Pilot Plant for Process Development - PPDP
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Transcript of 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
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
CAPELA DEFLUXO LAMI NAR
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
CAPELA DEFLUXO LAMI NAR
ELETROFORESE
A
A
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
Lay-out
CBA
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
Front view of PPDP
1011
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
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
PILOT PLANT FOR PROCESS DEVELOPMENT - 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
nextback
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
Research, Development and Innovation
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.
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
•• 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
N° Identif. Qt Cap Un. Descrição Especificação9 B-02 1 50 tros/hora Equipamento a especificar
N° Identif. Qt Cap Un. Descrição Especificação10 B-03 1 1500 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
Equipamento a ser especificado em parceria com o fornecedor
Equipamento a ser especificado em parceria com o fornecedor
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
Equipamento a ser especificado em parceria com o fornecedor
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).
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
• 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:
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
• 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.
CTBE support to Research Groups:
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
• 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.).
CTBE support to Research Groups:
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
• 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::
PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP
• 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