Pilot Plant for Process Development - PPDP

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Presentation of Carlos Eduardo Vaz Rossell for the Workshop on Hydrolysis Route for Cellulosic Ethanol from Sugarcane.

Apresentação de Carlos Eduardo Vaz Rossell realizada no "Workshop on Hydrolysis Route for Cellulosic Ethanol from Sugarcane"

Date / Data : February 10 - 11th 2009/
10 e 11 de fevereiro de 2009
Place / Local: Unicamp, Campinas, Brazil
Event Website / Website do evento: http://www.bioetanol.org.br/workshop1

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Pilot Plant for Process Development - PPDP

  1. 1. PILOT PLANT FORPROCESS DEVELOPMENT – PPDPCentro de Ciência e Tecnologia do Bioetanol – CTBE Carlos Eduardo Vaz Rossell crossell@bioetanol.org.br Workshop on Hydrolysis Route for Cellulosic Ethanol from Sugarcane February 10-11 th 2009-Campinas, Brazil
  2. 2. PILOT PLANT FORPROCESS DEVELOPMENT - PPDP• Bagasse conversion to Bio-Ethanol;• PPDP, site location, project;• Main scope: Enzymatic hydrolysis conversion of Bagasse to Ethanol;• Justification for the project• Scope of the Pilot Plant,• Conceptual Project;• CTBE support to Research Groups.
  3. 3. 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.
  4. 4. PPDP location at the Campus of LNLS
  5. 5. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP Lay-out A 1 2 3 4 5 6 7 8 9 10 11 12 13 C CIRCULAÇÃOB FERMENTADOR DE 40L SEMI-ANALITICAS PREPARO DE MATERIAL BALANÇAS FREEZER AUTOCLAVE ESPECTOFOTÔMETRO CENTRIFUGA LABORATÓRIO 1 NB-2 AUTOCLAVE FERMENTADOR GELADEIRAS DE 10L MICRO BALANÇA GELADEIRA CENTRIFUGA ANALITICA PREPARO BANCADA PARA ELETROFORESE DE MEIO DE ESPECTOFOTOMETRO CULTURA FILTRAÇAO ACOMPANHAMENTO FERMENTADOR MICRO DE 10L BALANÇA PREPARAÇAO DE MATERIAL BALANÇA ANALÍTICA MICROCENT. GELADEIRA BALANÇA SEMI ANALÍTICA PCR ESTUFA CAPELA DE CAPELA DE 4.60 CAPELA DE PHMETRO FLUXO LAMINAR FLUXO LAMINAR FLUXO LAMINAR SHAKER PCR SHAKER PLACA AGITADORAC A
  6. 6. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDPFront view of PPDP A B C
  7. 7. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDPLayout of PPDP6 – Unit for ethanol Fermentation 11 10
  8. 8. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP Enzymatic hydrolysis conversion ofBagasse to Ethanol, the main purpose of the PPDP
  9. 9. Critical steps for hydrolysis technology 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.
  10. 10. Enzymatic Hydrolysis for bagasse/ethanol conversion BAGASSE ETHANOL CLEANING DISTILLATION/DEHYDRATIONSAND,SOILMETALS 4 PENTOSE FERMENTATION FRACTIONATION TO ETHANOL FINES WINE YEAST PRODUCTION AND RIND PREHYDROLYSIS PENTOSE LIQUOR HEXOSE FERMENTATION TO ETHANOL SPECIAL YEAST 1 HEXOSE LIQUORLIGNIN LIQUOR PURIFIYNG DESLIGNIFIYNG CELULASE TREATED FIBER PRODUCTION 2 ENZYMATIC HEXOSE LIQUOR HYDROLYSIS 2 CELULASE RECOVER CELULASES 10 back next
  11. 11. 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.
  12. 12. 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.
  13. 13. PPDP- Scope 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.
  14. 14. 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,
  15. 15. PPDP- Conceptual ProjectOperational model between Research Groups and CTBE facilities: LDP, PPDP, Scientists and Engineers team and the Virtual Bio- Refinery project.
  16. 16. Research, Development and Innovation Research Groups (including CTBE group) PDU Process LDP PPDP Demonstration Process Pilot Plant UnitDevelopment For Process Laboratory Development STEPS NOT CONSIDERED IN THIS PROJECT COMMERCIAL UNIT CTBE
  17. 17. Research, Development and Innovation Research, Development and Innovation Basic and Process Start-up and Engineering Operation of PDU Conceptual Engineering Detailed Design and Building Engineering of an Industrial UnitAreas in which PDU Building Industrial UnitsCTBE is directly involved Areas in which CTBE could be indirectly involved through technical support
  18. 18. Interaction between PPDP and the Virtual Bio-refinery Project Hydrolysis process Technical, Economical development involving and Sustainable Research Groups, LDP evaluation of the and the PPDP technology. Technologicalroute for Hydrolysis Virtual Bio-Refinery PDU Assessment of technology for Hydrolysis
  19. 19. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP Organization• PPDP1– Unit for physical treatment of sugarcane bagasse;• PPDP2 – Unit for physical chemical pretreatment of Lignin-cellulose material;• PPDP3 – Unit for Fungi, Yeasts and Bacteria Production;
  20. 20. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDP Organization• PPDP4 – Unit for biomass enzymatic Hydrolysis;• PPDP5 – Unit for Separation and Purification;• PPDP6 – Unit for ethanol Fermentation.
  21. 21. PROCESS DEVELOPMENT - PPDP Organization• PPDPns: area reserved (600 m²) for new experimental units to be developed and installed once new developments be introduced;• Utilities: Saturated Steam at 10 Bar and 35 Bar, Thermal Utilities fluid (35-280ºC), cooling water (25-29ºC), cold water (6- 12ºC), compressed air at 10 Bar (dry, oil and particle free);• Support Units: Control Laboratory, Workshop, Instrumentation and Control Office, Visitant Researchers Offices
