Concept evaluations

Concept evaluations

FuBio Seminar

28.8.2013 Eemeli Hytönen, Lotta Sorsamäki, Marja Nappa, Juha Leppävuori

(VTT Technical Research Center of Finland)

Hanna Kalanne, Jukka Seppänen, Jari Aittakari (GloCell Oy)

2 16.5.2013

Eemeli Hytönen, Concept evaluations, FuBio Seminar, 27.8.2013

Motivation Many focus areas of FuBio research

Research topic

PHWE

ILs

Composites

Barriers

Hydroxy acids

All – Combination

Examples of concepts

• HWE at a saw mill, Kraft pulp mill, TMP plant, or

CTMP/soda plant

• Extraction of high or low molecular weight hemicelluloses

• Extraction of sawdust or chips

• Kraft pulp to acetate-grade dissolving pulp

• Wood to TMP pulp-like pulp

• Wood to kraft pulp-like pulp

• Internally, externally or unmodified (using internal

plastization, chemicals, enzymes)

• Different lignin-fibre-plasticizer ratios

• PHWE-xylan

• Modification of GGM

• TOFA hybrid polymers

• Fatty acid cellulose esters

• Reactive milling

• Cellulose-polymer blends

• HA separation technologies (separate & combined): a)

Electrodialysis, b) Ion-exchange, c) Chromatography, d)

Acidification, e) Cooling crystallization

• Products: a) Hot glues, b) Chelating agents

Ideas TBD

3 16.5.2013


Motivation

FuBio concepts often at idea-level process design work = screening out non-

promising alternatives

Large amount of potential concepts can be built around the idea and high degree of

uncertainty exists, BUT a systematic analysis can help identifying important factors

to consider in building sustainable concepts from the experimental research

Concept

demonstrationPre-feasibility Feasibility

Engineering for

definition

Detailed

engineering

Engineering process design steps

Screening out

process-product

alternatives

Number of

process-

product

alternatives

Process

creation

Many

Few

One

Selection of technological

solutions, refinement of

alternativesOrder of

magnitude

/

High

+ 5%

/

Low

Design

precision

/

Degree of

uncertainty

* E. Hytönen and P. Stuart "Techno-Economic Assessment and Risk Analysis of Biorefinery Processes" in Integrated Biorefineries: Design, Analysis, and Optimization. M. M.

El-Halwagi and P. R. Stuart, Eds.: CRC Press/Taylor & Francis, December 2012

4 16.5.2013


Outline

Motivation

Objective

Methods

Overall concept evaluation approach of FuBio JR2

Preliminary screening of ideas – Light techno-economic analysis

Quantitative economic modelling of concepts

Example results

Preliminary screening process

Hot water extraction

Ionic liquids fractionation

Preliminary screening and quantitative economic modelling

Hydroxy acids separation from black liquor

Conclusions

Acknowledgements

5 16.5.2013


Objective

To illustrate the concept evaluation approach

Light techno-economic analysis of research ideas (Generation of

comparable economic screening data)

Quantitative economic modelling

To show results of some evaluated ideas and concepts

6 16.5.2013


Methods – Overall concept evaluation approach of FuBio JR2 Concept development & screening for quantitative and qualitative analysis

• Concept = feedstock + process + product(s) + capacity

• Concept alternatives created and screened with

industry experts

Concept

Concept

alternative

creation

Screening &

setting

boundaries

A – Process

Modelling and Value Chains

C – Qualitative

Opportunity

Assessment Model

B – Quantitative

Economic Model

D – Analysis and Report

with Key Findings

A – The selected concept is modelled at suitable level of detail for

obtaining balances for cost estimation

B – Quantitative modelling of costs and profitability under

uncertainties in process parameters and prices

C – Technical and economic feasibility are combined with other

qualitative factors impacting the opportunities of the case (including

e.g. political, environmental factors) and combined to a opportunity

score of the case

D – Iteration back to the beginning if the case assumptions need to

be adjusted

Concept

Non-attractive alternatives

Screening Analysis

7 16.5.2013


Methods – Preliminary screening of ideas Light assessment

M&E Balances

”INPUT-OUTPUT” -model

Spreadsheet balancing – no simulation

model

Included

Feedstocks

Yields

Main product

By-product(s)

