pilot plant for process development - ppdp

Centro de Ciência e Tecnologia do Bioetanol – CTBE

Carlos Eduardo Vaz [email protected]

Workshop on Hydrolysis Routefor Cellulosic Ethanol from Sugarcane

February 10-11 th 2009-Campinas, Brazil

PILOT PLANT FOR PROCESS DEVELOPMENT – PPDP

mailto:[email protected]

PILOT PLANT FORPILOT PLANT FOR PROCESS DEVELOPMENT PROCESS DEVELOPMENT -- PPDPPPDP

•• Bagasse conversion to BioBagasse conversion to Bio--Ethanol;Ethanol;•• PPDP, site location, project;PPDP, site location, project;•• Main scope: Enzymatic hydrolysis Main scope: Enzymatic hydrolysis

conversion ofconversion of Bagasse to Ethanol;Bagasse to Ethanol;•• Justification for the projectJustification for the project•• Scope of the Pilot Plant, Scope of the Pilot Plant, •• Conceptual Project;Conceptual Project;•• CTBE support to Research Groups.CTBE support to Research Groups.

Sugar cane Bagasse and straw conversion to Bio-Ethanol

• Bio-Ethanol (1st Generation technology) Fuel from Sugar Cane Agro-Industrial Sector is very important to Brazilian Economy, it is sustainable, green, captures CO2 , has a net positive energy balance, does not compete with food crops and generate employment and welfare.

• A better use of energy available in sugar cane can be attained if Ethanol Distilleries are revamped and optimized, straw remaining after cane harvesting be recovered, as well as the most of remaining bagasse is obtained after cane processing.

• This lignin-cellulose biomass recovered if converted to ethanol by Hydrolysis and fermentation can increase ethanol productivity in at least 40% for the same planted area.

• Assessment of a feasible, economic and sustainable technology it is strategic for Brazil continues his leadership in Bio-fuels production.

PPDP location at the Campus of LNLS

ACOMPANHAMENTO

LABORATÓRIO 1 NB- 2

1

C

2 3 4 5 6 7 8 9 10

CAPELA DEFLUXO LAMI NAR

SHAKER

GEL

ADEI

RA

SHAKER

GEL

ADEI

RAS


BANCADA PARA

FREEZER

CENTRIFUGA

GELADEI RA

ESPECTOFOTOMETRO

BALANÇA

MICROCENT.

PCR

PCR

ESTUFA

AUTOCLAVE

AUTOCLAVE

BALANÇA SEMI ANALÍTICA

PHMETRO

PLACA AGITADORA

PREPARAÇAO DE MATERIAL

PREPARO DE MEIO DE

CULTURA

BALANÇA ANALÍTICA

PREP

ARO

DE

MA

TERI

AL

BALANÇA

FERMENTADOR

BALA

NÇAS

SEM

I-ANA

LITI

CAS

ESPECTOFOTÔMETRO

MICRO

MIC

RO

11 12 13

B

C

4.60

CIRCULAÇÃO

CENTRIFUGAANALITICA

DE 10L

FERMENTADORDE 10L

FERMENTADORDE 40L

FILT

RAÇ

AO


ELETROFORESE

A

A

PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP

Lay-out

CBA


Front view of PPDP

1011


Layout of PPDP6 – Unit for ethanol Fermentation

Enzymatic hydrolysis conversion ofEnzymatic hydrolysis conversion of Bagasse to Ethanol, the main purpose Bagasse to Ethanol, the main purpose

of the PPDPof the PPDP


Physical Chemistry pretreatment of sugar cane bagasse (and straw);Development of enzymes tailored for conversion of sugar cane cellulosic raw materials into fermentable sugars;Development of enzymatic hydrolysis processes of sugar cane bagasse conversion ;Development of microorganisms for fermentation of pentoses to ethanol.

Critical steps for hydrolysis technology

10

Enzymatic Hydrolysis for bagasse/ethanol conversion

CLEANING

FRACTIONATION

PREHYDROLYSIS

DESLIGNIFIYNG

ENZYMATIC HYDROLYSIS

PENTOSE FERMENTATION TO ETHANOL

HEXOSE FERMENTATIONTO ETHANOL

LIQUOR PURIFIYNG

DISTILLATION/DEHYDRATION

CELULASEPRODUCTION

CELULASE RECOVER

YEAST PRODUCTION

ETHANOLBAGASSE

SAND,SOILMETALS

FINES AND RIND

PENTOSE LIQUOR

LIGNIN

TREATED FIBER

HEXOSE LIQUOR

HEXOSE LIQUOR

CELULASES

SPECIAL YEAST

WINE

2

2

1

4

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PPDP- Justification for the project

• Processes involved in Hydrolysis are extreme complex and we must advance in the domain of them;

• Bio-fuels are strategic for Brazil and it must be assured the maintenance of leadership;

• Brazilian research projects are been executed (most of them) in laboratory scale which does not assure their reproduction at industrial scale;

• Facilities for experimentation at near industrial conditions are required.

