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The Research Association of Innovative Bioethanol Technology The University of Tokyo
An Integrated System of
Ethanol Production from the Cellulosic
Energy Crop Napier Grass
Pacific Rim Summit on Industrial Biotechnology and Bioenergy December 9, 2013@ San Diego
M. Samejima, S. Morita Graduate School of Agricultural and Life Sciences
The University of Tokyo, JAPAN
E. Morita, S. Mihashi Research Association of Innovative Bioethanol Technology, JAPAN
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Political background on biofuel in Japan
"Sophisticated Methods of Energy Supply Structures" law in
Japan mandates to introduce 850,000 kL/yr of ethanol
equivalent to 500,000 kL/yr of crude oil in the trasnportation
sector by 2017.
The criteria of assessing biofuel is requested to be more than
50% reduction of greenhouse effect gases (GHG) versus the
same action by gasoline.
Introduction
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Final target on bioethanol technology project
To proceed biofuel project, establishment of technology to
produce ethanol from cellulosic energy crops should be
addressed as following conditions.
Production cost of ethanol : 40 JPY/L (ca. 0.4 US$/L)
Production scale of ethanol: 200,000kL/y
Balance ratio by fossil energy used: over 2.0
Reduction of CO2 emission: over 50%.
Introduction
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
NEDO Technology Development Organization
Contract
Research Association of Innovative Bioethanol Technology (RAIB) Head Quarter/ Common laboratory (at Entrepreneur Plaza in UT)
Member Companies: JX-Nippon Oil and Energy, Mitsubishi Heavy Industries,
Toyota Motors, Kajima Corp., Sapporo Engineering, Toray Industries
Framework of research group
The University of Tokyo (UT), Graduate School of Agricultural & Life Sciences
In 2009, to proceed this project, Research Association of
Innovative Bioethanol Technology (RAIB) was established by six
leading companies in Japan and our university cooperates with
their activities.
Introduction
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Process flow of our project
Cellulose
Hemicellulose
Cultivation Harvest, Storage
Transport Pre-treatment Saccharification Fermentation
Concentration, Dehydration Process
Non-arable land Energy crops Lignin
Glucose
Xylose
Dehydrated ethanol
Ethanol
Toyota Kajima JX Energy Toray Sapporo
Mitsubishi, RAIB
University of Tokyo
Fundamental Idea and technologies
The aim of our project is to establish an integrated system of ethanol production
from the cellulosic energy crop Napier grass with a size of bench-scale production
(75 L of ethanol from 300 kg of feedstock for each run).
Introduction
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Biomass Supply
shredding
NH3 treatment
Enzymatic
Saccharifi-
cation
Fermentation
Ammonia
Nitrogen Gas
Sulfuric Acid
Fertilizer(NPK)
Biomass Energy
Supply Center
Steam
Process Water
Ethanol
Ethanol Distillation
Ethanol Dehydration
Drying
Post treatment
Enzyme
Cooling Energy
Compressed Air
Electricity
Fertilizer(Urea)
Enegy Supply from
Saccharification
Residue
Life cycle assessment of system
LCA analysis
with GaBi6 software
Diesel Oil
Steam
Steam
Analysis
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Cultivation sites
Sapporo
Nasu
Tokyo
Ishigaki Island
Tropical & subtropical climate
Indonesia Australia
Cool-temperate climate
Temperate climate
Kumamoto
Cultivation and productivity of biomass Feedstock
0
1 0
2 0
3 0
4 0
5 0
6 0
Bio
ma
ss p
rod
uctivity (
t/h
a)
Example of biomass yield
under tropical climate
Eria
nth
us
Na
pie
r
Gra
ss
Se
taria
Su
ga
r C
an
e
Sw
icth
Gra
ss
Corn
Gu
ine
a G
rass
Cro
tala
ria
Ram
ie
So
rgh
um
Sugar Cane Napier Grass
Erianthus
Test Field of University of Tokyo (Tokyo)
Test Field of Toyota Mortors (Indonesia)
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Field A
Field B
Field C
Field D
Field E
Field F
Annual Supply
Case study of Nepier Grass in Indonesia (50 dried ton/year)
Rainy season Dry season
50t/ha・year
Cultivation for adjustment of supply
Cultivation for adjustment of supply
20t/ha 20t/ha 20t/ha
20t/ha 20t/ha 20t/ha
20t/ha 20t/ha
20t/ha
20t/ha
20t/ha 20t/ha
Year-round supply system of feedstock biomass Feedstock
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Highlights on biomass conversion technologies
Pretreatment Saccharification Fermentation
Technical Highlights:
Use of ammonia without
addition of water.
Technical Merits:
All pretreated materials
remain in solid without loss.
No waste water is produced.
Technical Targets:
Reduction of ammonia used.
Conversion
Biomass Ethanol
Technical Highlights:
Efficient production of enzymes.
Optimization of enzyme cocktail.
Recovery and reuse of enzymes.