  22. 22. PPDP1 – Unit for physical treatment ofsugarcane 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
  23. 23. 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 SAS H2O SAS H2OC H2OR H 2O H2OG H SA MT-01 CON H2OR SAS H2O SA FE- FE-03 H2OR SA CON H 2O SAS PT-01 CON H2OR H2OC H 2O H2OR PC-01 H2OC H2OC CO SA CON SAS H2 H2 H2OR CA H2OC CAR FIM XT-01 SA FIM P-05 P-03 CE-01 CAR P-02 MF- DE-01 P-04 LEV
  24. 24. PPDP3 – Unit for Fungi, Yeasts and Bacteria Production PPDP3: Unidade de produção de fungos, leveduras e bactérias (produção de leveduras para fermentação, produção de hidrolases) N° Identif. Qt Cap Un. Descrição Especificação 1 TM-01 1 250 litros Tanque de Tanque em aço inox 304, atmosférico, com camisa para Equipamento a ser projetado preparo de 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) N° Identif. Qt Cap Un. Descrição Especificação 2 TC-01 1 1000 tros/horaEsterilizador Conjunto para esterilização com seção de aquecimento Equipamento a ser especificadoPreliminary continuo 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 em parceria com o fornecedorEquipment N° 3 Identif. FE-02 Qt 1 Cap 75 Un. litros Descrição Fermentador Especificação Fermentador em aço inox 316 L, com controles Equipamento a ser especificado automáticos de temperatura, pH, O2 dissolvido, aeração, em parceria com o fornecedor ciclo de esterilização, rotação variável (0-500 rpm),Data Sheet condensador de saída, com sonda de capacitância, 04 entradas padrão para adição de sondas suplementares (NIR, potencial redox, etc), composição de gas de saída N° Identif. Qt Cap Un. Descrição Especificação 4 FE-03 1 250 litros Fermentador Fermentador em aço inox 316 L, com controles Equipamento a ser especificado automáticos de temperatura, pH, O2 dissolvido, aeração, em parceria com o fornecedor 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 N° Identif. Qt Cap Un. Descrição Especificação 5 CE-01 1 1000 tros/horaCentrífuga de Centrífuga contínua com descarga automática de Equipamento a especificar separação sólidos, esterilizável "in situ", com rotação variável de microorganis N° Identif. Qt Cap Un. Descrição Especificação 6 MF-01 1 1000 tros/hora Microfiltro Conjunto de microfiltração de feixe de tubos capilares, Equipamento a ser especificado para esterilizavel in situ , com bomaba de recirculação, em parceria com o fornecedor concentração sistema de contralavagem,tanques auxiliares, modulo de de leite de controle, casco, válvulas, tubulaçoes e acccessórios em levedura aço inox 316, construção sanitária N° Identif. Qt Cap Un. Descrição Especificação 7 DE-01 1 250 litros Decantador Tanque em aço inox 304, atmosférico, com fundo cónico, Equipamento a ser projetado para construção sanitária, com agitador tipo áncora (1/2 HP), concentração rotação variável ( 0-50 rpm) de biomassa d N° Identif. Qt Cap Un. Descrição Especificação 8 B-01 1 2500 tros/hora Bomba Bomba em aço inox 316, construção sanitária com selo Equipamento a especificar centrífuga de mecânico alimentação de mosto ao fermentador N° Identif. Qt Cap Un. Descrição Especificação 9 B-02 1 50 tros/hora Bomba de Bomba em aço inox 316, construção sanitária com selo Equipamento a especificar mecânico dosagem de mosto ao fermentador N° Identif. Qt Cap Un. Descrição Especificação 10 B-03 1 1500 tros/hora Bomba Bomba em aço inox 316, construção sanitária com selo Equipamento a especificar
  25. 25. 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
  26. 26. 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).
  27. 27. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDPCTBE support to Research Groups: • 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.
  28. 28. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDPCTBE 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.
  29. 29. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDPCTBE support to Research Groups: • 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.).
  30. 30. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDPMain users of the PPDP facilities:• Research team of CTBE• Research Groups and Institutions involved in Research and Development of the conversion of sugarcane bagasse and trash to Bio-ethanol.
  31. 31. PILOT PLANT FOR PROCESS DEVELOPMENT - PPDPPotential 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).
  32. 32. PPDP - Interaction Between CTBE and third partiesResearch groups: • 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.
  33. 33. PPDP - Interaction Between CTBE and third partiesProject approval: • 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.
  34. 34. PPDP- Project Group• Carlos E. V. Rossell - Coordinator• José Geraldo Pradella- Senior Researcher• Edgardo O. Gomes- Engineer• Fabio Squina- Researcher
  35. 35. Workshop on Hydrolysis Routefor Cellulosic Ethanol from SugarcaneThanks very much for your attention

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