Heating, cooling and electricity

Main chemicals (with recycling

rate)

Water and main waste streams

Variable costs based on input-output

balances and publicly available

price/cost information

Fixed costs

Labour (cost/person – 70 000 €/a)

Maintenance (1.5 % of total capital

cost estimate)

Other (3 % of sales)

Capital charges (10% of total capital

cost estimate)

Capital cost estimate

Bridgewater, Zevnik & Buchanan *

methods used

Values systematically evaluated for

all new concepts

Order of magnitude values obtained

Methods seem to give results within

+25% of detailed CAPEX estimates

fro biomass-based processes

* Holland, F.A. & Wilkinson, J.K., Perry's Chemical Engineers' Handbook, section 9

(Process Economics), McGraw-Hill, 1999

8 16.5.2013


Methods – Quantitative economic modelling of concepts

9 16.5.2013


Outline

Motivation

Objective

Methods


Preliminary screening of concepts – Light techno-economic analysis


Example results






Conclusions

Acknowledgements

10 16.5.2013


Example results – Preliminary screening process Hot water extraction

Products identified with WP1 for the hemicelluloses:

high MW hemicellulose for barriers, animal feed,

chemicals, ethanol

Processing of solid fraction not included

Total 32 concepts

Hot water

extraction (Yield, DC)

Purification &

concentration

Chips

Sawdust

(Spruce,

birch)

Crude extract

Fuel

Fibre for composite

Polymeric hemis

Oligomeric hemis

Monomeric hemis

Host process capacities as

basis for production capacity

Sawmill – 14 000 bdt

sawdust/a

Powerplant – 50-100-200

MW feedstock (100 000-

200 000-400 000 bdt/a)

TMP plant – 250 000 bdt

chips/a

Soda/Kraft pulping plant –

250 000-500 000 bdt

chips/a

11 16.5.2013


-4000

-2000

0

2000

4000

6000

80008

38

t/a

he

mi (

15

%yi

eld

), F

uel

83

8 t

/a h

em

i (1

5%

yie

ld),

Fee

d

39

74

t/a

he

mi (

10

%yi

eld

), F

uel

79

49

t/a

he

mi (

10

%yi

eld

), F

uel

15

89

8 t

/a h

emi (

10

%yi

eld

), F

ue

l

15

89

8 t

/a h

emi (

10

%yi

eld

), F

ue

l

99

30

t/a

he

mi (

10

%yi

eld

), W

W

14

34

1 t

/a h

emi (

15

%yi

eld

), W

W

14

34

1 t

/a h

emi (

15

%yi

eld

), F

eed

14

34

1 t

/a h

emi (

15

%yi

eld

), W

W

28

68

2 t

/a h

emi (

15

%yi

eld

), W

W

28

68

2 t

/a h

emi (

15

%yi

eld

), F

eed

67

0 t

/a h

em

i (1

5%

yie

ld),

Fu

el

67

0 t

/a h

em

i (1

5%

yie

ld),

Fee

d

31

80

t/a

he

mi (

10

%yi

eld

), F

uel

63

59

t/a

he

mi (

10

%yi

eld

), F

uel

12

71

8 t

/a h

emi (

10

%yi

eld

), F

ue

l

12

71

8 t

/a h

emi (

10

%yi

eld

), F

ue

l

79

44

t/a

he

mi (

10

%yi

eld

), W

W

11

47

3 t

/a h

emi (

15

%yi

eld

), W

W

11

47

3 t

/a h

emi (

15

%yi

eld

), F

eed

11

47

3 t

/a h

emi (

15

%yi

eld

), W

W

22

94

6 t

/a h

emi (

15

%yi

eld

), W

W

22

94

6 t

/a h

emi (

15

%yi

eld

), F

eed

30

74

t/a

he

mi (

25

%yi

eld

), S

awm

ill

85

46

9 t

/a h

emi (

20

%yi

eld

), P

ow

erp

lan

t

52

63

8 t

/a h

emi (

25

%yi

eld

), T

MP

10

52

76

t/a

hem

i (2

5%

yie

ld),

So

da

29

51

t/a

he

mi (

30

%yi

eld

), S

awm

ill

55

65

7 t

/a h

emi (

20

%yi

eld

), P

ow

erp

lan

t

50

52

3 t

/a h

emi (

30

%yi

eld

), T

MP

10

10

45

t/a

hem

i (3

0%

yie

ld),

So

da

Sawdust Sawdust Chip Chip Chip Sawdust Sawdust Chip Chip Chip Sawdust Chip Sawdust Chip

