new 2g process for ethanol from wood

2010-10-06Berglin - New 2G process for ethanol from wood

1

New 2G process for ethanol from wood

Niklas Berglin, Innventia

2010-10-06

2Berglin - New 2G process for ethanol from wood

2010-10-06


Slash

0.4

Chips

0.8

Wood pellets

3

Torrefied wood & Lignin

powder

5

Ethanol

6

Energy density is a key

issue for biofuels

Our focus

2010-10-06


2010-10-06

0

10

20

30

40

50

60

70

80

90

100

1990 1995 2000 2005 2010 2015

Pro

du

cti

on

(m

illio

n m

3/y

r)

Biodiesel

Ethanol

(Data from F.O. Licht, 2006, quoted by www.earthpolicy.org

and REN21. 2009. Renewables Global Status Report: 2009 Update

Biofuels:

Potential

growth

10-20 %

per year


http://www.earthpolicy.org/

2010-10-06

6

Outline

Driving forces

Process concept

Large scale trial

Conclusions

Berglin - New 2G process for ethanol from wood

2010-10-06

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What would be the role of the P&P industry?

Demand for solid and liquid biofuels will increase rapidly

in the coming years

Pulp and paper industry has potential to be an important

actor with several advantages:

–Raw materials handling

–Process knowhow

– Integration possibilities

–Existing infrastructure


2010-10-06

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Methanol

DME

FT fuels

Hydrogen

Hemicellulose

Cellulose

Extractives

WoodLignin

FAME

(Biodiesel)

Hydrolysis/Fermentation

Gasification

/Synthesis

Esterification

Ethanol

F

R

A

C

T

I

O

N

A

T

I

O

N

Hydrolysis/Fermentation

Ethanol

Waste Biogas

Anaerobic digestion

Process routes


2010-10-06

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Methanol

DME

FT fuels

Hydrogen

Hemicellulose

Cellulose

Extractives

WoodLignin

FAME

(Biodiesel)

Ethanol

500 EUR/t

(250 EUR/t wood)

Ethanol

Waste Biogas

Process routes

90 EUR/t

400-600 EUR/t

(100-150 EUR/t

wood)


2010-10-06

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Wish list

Several value-added products

Robust with respect to raw material

Minimize capital expenditure

Closed cycle

Minimize waste

Profit from integration


2010-10-06

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Alkaline

fractionation

Hydrolysis,

Fermentation &

Distillation

Lignin

Separation

Energy

Recovery

Chemicals

Recovery

Forestry Residues Ethanol

+ biogas

Sulphur-Free

Lignin

Electric Power

Alkaline route from wood to ethanol

CO2


2010-10-06

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Alkaline

fractionation

Hydrolysis,

Fermentation &

Distillation

Gasification

Synthesis

Chemicals

Recovery

Forestry Residues

Process concept with gasification

Methanol

/DMEEnergy

Recovery

Ethanol

+ biogas


2010-10-06

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Results from system study

Mostly known and well proven technology

Possible to produce 200-250 liters of ethanol per tonne of wood

Possible production in typical mill, ca 120 000 m3/year

Alternative with lignin extraction (ca 60 % of available lignin) gives

steam balance and an excess of lignin and electric power

Alternative with gasification of the spent liquor and synthesis to DME

gives steam balance but a deficit of electric power

– DME production greater than the ethanol production

Production costs are on the order of 0.50 EUR/litre ethanol


2010-10-06

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Will it work in practice?

Project to test the concept in mill

and pilot scale trials


2010-10-06

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Simplified process layout (modelled in

WinGEMS)

Alkaline

frac.

Lignin

separationFeed Evaporation

Recovery

boiler

Lime kiln

Lignin fuel

pH adjAcid

CO2

Dewatering

Dis

tillatio

n

Ethanol

Combustible

solids Cooking liquor

Steam turbine Electricity

HP

Steam

Simultaneous

Saccharification and

Fermentation (SSF)

Water Enzymes Yeast

Caustisizing

To evap. &

then to power

boilerLiq.-phase

Pre-

Hydrolysis

Alkaline

frac.

