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2010-10-06Berglin - New 2G process for ethanol from wood
1
New 2G process for ethanol from wood
Niklas Berglin, Innventia
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
4Berglin - New 2G process for ethanol from wood
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
5Berglin - New 2G process for ethanol from wood
2010-10-06
6
Outline
Driving forces
Process concept
Large scale trial
Conclusions
Berglin - New 2G process for ethanol from wood
2010-10-06
7
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
Berglin - New 2G process for ethanol from wood
2010-10-06
8
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
Berglin - New 2G process for ethanol from wood
2010-10-06
9
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)
Berglin - New 2G process for ethanol from wood
2010-10-06
10
Wish list
Several value-added products
Robust with respect to raw material
Minimize capital expenditure
Closed cycle
Minimize waste
Profit from integration
Berglin - New 2G process for ethanol from wood
2010-10-06
11
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
Berglin - New 2G process for ethanol from wood
2010-10-06
12
Alkaline
fractionation
Hydrolysis,
Fermentation &
Distillation
Gasification
Synthesis
Chemicals
Recovery
Forestry Residues
Process concept with gasification
Methanol
/DMEEnergy
Recovery
Ethanol
+ biogas
Berglin - New 2G process for ethanol from wood
2010-10-06
13
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
Berglin - New 2G process for ethanol from wood
2010-10-06
14
Will it work in practice?
Project to test the concept in mill
and pilot scale trials
Berglin - New 2G process for ethanol from wood
2010-10-06
15
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
Berglin - New 2G process for ethanol from wood
2010-10-06
16
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
Berglin - New 2G process for ethanol from wood
2010-10-06
17
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
Berglin - New 2G process for ethanol from wood
2010-10-06
18
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
Berglin - New 2G process for ethanol from wood
2010-10-06
19
Results mill trial
Delignification to a kappa number of < 20
(i.e. lignin content < 3 %)
0
5
10
15
20
25
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
Berglin - New 2G process for ethanol from wood
2010-10-06
20
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
Berglin - New 2G process for ethanol from wood
2010-10-06
21
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
Berglin - New 2G process for ethanol from wood
2010-10-06
22
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
Berglin - New 2G process for ethanol from wood
2010-10-06
23
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.
Berglin - New 2G process for ethanol from wood