Sawmill Powerplant TMP Soda Sawmill Powerplant TMP Soda

Spruce Birch Spruce Birch

High MW hemicellulose Sugar

Co

sts

and

by-

pro

du

ct c

red

its

(€/b

dt

mai

n p

rod

uct

)

Creditsfrom by-prod

Other fixed

Labour

Capital charges

Wastes

Energy

Chemicals

Water

Feedstock

total

Selling price

Example results – Preliminary screening process Hot water extraction concepts – cost estimates

Indicative prices:

• High MW hemi –

1200 €/bdt

• Sugar – 300 €/bdt

SUGAR High MW hemicelluloses

12 16.5.2013


Example results – Preliminary screening process IL fractionation methods

IL #1 IL #2 IL #3 Raw material Birch kraft pulp birch spruce

Products Dissolving pulp 76% "kraft-like” pulp 57% ”CTMP-like” pulp 90-95%

Hemicellulose 24 % lignin, hemi 43% Pectin, hemi, lignin 5-10%

Ionic liquid [Emim]OAc Switchable ionic liquid [Emim]Me2PO4 (and water) DBU, MEA, CO2/SO2

Antisolvent water ethanol Isopropanol Antisolvent recovery method evaporation distillation evaporation

Production scale 150 000 adt/a 700 000 adt/a 250 000 adt/a

• Total 11 concepts

13 16.5.2013


Example results – Preliminary screening process IL fractionation concepts – cost estimates

1 175 1 112

860 1 068

720 935

1 214

872 1 035

844 1 004

-1000,00

-500,00

0,00

500,00

1000,00

1500,00

2000,00

stan

dal

on

e

inte

grat

ed

ble

ach

ed

kra

ft a

nd

hem

i&lig

nin

ble

ach

ed

kra

ft a

nd

en

ergy

un

ble

ach

ed k

raft

an

d h

em

i&lig

nin

un

ble

ach

ed k

raft

an

d e

ner

gy

hem

i&lig

nin

an

d e

ne

rgy

BC

TMP

an

d li

gnin

&p

ecti

n

BC

TMP

CTM

P a

nd

lign

in&

pe

ctin

CTM

P

IONCELL SIL pulping IL fibrillation

€/a

dt

Creditsfrom by-prod

Other fixed

Labour

Capital charges

Wastes

Energy

Chemicals

Water

Feedstock

Total

Selling price

IL #1 IL #2 IL #3

14 16.5.2013


Outline

Motivation

Objective

Methods




Example results






Conclusions

Acknowledgements

15 16.5.2013


Example results – Preliminary screening and quantitative economic modelling Hydroxy acids separation from black liquor – Case definition

Pulp mill production capacity 700 000 adt/a

Theoretical hydroxy acids (HA) yield 15 % of pulping raw material (includes

mono and dihydroxyacids)

1/3rd of BL processed HA production 35 000 t/a (50 kg/adt), 50% DC

Volatile (formic and acetic) acids yield 7% of pulping raw material

H2S handling and volatile acids recovery excluded

Pulp mill integration

Cooking variables (effective alkali and sulfidity) kept constant by NaOH makeup

and fly ash purge

Black liquor (25% TDS) is taken to HA separation

Liquor from separation is fed back to evaporation plant (including added water

and chemicals)

HA product is concentrated in a separate evaporator

16 16.5.2013


EDCO2/

UF

NaOHto green liquor dilution

Water

Ligninto evaporation or recovery boiler

to foul condensate

VA

EVAP CHRHA

EVAP

Intermediateblack liquor

to foul condensate

UF



CHR

Water

IEX

H2SO4

EVAP

VA to foul condensateWater

Na2SO4to green liquor dilution

UF



CHR

Water

EVAP

VA To foul condensate

ED

Water

NaOHto green liquor dilution

CO2+ H2SO4



COOL CRST

Inorganicsto green liquor dilution

EVAP/NF

CHR EVAP

To foul condensate

ISA

HA

ISA

HA

ISA

HA

ISA

to foul condensate

VA

CO2

H2SO4CO2

Example results – Preliminary screening and quantitative economic modelling Hydroxy acids separation from black liquor – Case definition

