefore, the enzyme type and loading should be carefully defined, not only by the capital costs involved, but also by the possibility of increasing the fermentation inhibitors.     

Economic analysis of small-scale agricultural digesters in the United States

Anaerobic digestion (AD) is an economically viable manure treatment option for large dairies (>500 cows) in the U.S. However, roughly 90% of U.S. dairies have less than 200 cows, making this technology economically inaccessible to the vast majority of U.S. dairies. While there have been case studies of individual small dairies with anaerobic digesters, there are no comparative studies using cost data from these systems. The objectives of this study were to (1) determine the economic viability of small-scale U.S. digesters using cost data from nine existing 100 to 250-cow dairies and seven theoretical systems and (2) reevaluate the minimum size dairy farm needed for economically feasible AD in the U.S. Cash flow analysis results showed that total capital costs, capital costs per cow, and net costs per cow generally decreased with increasing herd size in existing systems. Among existing revenue streams, use of digested solids for bedding generated the highest revenue ($100 cow⁻¹ year⁻¹), followed by biogas use for heating and/or electrical generation ($47 to $70 cow⁻¹ year⁻¹) and CO₂ credits ($7 cow⁻¹ year⁻¹). No system had a positive cash flow under the assumed conditions (8% discount rate, 20-year term). However, six of the 16 systems had positive cash flows when 50% cost sharing was included in the analysis. Our results suggest that, with cost sharing, economically viable AD systems are possible on 250-cow dairies. Additional revenue streams, such as tipping fees for food waste, may reduce the minimum size to 100-cow dairies.     

Harvesting productivity and costs when utilizing energywood from pine plantations of the southern Coastal Plain USA

For woody biomass to make a significant contribution to the United States' energy portfolio, harvesting contractors must economically harvest and transport energywood to conversion/processing facilities. We conducted a designed operational study in the Coastal Plain of North Carolina, USA with three replications of three treatments to measure harvesting productivity and costs when utilizing woody biomass. The treatments were: a conventional roundwood only harvest (control), an integrated harvest in which merchantable roundwood was delivered to mills and residuals were chipped for energy, and a chip harvest in which all stems were chipped for energy use. The harvesting contractor in this study typically delivers 2200–2700 t of green roundwood per week and is capable of wet-site harvesting. Results indicate that onboard truck green roundwood costs increased from 9.35 $ t⁻¹ in the conventional treatment to 10.98 $ t⁻¹ in the integrated treatment as a result of reduced felling and skidding productivity. Green energy chips were produced for 19.19 $ t⁻¹ onboard truck in the integrated treatment and 17.93 $ t⁻¹ in the chip treatment. Low skidding productivity contributed to high chip costs in the integrated treatment. Residual green biomass was reduced from 18 t ha⁻¹ in the conventional treatment to 4 and 3 t ha⁻¹ in the integrated and chip treatments, respectively. This study suggests that until energywood prices appreciate substantially, loggers are unlikely to sacrifice roundwood production to increase energywood production. This research provides unique information from a designed experiment documenting how producing energywood affects each function of a harvesting system.     

Energy self-sufficient production of bioethanol from a mixture of hemp straw and triticale seeds: Life-cycle analysis

Industrial hemp shows exceptional potential for cellulosic ethanol production, especially regarding yields per hectare, costs and environmental impact. Additionally, co-products, such as high-value food-grade oil, increase the value of this plant. In this work, hemp straw was steam-exploded for 45 min at 155 °C and hydrolysed with a cellulase/xylanase mixture. Up to 0.79 g g⁻¹ of cellulose was degraded and subsequent simultaneous-saccharification-and-fermentation with added triticale grist resulted in >0.90 g g⁻¹ fermentation of cellulose. Hemp straw is very suitable, as it contains 0.63 g g⁻¹ of cellulose and only 0.142 g g⁻¹ of hemicellulose.A 2000 m³ a⁻¹ ethanol biorefinery requires a land use of 3 km² each for hemp and for triticale. A total of 2630 kg ethanol and 150 kg hemp oil can be gained from 1 ha. Slurry and triticale straw serve as raw material for the biogas fermenter or as animal feed. Biogas supplies thermal and electric energy in combined heat and power. Ethanol will remain at 0.66 € dm⁻³ based on market prices. In addition, data have been calculated for market prices plus and minus 30% market prices (0.51–0.81 € dm⁻³). Carbon dioxide (CO₂) abatement for ethanol achieves 121 g MJ⁻¹ CO_2eq for a combined ethanol/biogas plant. The CO₂ abatement costs vary from 38 € to 262 € t⁻¹ CO_2eq.     