Lignin

separationFeed Evaporation

Recovery

boiler

Lime kiln

Lignin fuel

pH adjAcid

CO2

Dewatering

Dis

tillatio

n

Ethanol

Combustible

solids Cooking liquor

Steam turbine Electricity

HP

Steam

Simultaneous

Saccharification and

Fermentation (SSF)

Water Enzymes Yeast

Caustisizing

To evap. &

then to power

boilerLiq.-phase

Pre-

Hydrolysis

Mill trial in Norrsundet

Pilot plant trial in Örnsköldsvik


2010-10-06

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Objectives

To show that the concept can work on full scale by producing a well

delignified cellulose intermediate product and ethanol of fuel quality

as the final product

– To use a cooking liquor with no or low sulphidity to produce a well

delignified cellulose in an industrial digester

– During at least four hours produce a cellulose that can be used in

the Ethanol pilot plant

– During a 3-4 day trial hydrolyse the cellulose and ferment the

sugars to ethanol in the pilot plant


2010-10-06

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Mill trial

Fresh NaOH charged instead of normal white liquor

Cellulose removed at a consistency of 4%

Immediately trucked to the Ethanol pilot

Pulp transportation to theEthanol Pilot Plant

Storage of low S liquor

Extractionliquor

NaOH

Pulp tobleachplant

Oxygenbleachplant

StorageO2-bleached

pulp

Blow tank 4

Blow tank 5

Digester 5

Temperature, time and alkali charge adjusted


2010-10-06

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Results mill trial

0,00

0,05

0,10

0,15

0,20

0,25

0,30

06:00 08:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 00:00

HS

- in

extr

acti

on

liq

uo

r (m

ol/L

)

Planned digester stop

Low S liquor

to storage

Reached a low of nearly zero sulphidity

70 tonnes of “soda” pulp produced


2010-10-06

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Results mill trial

Delignification to a kappa number of < 20

(i.e. lignin content < 3 %)

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5

10

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30

35

40

2008-10-21 2008-10-21 2008-10-22 2008-10-22 2008-10-23 2008-10-23 2008-10-24

Ka

pp

a n

um

be

r

Kappa after blow tank

Kappa before O2

Kappa before bleach plant


2010-10-06

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Pilot plant trial

40 m3 of cellulose suspension used in the trial

Two enzyme “cocktails”

Two levels of enzyme charge in SSF

700 litres of ethanol produced


2010-10-06

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Results pilot plant trial

0,00

2,00

4,00

6,00

8,00

10,00

12,00

14,00

16,00

0,00 10,00 20,00 30,00 40,00 50,00 60,00 70,00 80,00

Tid [h]

Eta

no

l [g

/l]

1: Novozymes låg

2: Novozymes hög

3: Roal hög

4: Roal låg; 1

5: Roal låg; 2

About 48 hours to complete SSF


2010-10-06

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Results pilot plant trial

0

20

40

60

80

100

120

140

Novozymes låg Novozymes hög Roal låg Roal hög

Eta

no

lutb

yte

(%

av t

eo

reti

skt

maxim

um

)

Lund

SEKAB

80-90 % of theoretical yield


2010-10-06

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Summary and conclusions

Whole chain from wood to ethanol verified on large scale.

A conventional continuous digester can be used, and necessary

adjustments in temperature, alkali charge and retention time feasible

without modifications.

Sharp fractionation of the wood to an intermediate product with high

cellulose content and low lignin content, and a lignin with low

carbohydrate and ash content.

The cellulose produced is well suited for enzymatic hydrolysis.

The solid residue consists almost exclusively of yeast and it should

therefore be possible to recirculate the yeast to the SSF reactor.

The results from the large scale trial confirmed earlier lab scale

results. WinGEMS simulations of the process dynamics also showed

very good possibilities to predict actual concentrations and tank

levels during and after the trial.


Thank you for your attention!

2010-10-06Berglin - New 2G process for ethanol from wood

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new 2g process for ethanol from wood

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