Technical Targets:
Reduction of enzyme cost(less than
10 JPY/L of ethanol production) to
obtain 500 g of sugar from 1 kg of
biomass within 24 hrs incubation.
Adaptation for Scale-up.
Technical Highlights: Tandem C6/C5
fermentation.
Use of Non-GM for
C5 fermentation.
Technical Targets: High performance and yield.
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Effects of ammonia pretreatment
The reactivity of enzymes for biomass is dramatically improved by
following effects of ammonia pretreatment.
1) Breaking of ester linkages on xylan or between xylan and lignin
2) Swelling of cellulose structure
Cellulose
Lignin
Lignin-hemicellulose bond
Hemicellulose
Ammonia pretreatment
Swelling of cellulose structure Cleavage of chemical bond
Conversion
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Reduction of energy for pretreatment
Dried Biomass
High Pressure
Ammonia
Treatment
3.7 MPa, 80 C
Recovery
of
Ammonia
One-step process
under higher pressure
Dried Biomass
Low Pressure
Ammonia
Treatment
Liquid Phase
Ammonia
Treatment
Recovery
of
Ammonia
Reduction of
88 % of
Energy
Two-steps process
under lower pressure
Conversion
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Enzymatic saccharification of pretreated biomass
0
100
200
300
400
500
600
未処理処理後 未処理処理後 未処理処理後 未処理処理後
糖収量(g/kg乾燥バイオマス)
キシロース
グルコース
Erianthus
Napier grass
Switchgrass Salix
Xylose
Glucose
Before/After NH3-treat.
Before/After NH3-treat.
Before/After NH3-treat.
Before/After NH3-treat.
Su
ga
r yie
ld (
g/k
g-d
ry b
iom
ass)
-Most of sugar compounds retains in pretreated biomass as solid-state.
-Dramatic improvement of sugar yield from biomass by enzymatic
saccharification.
Sugar yield from biomass
Conversion
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Strategy on reduction of enzyme cost
(3) Enzyme
Recovery & Reuse
Enzyme cost
10 JPY/L
(2) Highly-efficient
Saccharification (1) Production of
Enzyme
Improvement of enzyme-producing fungi
Optimization of culture condition
Minimum enzyme components production
→ Less than 1,000 JPY/kg of enzyme
Optimization of enzyme
components for ammonia-
pretreated biomass
→ Less than 1/100 (Enzyme/Biomass)
Optimization of enzyme recovery
Optimization of enzyme components for reuse.
→ More than 75 %
Conversion
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Analysis of Base Enzymes Preparation
Improvement of Enzyme Cocktail
Analysis and improvement of enzyme cocktail
Feedstock: Ammonia treated Napier grass Enzyme/Biomass (1/100)
Conversion
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Tandem system for ethanol fermentation
1st Step: Glucose
fermentation
2nd Step: Xylose
fermentation
Ethanol
separation
Ethanol
Yield: 93 %
Yield: 90 %
Conversion
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Outline of bench-scale plant (1)
Pre-treatment process
Saccharification process
Cru
she
r &
Dry
er
Re
acto
r
Sacc
har
ific
atio
n v
ess
el
Solid
-liq
uid
se
par
ato
r
Enzy
me
se
par
atio
n m
em
bra
ne
Suga
r co
nce
ntr
atin
g m
em
bra
ne
Fermentation process
C6
Fe
rme
nta
tio
n v
ess
el
Yeas
t se
par
atio
n f
acili
ty
Eth
ano
l se
par
ato
r
Sto
rage
B
iom
ass
Pre
-tre
ate
d b
iom
ass
Ammonia
Ammonia/ Effluent treatment
Enzyme solution Enzyme /Recycle
Residue Discharged water
Yeast /Recycle
Ethanol solution
Yeast
Ce
llulo
sic
Su
gar
De
hyd
rate
d e
than
ol
Discharged water
Dis
tille
r
De
hyd
rato
r
Sto
rage
C5
Fe
rme
nta
tio
n v
ess
el
Bench Plant
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JX Energy Toray Industries Sapporo Engineering
The Research Association of Innovative Bioethanol Technology The University of Tokyo
Biomass feedstock
(Napier grass)
Ethanol
Ammonia pretreatment (JX energy)
Enzymatic saccharification (Toray)
Ethanol fermentation &
purification (Sapporo)
Outline of bench-scale plant (2) Bench Plant
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The Research Association of Innovative Bioethanol Technology The University of Tokyo
Summary of our achievement
Production of feedstock (Napier grass): over 50 dried ton/ha
Production cost of feedstock : less than 3 JPY/kg (ca 0.03 US$/kg)
Enzyme cost : 10 JPY/L of ethanol production (ca 0.1 US$/L)
Production cost of ethanol : less than 80 JPY/L (ca. 0.8 US$/L)
Balance ratio by fossil energy used: over 2.0
Reduction of CO2 emission: over 50%.
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