Impact of miscanthus yield on harvesting cost and fuel consumption

Miscanthus is emerging as a potential bioenergy crop because of its high yield and ability to reduce greenhouse gas emissions. However, there is a lack of data on harvesting machinery performance for the USA conditions, and influence of yield on harvesting cost and fuel consumption. This study quantified performance of a mower-conditioner and a large square baler for Illinois conditions, and investigated influence of yield on fuel consumption and harvesting costs. To calculate performance parameters, a field area was segmented from which a bale was formed. Then in the segmented field area, yield and machine performance parameters were determined. The mower-conditioner's field capacity was 1.8 ha h⁻¹, and diesel consumption was 19.2 L ha⁻¹. The baler's field capacity was 1.4 ha h⁻¹, and diesel consumption was 19.7 L ha⁻¹. The mowing cost was 4.8 $ Mg⁻¹, and baling cost was 6.8 $ Mg⁻¹. An inverse correlation (R² = 0.62) was found between miscanthus yield and harvesting cost ($ Mg⁻¹), and a direct correlation (R² = 0.67) was found between miscanthus yield and fuel consumption (L ha⁻¹). It is expected that this study would help in more accurate assessment of environmental impact and economic feasibility of miscanthus, and may lead to further studies for quantifying crop yield and machine performance interactions.     

Processing and sorting forest residues: Cost,productivity and managerial impacts

Feedstocks generated from processing forest residues have traditionally been considered as a low value product. The economic potential of these materials can be enhanced by emerging biomass conversion technologies, such as torrefaction, briquetting, and gasification; however, these systems require higher quality feedstock. The objective of this study was to determine the cost of processing and sorting forest residues to produce feedstock, so that the best comminution machines (i.e. chipper vs. grinder) could be used to better control feedstock size distribution. The tree tops left from sawlog processing and small-diameter trees were delimbed and separated from the slash pile. Three harvest units were selected and each unit was divided into three sub-treatment units (no-, moderate, and intensive sorting). Results showed that the cost of operations were higher for the sorted sub-units when compared to the non-sorted. The total cost of operation (felling to loading) for sawlogs was lowest at 40.81 $ m⁻³ in the nosorting treatment unit, followed by moderate (42.25 $ m⁻³) and intensive treatment unit (44.75 $ m⁻³). For biomass harvesting, the cost of operation (felling to delimbing and sorting) ranged from 27 to 29 $ oven dry metric ton⁻¹. The most expensive operational phase was primary transportation; therefore, cost of treating the forest residues had less impact on the overall cost. The cost increase (1150 $ ha⁻¹) of sorting forest residues could offset cost savings from avoided site preparation expenses (1100 $ ha⁻¹), provided that the forest residues were utilized.     