17 16.5.2013


0

200

400

600

800

1000

1200

1400

1600

1800

2000

€/t

Maintenance (€/t)

Steam (€/t)

Fly ash disposal (€/t)

NaOH (€/t)

H2SO4 (€/t)

CO2 (€/t)

Electricity (€/t)

Electrodialysis

Chromatography

Cooling crystallization

Example results – Preliminary screening and quantitative economic modelling Hydroxy acids separation from black liquor – Preliminary screening cost estimates

18 16.5.2013


Separation of hydroxy acids (HA) from black liquor

LMW (lactic, glycolic, 2-hydroxy-butyric acid)

HMW (glucoisosaccharinic, xyloisosaccharinic acid)

Applications

Hot melts in non food contact cardboard packaging (LMW and HMW)

Chelating agents in water purification (HMW)

Pulp mill

Hydroxy acids

separation*

HMW

LMW and HMW Hot Melts

Chelating agents

Cardboard

packaging

Water

purification * Two separation technologies

• UF + CHR + IEX

• UF + CHR + ED

Hydroxy acid polymer

HMW hydroxy acids

(Reference EDTA)

Example results – Preliminary screening and quantitative economic modelling Hydroxy acids separation from black liquor – concepts for more detailed analysis

19 16.5.2013


Example results – Preliminary screening and quantitative economic modelling Hydroxy acids separation from black liquor – Integration impact assessment

Pulp mill reference

model (WinGems-

simulation software) *

Capacity 700 000 adt/a.

Process water usage ~

15 m3/adt. Based on

BAT technologies

SPLIT

dust dump141

M IX

M i x30

30

M IX

M i x2626

BLEACHING

Bl eachi ng

25

WW-T REAT

Ef f l uent

t r eatment

24

ST ORE

Par ameter s

23

DEBARKIN

Debar ki ng

22

M IX21

SUM

Steam 4.2 bar

20

T RACOM P

Addi ng of

t r ace

components

16

M IX15

PID

P i d1414

SUM

Steam 13 bar

13

ST ORE

Pr oduct i on

12

DRYEND

Dr yer sect i on

11

SPLIT

Spl i t1010

T URB_PLANT

T ur bi ne pl ant

6

EVAPO

Evapor at i on

5

BOILERS

Boi l er pl ant

4

ST ORE

Wood

par am

i nput

3

RECOVERY_SK

Whi te l i quor pr epar at i on

2

DELIGNIFICA

Cooki ng and oxygen d

1

348

t/h

42 t/h123 t/h

Effluent 1740 t/h

0 t/h

Shaft power 95.1 MW

Floor channel 120 t/h, TDS 5 g/l

Wood properties:

