Small Scale Continuous Biomass Pretreatment Reactor ... bio... · Small Scale Continuous Biomass...
Transcript of Small Scale Continuous Biomass Pretreatment Reactor ... bio... · Small Scale Continuous Biomass...
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Small Scale Continuous Biomass
Pretreatment Reactor Development:
A Case Study Dale Monceaux1 and Richard C. Agar, AdvanceBio, LLC, Milford, OH, USA
2013 BIO World Congress on Industrial Biotechnology
June 16-19, 2013 Montréal, Canada
• Company intro
• Feedstock characterization
• Technology scaleup
• Pretreatment reactor design
• Learnings
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AdvanceBio
AdvanceBio, LLC
• Formed in 2007
• Provide technology, engineering
and process design services for first
generation starch and sugar based
ethanol production.
• Provide consulting services in
support of project development.
• Consult and provide services
related to first and second
generation biofuels and.
• Application of process simulation
modeling of ethanol plants to
support efficiency and technology
upgrades and capacity expansion.
AdvanceBio Systems,
LLC
• Formed in 2009
• Exclusive rights to IP related to the
mechanical design of biomass
processing equipment used in the
pulp & paper and biomass to
chemicals at capacities to 700 bdtp
• Scaled the process down to meet
the immediate needs of the current
market.
• Design, engineer, fabricate and
supply biomass pretreatment
reactors and ancillary equipment.
• Provide design, engineering and
fabrication of small scale skid-
mounted process equipment based
on non-ABS IP.
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AdvanceBio
• Core group of technologists and engineers
with each with over 30 years of development,
design and operations experience
• Technology development and consulting
services for biofuels and biochemicals projects
– Conventional
• starch and sugar
• plant capacities up to 100 mm gpy
– Advanced
• lignocellulosic
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ENZYME
PROD
FEEDSTOCK
SIZE
REDUCTION
Context for Pretreatment
CONDITION
PRETREAT
FERMENT
SACCHARIFY
IMPREGNATE
FEEDSTOCK
CLEANING
RESIDUAL
PRODUCT
RECOVERY
FEEDSTOCK
PROD &
HARVEST
Pretreatment has a
central role and
pervasive impact on
all other processes
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How to Reduce Uncertainty/Risk
•Successive scale-up to bench, pilot, modules,
demonstration processes before commercial
plant – historical industrial approach
– Provides data valued by investors
– Time consuming
– Costly
– Private investors reluctant to incur costs, risks, long
time horizons
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Feedstock Bulk Density
6
720
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Developmental Scale Equipment
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Overall Glucose and Xylose Yields
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 20 40 60 80 100 120
Pretreatment time (min)
Yie
ld (
% o
f o
rig
ina
l g
luco
se +
xy
lose
)
Maximum potential glucose
Maximum potential xylose
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Combined
Glucose in
Stage 1
Xylose in
Stage 2
Maximum glucose yield – even more
challenging for low enzyme loadings
Maximum xylose yield
Maximum total yield
Dilute Acid Pretreatment and Subsequent Enzymatic Hydrolysis
160oC with 0.49% H2SO4
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Design Basis Considerations
–Reaction Chemistry – Catalyst
–Reaction Conditions • Time
• Temperature / Pressure
–Liquid Solids Ratio
–Bulk Density
–Feedstock Composition
–Conversion Efficiencies
–Plant Capacity
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Reactor Volumetric Capacity
10
per 10 minutes of residence at 50% active volume per 100 mm lpy of Ethanol
Bagasse
CornStover
WheatStraw
RiceStraw
Reed
Bamboo
Hardwood
So wood
750 800 850 900 950 1,000
ODtpd
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Thermal Conductivity
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Scaleup………Scaledown
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VISUALIZE
DESIGN
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Commercial Scale Biomass to Sugars
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Sugarcane Bagasse
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Commercial Reactors for Making Furfural
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Commerical-Scale Process
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AdvanceBio Reactor Design Basis Criteria
•Continuous feed and discharge
•Temperature control (pressure)
•Time control
•Feedstock flexibility
•High solids
•Catalyst flexibility
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Reactor Metallurgy
•Metals-
– High pH
• Carbon steel
• 304
• 316
– Low pH
• Alloy 825
• Alloy C-276
• Monel® 400
• Zirconium
•Commercial
– Corrosion rate
– Erosion
– Cost
•Research
– Corrosion
– Cost
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Operating
Life
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Scope of Supply
By AdvanceBio
• Feedstock flow control
mechanism
• Reactor
– Feedstock flexibility
– Chemistry flexibility
– Residence time control
– Temperature control
• Discharge mechanism
• Flash separation
• Steam generation capacity
• Control system
• Mobile skid package
By Owner
• Boiler feedwater
• Instrument air
• Electricity
• Catalyst
• Feedstock
• Process conditions
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Design Basis Criteria
• Nominal Capacity: 10 dry kg/hr at 10 minutes
retention
• Raw Material: Shredded biomass – Length: Less than 12 mm
• Reaction Conditions: – Retention Time: 2.0 to 60 minutes
– Operating Temperature: Typical 120° to 190°C
– Operating Pressure: 11.5 bar at 190°C
– Catalyst Chemical: Mixed with solids before feeding
– Design Feedstock Density: Typical 80 dry kg/m3
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Bench Scale Pretreatment Reactor
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Small Scale System
Mechanical
Considerations
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Biomass Bulk Density Variability
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
5.1
3.4 27.0 216.0 729.0
Bu
lk D
en
sit
y
(lb
/ft3
)
Container Size (in3)
3.0 30.0 300
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Corrosion - Errosion
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Other Learnings
•Catalyst feed rates at ultra-low
throughput rates are not conducive to
continuous feed and good distribution.
•Apparent minor changes in equipment
can have a significant impact on the
overall design and fabrication schedule.
• “Standard design” will generally require
custom features.
•The direction of research groups will
change. 25
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Generation 2 Bench Reactor
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Lab Scale Reactor
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Future…
• Continue to focus on optimizing the design and
fabrication of bench, lab and pilot units with
learnings transferable to commercial systems.
• Currently working on non-liquid catalyst recovery
systems.
• Providing small, self-contained equipment skids for
process technologies other than biomass
pretreatment.
• Developing reactors optimized for producing,
furfural, etc.
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