Environmental and economic assessment of producing hydroprocessed jet and diesel fuel from waste oils and tallow

Animal fats and waste oils are potential feedstocks for producing hydroprocessed esters and fatty acids (HEFA) jet and diesel fuels. This paper calculates the lifecycle greenhouse gas (GHG) emissions and production costs associated with HEFA jet and diesel fuels from tallow, and from yellow grease (YG) derived from used cooking oil. For YG, total CO₂ equivalent (CO₂ eq.) GHG emissions of jet and diesel were found to range between 16.8–21.4 g MJ⁻¹ and 12.2–16.9 g MJ⁻¹ respectively. This corresponds to lifecycle GHG emission reductions of 76–81% and 81–86% respectively, compared to their conventional counterparts. Two different system boundaries were considered for tallow-derived HEFA fuels. In System 1 (S1), tallow was treated as a by-product of the rendering industry, and emissions from rendering and fuel production were included. In System 2 (S2), tallow was considered as a by-product of the meat production industry, and in addition to the S1 emissions, cattle husbandry and slaughtering were also included. The lifecycle emissions (CO₂ eq.) from HEFA jet fuel for S1 and S2 were estimated to be 25.7–37.5 g MJ⁻¹ and 67.1–83.9 g MJ⁻¹ respectively. HEFA diesel lifecycle emissions were found to be 21.3–33.3 g MJ⁻¹ for S1 and 63.4–80.5 g MJ⁻¹ for S2. Production costs for these fuels were calculated using a discounted cash flow rate of return model. The minimum selling price was estimated to be 880 $ m⁻³–1060 $ m⁻³ for YG-derived HEFA, and 1050–1250 $ m⁻³ for tallow-derived HEFA fuels.     

Evaluation of alternatives for the evolution of palm oil mills into biorefineries

Six alternatives for the conversion of an average Colombian palm oil mill (30 t h⁻¹ of fresh fruit bunches (FFB) into biorefineries were evaluated. The alternatives studied were: (C1) Production of biogas from the Palm Oil Mill Effluents (POME), (C2) Composting of empty fruit bunches (EFB) and fiber, (C3) Biomass combustion for high pressure steam combined heat and power, (C4) Pellets production, (C5) Biochar production and, (C6) Biochar and bio-oil production. The available biomass could result in up to 125 kWh of electricity, 207 kg of compost, 125 kg of pellet, 44 kg of biochar and 63 kg of bio-oil per metric ton of FFB. The global warming potential (GWP), eutrophication potential (EP), net energy ratio (NER), capital expenditures (CAPEX), operational costs (OPEX), net present value (NPV) and internal rate of return (IRR) were calculated for all the alternatives. GHG reductions of more than 33% could be achieved. Anaerobic digestion and composting contributed to 30% reduction of the EP. The CAPEX for all of the biorefinery alternatives studied varies between 0.7 $ t⁻¹ and 2.8 $ t⁻¹ of FFB. The OPEX varies between 1.6 $ t⁻¹ and 7.3 $ t⁻¹ of FFB. The NPV for viable scenarios ranged between 2.5 million and 13.9 million US dollars. The IRR calculated varied between 3% and 56% and the payback periods were between 3 and 8 years. The total extra incomes reached values up to 15.2 $ t⁻¹ of FFB. Overall the pellets production biorefinery was the preferred alternative.     

Economics of small-scale on-farm use of canola and soybean for biodiesel and straight vegetable oil biofuels

While the cost competitiveness of vegetable oil-based biofuels (VOBB) has impeded extensive commercialization on a large-scale, the economic viability of small-scale on-farm production of VOBB is unclear. This study assessed the cost competitiveness of small-scale on-farm production of canola- [Brassica napus (L.)] and soybean-based [Glycine max (L.)] biodiesel and straight vegetable oil (SVO) biofuels in the upper Midwest at 2007 price levels. The effects of feedstock type, feedstock valuation (cost of production or market price), biofuel type, and capitalization level on the cost L⁻¹ of biofuel were examined. Valuing feedstock at the cost of production, the cost of canola-based biodiesel ranged from 0.94 to 1.13 $ L⁻¹ and SVO from 0.64 to 0.83 $ L⁻¹ depending on capitalization level. Comparatively, the cost of soybean-based biodiesel and SVO ranged from 0.40 to 0.60 $ L⁻¹ and from 0.14 to 0.33 $ L⁻¹, respectively, depending on capitalization level. Valuing feedstock at the cost of production, soybean biofuels were cost competitive whereas canola biofuels were not. Valuing feedstock at its market price, canola biofuels were more cost competitive than soybean-based biofuels, though neither were cost competitive with petroleum diesel. Feedstock type proved important in terms of the meal co-product credit, which decreased the cost of biodiesel by 1.39 $ L⁻¹ for soybean and 0.44 $ L⁻¹ for canola. SVO was less costly to produce than biodiesel due to reduced input costs. At a small scale, capital expenditures have a substantial impact on the cost of biofuel, ranging from 0.03 to 0.25 $ L⁻¹.     