PPDP- Justification for the project• Most of the processes and unit operations involve a two

phases solid-fluid heterogeneous system, which increases complexity and makes scaling-up difficult;

• Main technical barriers to the advance of Hydrolysis require the confirmation of laboratory results in a scale more representative;

• Consumption of utilities: steam, water, electrical power and products: enzymatic complex, chemicals, etc., require a more precise estimate which can only be obtained in a pilot unit;

• Investments in fixed capital only could be forecasted with a certain precision level after pilot plant trials.

PPDPPPDP-- Scope of the Pilot PlantScope of the Pilot Plant

• Development of the route(s) for sugar cane bagasse and straw conversion in Bio-Ethanol;

• To scale-up Physical, Chemical and Biological processes related to Hydrolysis;

• To validate laboratory experiments;• Assessment of reliable mass and energy balances and

kinetics data of processes involved in Hydrolysis technology;• Optimization of the operational ranges of the processes being

studied; • Assessment of data for selection of building materials

(resistant to corrosion, abrasion, high temperature and pressure);

• Obtaining of data for the conceptual design of processing equipment.

PPDP- Conceptual Project• Basis of the Project:

A multipurpose unit;

The highest level of flexibility;

Size (compatible with installation and operation in a Research Center. Minimum size (batch size or production rate) able to reproduce industrial operation;

Divided in independent units that do not operate simultaneously and are able to combine different arrangements of Physical, Chemical and Biological processes.

Units must be able to incorporate new processes and to reformulate and up-grade existing processing lines; The highest level of Instrumentation, Automation and Data Acquisition and Transfer,

PPDP- Conceptual Project

Operational model between Research Groups and CTBE facilities: LDP, PPDP, Scientists

and Engineers team and the Virtual Bio- Refinery project.

LDPProcess

Development Laboratory

PPDPPilot Plant

For Process Development STEPS NOT CONSIDERED

IN THIS PROJECT

PDUProcess

Demonstration Unit

COMMERCIAL UNIT

Research Groups (including CTBE group)

CTBE

Research, Development and Innovation



Conceptual Engineering

Basic and ProcessEngineering

Detailed Engineering

PDU Building

Start-up and Operation of PDU

Industrial UnitsAreas in which CTBE is directly

involvedAreas in which CTBE

could be indirectly involved through technical support

Design and Building of an Industrial Unit

Interaction between PPDP and the Virtual Bio-refinery Project

Technological route for Hydrolysis

Hydrolysis process development involving Research Groups, LDP

and the PPDP

PDU

Virtual Bio-Refinery

Assessment of technology for Hydrolysis

Technical, Economical and Sustainable evaluation of the

technology.


•• PPDP1PPDP1–– Unit for physical treatment of sugarcane Unit for physical treatment of sugarcane bagasse;bagasse;

•• PPDP2 PPDP2 –– Unit for physical chemical pretreatment Unit for physical chemical pretreatment of Ligninof Lignin--cellulose material;cellulose material;

•• PPDP3 PPDP3 –– Unit for Fungi, Yeasts and Bacteria Unit for Fungi, Yeasts and Bacteria Production;Production;

Organization

PILOT PLANT FORPILOT PLANT FOR PROCESS DEVELOPMENT PROCESS DEVELOPMENT -- PPDPPPDP

• PPDP4 – Unit for biomass enzymatic Hydrolysis;

• PPDP5 – Unit for Separation and Purification;

• PPDP6 – Unit for ethanol Fermentation.