1) I: Wood temp. [C] 15

2) I: Dry content of wood [%] 50

3) I: Cellulose in wood [%] 44.1

4) I: Hemicellulose in wood [%] 30.7

5) I: Lignin in wood [%] 23.9

6) I: Extractives in wood [%] 1.6

102 t/h

Water 100 t/h

Pyrolysis gas properties

69 t/h

71 t/h

Bark 46 t/h,30 °C, 40 %

104 t/h, TDS 11 g/l

Wood 404 t/h,15 °C, 49 %

Sootblowing steam 16 t/h, 30 bar

LP 6 t/h

MP 71 t/h

MP 76 t/h

195 t/h

LP 91 t/h

MP 32 t/h

MP 16 t/h

LP 26 t/h

227 t/h

Acidic filtrate 867 t/h, TDS 4 g/l

Cond. B 278 t/h

Saltcake 5 t/h

Bio-sludge 0 t/h0 %

Alkaline filtrate 649 t/h, TDS 8 g/l

900 t/h

636 t/h

Air 695 t/h24 °C

CTO 0 t/h

Water 351 t/h

BL 933 t/h,TDS 132 kg/t

Pulp 100 t/h, 75 °C, 90 %

1: Bark content of wood: 10 w-%

2: Wood LHV: 19.35 MJ/kgDS

3: Wood HHV: 19.3 MJ/kgDS

4: Not in use

5: Bark Dry content: 40 %

6: Carbon fraction in bark: 0.5159

7: Oxygen fraction in bark: 0.4069

8: Hydrogen fract. in bark: 0.0577

9: Sulfur fraction in bark: 3.000E-04

10: Ash fraction in bark: 0.0192

11: Gasification lost: 6 %

Water

LP 104 t/h

Cond. A 421 t/h

Boiler blow-down 6 t/h, 103 bar, 313 °C

BFW 604 t/h, 120 bar, 187 °C

13 b

ar

4.2

bar

7 ba

r 0

t/h

Chips 355 t/h, 15 °C, 50 %

Saltcake 1.4 t/h

LP-condensate 267 t/h

Pyrolysis gas

180 t/h, 66 °C, 50 %

HP -steam 598 t/h, 103 bar, 505 °C

Flue gas 806 t/h183 °C

Smelt 63 t/h

Bark parameters

Oxidised WL

WL 346 t/h, AA 113 g/l

BL

156

t/h,

TD

S 8

22 k

g/t

MP-condensate 140 t/h

* Kangas, Kaijaluoto and Määttänen (2013), Evaluation of Future Pulp Mill Concepts – Reference Model of Modern Nordic Kraft Pulp Mill, to be submitted to NPPRJ

20 16.5.2013


All sales to hotmelt (750 – 1500 €/t) Split sales to hotmelt (750 – 1500 €/t)

and chelating agent (500 – 800 €/t)

UF + CHR + ED

ROI: 90% probability to be positive


UF + CHR + IEX


ROI: 0,1% probability to be positive

Example results – Preliminary screening and quantitative economic modelling Hydroxy acids separation from black liquor – Feasibility and uncertainty

21 16.5.2013


Outline

Motivation

Objective

Methods




Example results






Conclusions

Acknowledgements

22 16.5.2013


Conclusions

2-step method used in FuBio JR2 programme for biorefinery design

was illustrated

Preliminary screening useful for identifying promising feedstock-process-

product combinations for more detailed analysis of e.g. integration

implications, markets, and quantitative and qualitative performance of the

concepts

More detailed case study evaluations are being done with focus on

Uncertainties

Variable and fixed costs

Qualitative performance

Results of light techno-economic assessment and quantitative

economic modelling of three sets of ideas was presented

Hot water extraction of hemicelluloses integrated into different biomass

processing plants

IL fractionation of biomass

Hydroxy acids separation from Kraft black liquor

23 16.5.2013


Acknowledgements

FIBIC Ltd.

Industrial tutors of FuBio Joint Research 2 –programme

Research groups involved in the experimental research of the

concepts in FuBio Joint Research 2 –programme

Researchers involved in the concept evaluation

24 16.5.2013


VTT creates business from technology

25 16.5.2013


Example results – Preliminary screening and quantitative economic modelling Hydroxy acids separation from black liquor – key process input variables

26 16.5.2013


Increased fly ash disposal and NaOH makeup (IEX)

Decreased electricity generation (IEX and ED)

Increased evaporation requirement at evaporation plant

LP steam used in HA product condensation (separate evaporator)

Increased electricity usage (IEX and ED)

Reduced lime circulation (IEX and ED)

reference IEX ∆ ED ∆

Electricity

Generation 1440 1320 -8 % 1220 -15 % kWh/adt

Usage 600 621 4 % 770 28 % kWh/adt

Out 840 700 -17 % 450 -46 % kWh/adt

H2SO4 5 69 1306 % 5 0 % kg/adt

NaOH 30 96 220 % 30 0 % kg/adt

Fly ash 13 122 838 % 13 0 % kg/adt

Lime circulation 0.24 0.19 -21 % 0.22 -8 % kg/adt

Evaporation plant 3 3.8 27 % 3.5 17 % GJ/adt

Example results – Preliminary screening and quantitative economic modelling Hydroxy acids separation from black liquor – Integration impact assessment

Technology

Concept evaluations