Efficient ethanol production from inulin by two-stage aerate strategy

A major concern for ethanol production from inulin-containing materials, is the higher unconverted sugar, which increases the cost of ethanol production and wastewater treatment. Some key factors, such as inulinase, biomass or aeration rates, were studied to solve the problems in the process of ethanol fermentation from inulin. It was showed that more inulinase and increasing inoculum size can shorten the fermentation time, but could not reduce residual sugars. Two-stage aerate strategy was developed to utilize the remained sugars: keep the aeration at 5 h⁻¹ at the first 12 h, and drop it to 1.2 h⁻¹. Under this condition, contradiction between fermentation time and high ethanol yield was solved (60 h and 0.43 g g⁻¹), and the final residual sugar concentration decreased to about 10 g L⁻¹ with 98 g L⁻¹ ethanol. The ethanol productivity was up to 1.63 g L⁻¹ h⁻¹, which is the highest productivity of ethanol fermentations from inulin-containing materials.     

Should straw/stover be turned into syndiesel or ethanol?

Straw and corn stover can be used to produce ethanol by enzymatic hydrolysis and fermentation, or syndiesel by oxygen gasification and Fischer Tropsch (FT) reaction. FT has a higher processing cost and a higher energy yield of liquid transportation fuel. We analyze the cost of produced liquid fuel as a function of the field cost of biomass. At 80 $ t^?1 (dry basis) a crossover point is reached. Below this value, the cost of producing energy as ethanol is lower; above this value, FT syndiesel is lower. However, the crossover point occurs at a very high field cost of biomass, more than 5.50 $ GJ^?1, and ethanol plants are less capital intense than FT and hence have a smaller economic size. For both reasons ethanol is likely to be the preferred processing alternative.     

Comparison of quality and production cost of briquettes made from agricultural and forest origin biomass

This paper presents the quality and cost of small-scale production of briquettes, made from agricultural and forest biomass in north-eastern Poland. The experiment involved production of eight types of briquettes. The highest net calorific value was determined for briquettes made from pine sawdust (18,144 MJ t⁻¹). The value measured for briquettes made from perennial energy plants was over 1500 MJ t⁻¹ lower, and for those made from straw 2000 MJ t⁻¹ lower than for sawdust briquettes. The sawdust briquettes left significantly the lowest amount of ash (0.40% of dry mass). The significantly highest content of hydrogen, sulphur and nitrogen was found in briquettes containing the highest portion of rapeseed oilcake. The quality of briquettes varied and only some of them met the requirements of DIN 51731. Briquettes made from pine sawdust were of the highest quality. The briquette production cost ranged from 66.55 € t⁻¹ to 137.87 € t⁻¹ for rape straw briquettes and for those made from a mixture of rape straw and rapeseed oilcake (50:50), respectively. In general, briquette production was profitable, except for the briquettes made from a straw and rapeseed oilcake mixture.     