Organization

PROCESS DEVELOPMENT PROCESS DEVELOPMENT -- PPDPPPDP

•• PPDPnsPPDPns: area reserved (600 m: area reserved (600 m²²) for new experimental ) for new experimental units to be developedunits to be developed and installed once new and installed once new developments be introduced;developments be introduced;

•• UtilitiesUtilities: Saturated Steam at 10 Bar and 35 Bar, Thermal Saturated Steam at 10 Bar and 35 Bar, Thermal fluid (35fluid (35--280280ººC), cooling water (25C), cooling water (25--2929ººC), cold water (6C), cold water (6-- 1212ººC), C), ccompomprresesssed air at 10 Bar (dry, oil and particle ed air at 10 Bar (dry, oil and particle free);free);

•• Support Units: Control Laboratory, Workshop, Support Units: Control Laboratory, Workshop, Instrumentation and Control Office, Visitant Researchers Instrumentation and Control Office, Visitant Researchers OfficesOffices

Organization

PPDP1 – Unit for physical treatment of sugarcane bagasse

• Development of flexible new technologies for sugarcane bagasse and trash physical treatment, adaptable to downstream processes

• Study sugarcane raw bagasse depithing process and the applicability of its fractions in the enzymatic route for ethanol production

• Development of a methodology for the characterization of the fractions obtained from sugarcane bagasse and trash

• Establishment of operational and project parameters to validate developed technologies, provide knowledge to scale-up and for technical, economical and sustainability evaluation.

• Production of sugarcane bagasse and trash samples for studies at CTBE and at the Research Groups involved with Hydrolysis

MT-01

XT-01

P-02

FIM

H2

H2O FE- FE-03PT-01

P-04

P-05

FIM

LEV

DE-01MF-

SAS

H2O

SA

CON

SAS

H2O

H2OC

H2OR

SA

CO

H2

SA

CAR

CAR

CON

H2OR

H2OC

SA

P-03

SAS

H2OR

H2OG

SAS

H2OR

H2OC

CON

H2OR

H2OC

SA

H2O

H2O

CON

H2OR

H2OC

SASCA

H

PC-01

CE-01

PPDP3 – Unit for Fungi, Yeasts and Bacteria Production

Process Flow sheet-2008.23.100.04.001.000-SUBMERGED FERMENTATION FOR THE PRODUCTION OF YEASTS,

BACTERIA, FUNGI AND HYDROLASES

N° Identif. Qt Cap Un. Descrição Especificação1 TM-01 1 250 litros Equipamento a ser projetado

N° Identif. Qt Cap Un. Descrição Especificação2 TC-01 1 1000 tros/hora

N° Identif. Qt Cap Un. Descrição Especificação3 FE-02 1 75 litros

N° Identif. Qt Cap Un. Descrição Especificação4 FE-03 1 250 litros Fermentador

N° Identif. Qt Cap Un. Descrição Especificação5 CE-01 1 1000 tros/hora Equipamento a especificar

N° Identif. Qt Cap Un. Descrição Especificação6 MF-01 1 1000 tros/hora

N° Identif. Qt Cap Un. Descrição Especificação7 DE-01 1 250 litros Equipamento a ser projetado

N° Identif. Qt Cap Un. Descrição Especificação8 B-01 1 2500 tros/hora Equipamento a especificar



PPDP3: Unidade de produção de fungos, leveduras e bactérias (produção de leveduras para fermentação, produção de hidrolases)

Tanque de preparo de

Esterilizador continuo

Fermentador

Centrífuga de separação

de microorganis

Microfiltro para

concentração de leite de levedura

Decantador para

concentração de biomassa

d

Bomba em aço inox 316, construção sanitária com selo

Bomba de

dosagem de

mosto ao

fermentador

Bomba

Tanque em aço inox 304, atmosférico, com fundo cónico, construção sanitária, com agitador tipo áncora (1/2 HP), rotação variável ( 0-50 rpm)

Bomba em aço inox 316, construção sanitária com selo mecânico

Bomba centrífuga de alimentação de mosto ao fermentador

Bomba em aço inox 316, construção sanitária com selo mecânico

Centrífuga contínua com descarga automática de sólidos, esterilizável "in situ", com rotação variável

Conjunto de microfiltração de feixe de tubos capilares, esterilizavel in situ , com bomaba de recirculação, sistema de contralavagem,tanques auxiliares, modulo de controle, casco, válvulas, tubulaçoes e acccessórios em aço inox 316, construção sanitária

Fermentador em aço inox 316 L, com controles automáticos de temperatura, pH, O2 dissolvido, aeração, ciclo de esterilização, rotação variável (0-500 rpm), condensador de saída, com sonda de capacitância, 04 entradas padrão para adição de sondas suplementares (NIR, potencial redox, etc), composição de gas de saída