Technoeconomic analysis of jet fuel production from hydrolysis,decarboxylation, and reforming of camelina oil

The commercial production of jet fuel from camelina oil via hydrolysis, decarboxylation, and reforming was simulated. The refinery was modeled as being close to the farms for reduced camelina transport cost. A refinery with annual nameplate capacity of 76,000 cubic meters hydrocarbons was modeled. Assuming average camelina production conditions and oil extraction modeling from the literature, the cost of oil was 0.31 $ kg⁻¹. To accommodate one harvest per year, a refinery with 1 year oil storage capacity was designed, with the total refinery costing 283 million dollars in 2014 USD. Assuming co-products are sold at predicted values, the jet fuel break-even selling price was 0.80 $ kg⁻¹. The model presents baseline technoeconomic data that can be used for more comprehensive financial and risk modeling of camelina jet fuel production. Decarboxylation was compared to the commercially proven hydrotreating process. The model illustrated the importance of refinery location relative to farms and hydrogen production site.     

Environmental aspects of ethanol derived from no-tilled corn grain: nonrenewable energy consumption and greenhouse gas emissions

Nonrenewable energy consumption and greenhouse gas (GHG) emissions associated with ethanol (a liquid fuel) derived from corn grain produced in selected counties in Illinois, Indiana, Iowa, Michigan, Minnesota, Ohio, and Wisconsin are presented. Corn is cultivated under no-tillage practice (without plowing). The system boundaries include corn production, ethanol production, and the end use of ethanol as a fuel in a midsize passenger car. The environmental burdens in multi-output biorefinery processes (e.g., corn dry milling and wet milling) are allocated to the ethanol product and its various coproducts by the system expansion allocation approach.The nonrenewable energy requirement for producing 1 kg of ethanol is approximately 13.4–21.5 MJ (based on lower heating value), depending on corn milling technologies employed. Thus, the net energy value of ethanol is positive; the energy consumed in ethanol production is less than the energy content of the ethanol (26.8 MJ kg⁻¹).In the GHG emissions analysis, nitrous oxide (N₂O) emissions from soil and soil organic carbon levels under corn cultivation in each county are estimated by the DAYCENT model. Carbon sequestration rates range from 377 to 681 kg C ha⁻¹ year⁻¹ and N₂O emissions from soil are 0.5–2.8 kg N ha⁻¹ year⁻¹ under no-till conditions. The GHG emissions assigned to 1 kg of ethanol are 260–922 g CO₂ eq. under no-tillage. Using ethanol (E85) fuel in a midsize passenger vehicle can reduce GHG emissions by 41–61% km⁻¹ driven, compared to gasoline-fueled vehicles. Using ethanol as a vehicle fuel, therefore, has the potential to reduce nonrenewable energy consumption and GHG emissions.     

The economic potential of wood pellet production from alternative,low-value wood sources in the southeast of the U.S.

The global demand for wood pellets used for energy purposes is growing. Therefore, increased amounts of wood pellets are produced from primary forestry products, such as pulp wood. The present analysis demonstrates that substantial amounts of alternative, low-value wood resources are available that could be processed into wood pellets. For three resources, test batches have been produced and tested to qualify for industrial pellet standards. These include: primary forestry residues from premerchantable thinning operations, secondary forestry residues from pole mills and post-consumer wood wastes from discarded wooden transport pallets. The total wood potential of these resources in the southeast of the U.S. (Florida, Georgia, North Carolina, South Carolina), was estimated to be 1.9 Tg y⁻¹ (dry) available at roadside (excluding transport cost) for 22 $ Mg⁻¹ (dry) increasing to over 5.1 Tg y⁻¹ at 33 $ Mg⁻¹ (dry). In theory, 4.1 Tg y⁻¹ pellets could be produced from the estimated potential. However, due to the geographically dispersed supply of these resources, the cost of feedstock supply at a pellet plant increases rapidly at larger plants. It is therefore not expected that the total potential can be processed into wood pellets at costs competitive with those of conventional wood pellets. The optimal size of a pellet plant was estimated at between 55 Gg y⁻¹ and 315 Gg y⁻¹ pellets depending on the location and feedstock supply assumptions. At these locations and plant sizes, pellets could be produced at competitive costs of between 82 $ Mg⁻¹ and 100 $ Mg⁻¹ pellets.