Equipamento a ser especificado em parceria com o fornecedor

Fermentador em aço inox 316 L, com controles automáticos de temperatura, pH, O2 dissolvido, aeração, ciclo de esterilização, rotação variável (0-500 rpm), condensador de saída, com sonda de capacitância, 04 entradas padrão para adição de sondas suplementares (NIR, potencial redox, etc), composição de gas de saída



Tanque em aço inox 304, atmosférico, com camisa para aquecimento com vapor eserpentina para resfriamento com água, borbotor para injeção de vapor direto construção sanitária, com agitador tipo turbina com passo (1/2 HP), rotação variável ( 0-300 rpm)

Conjunto para esterilização com seção de aquecimento com aquecedor de placas, seção de retenção tubular e resfriamento com trocador de placas temperatura de operação até 140 ºC, com módulo de controle incorporado


PPDP3 – Unit for Fungi, Yeasts and Bacteria Production

Preliminary Equipment Data Sheet

Preliminary forecast of costs involved in the project of LDP and PPDP

• Buildings; R$ 9.800.000,00• LDP Equipment; R$ 4.900.000,00• PPDP Equipment: R$ 2.600.000,00• Utilities: R$ 1.300.000,00• Instrumentation and control: R$ 2.875.000,00• Costs related to LDP and PPDP

equipment installation: R$10.060.000,00• Total: R$ 31.535.000,00

PPDP - Project Schedule

• Conceptual Project (submitted to evaluation);• Scientist and Engineers hiring (to be finished until

6/2009);• Basic Project (to be finished until 3/2009);• Detailed Project ( to be finished until 4/2009);• Civil works and Buildings construction:

LDP (started and to be completed until 9/2008);

PPDP (forecasted to 10/2009);• Equipment Acquisition (from 3/2009 until 7/2009);• Equipment installation (until the end of 2009)• Testing of equipment and start-up (forecasted to the

beginning of 2010).


• A skilled team of postgraduates (Biologists, Physics, Chemists and Engineers) for:

Give support to researchers in processes and equipment operation, training, planning and execution of experimental work;

Management of PPDP and LDP (maintenance, calibration, installing, configuration and set-up of process lines and up-grade of equipments).

To support in the acquisition and storage of experimental data.

CTBE support to Research Groups:


• A set of Units (PPDP1 to PPDP6) that involve various alternatives of Physical, Chemical and Biological processes that could be combined in arrangements, in order to reproduce specific routes for bagasse conversion to ethanol;

• A Process Development Laboratory (LDP) with the aim of providing the required infra- structure for analytical procedures and the Physical, Chemical and Biological characterization of the process streams to be studied.



• Supply of standardized streams to Researchers:

Raw materials (as an example: raw and pretreated bagasse and straw);

Process Streams;

Intermediary products( Hydrolysis liquors, strains of microorganisms, etc.)

Final products (Bio-Ethanol, formulated hidrolases with various levels of purity , etc.).



• Research team of CTBE• Research Groups and Institutions

involved in Research and Development of the conversion of sugarcane bagasse and trash to Bio-ethanol.

Main users of the PPDP facilities::


• Engineering and contracting Companies;• Equipment Suppliers Companies;• Sugar cane to Ethanol Distilleries; • Public and Private Companies of the

Energy sector;• The Chemical, Petrochemical and Food

Industries (Bio-Refineries).

Potential users of the PPDP facilities:

PPDP - Interaction Between CTBE and third parties

• Research will be oriented to generate and make public knowledge, and innovative research and technology transfer in order to assure the Brazilian leadership in the Bio-Ethanol production chain;

• Confidentiality related to research will be assured for attaining the requirements for publications and thesis;

• Rights, Patent filing, technology transfer will follow the existing regulations of LNLS.

Research groups:

PPDP - Interaction Between CTBE and third parties

• The LNLS has well established procedures for the approval of projects and the use of it Laboratories by third parties. This procedures will be extended to the projects to be submitted to CTBE by Research groups and Institutions

• Research Projects from third parties in course at LDP and PPDP could be submitted to evaluation by the Virtual Bio- Refinery model.

Project approval:

PPDP- Project Group

• Carlos E. V. Rossell - Coordinator• José Geraldo Pradella- Senior Researcher• Edgardo O. Gomes- Engineer• Fabio Squina- Researcher

Workshop on Hydrolysis Route for Cellulosic Ethanol from Sugarcane

Thanks very much for your attention

pilot plant for process development - ppdp

Technology

pilot plant development

bioethanol ppdp

bioethanol bioethanol

ethanol justification

pilot plant trials

ethanol distilleries

project processes

ppdp scope