Bio-Hydrogen Production in Pilot Scale

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Bio-Hydrogen Production in Pilot Scale

  1. 1. Bio-Hydrogen Production in Pilot Scale
  2. 2. ERGOSTECH <ul><li>Founded as ¨Clean Energy Ltda¨ - Nov 2004 </li></ul><ul><li>Renamed into ¨Ergostech Ltda¨ - Nov 2007 </li></ul><ul><li>Capital: 1 Million R$ </li></ul><ul><li>Focus: </li></ul><ul><ul><li>R&D Biomass Technology </li></ul></ul><ul><ul><li>IBB – Consulting </li></ul></ul><ul><ul><li>Investment Projects in Brazil and Angola </li></ul></ul>Estrada da Rhodia, Km 16 Barão Geraldo/ Campinas/ SP
  3. 3. Strategic Location Unicamp CPqD LS Paulinia Replan www.randon.com.br/ .../ p_menu_10.htm IBM Bosch Motorola Green: Sugar Cane Plantation Honda Samsung
  4. 5. Overall Process Flow Sugar Cane Crushing Cane Juice Sugar Process Molasses Bagasse Hydrolysate: Hexose, Pentose, Lignin Residues: Ash, Char Ethanol Fermentation Distillation Vinasse Biomass Hydrogen Fermentation Methane Fermentation Hydrogen Process E. Power Methane Process Steam A B C D 10,000 t/day (1 sugar Mill) 3.000 t/day (50% moisture) Hexose 525 t Pentose 315 t Lignin 210 t Residues 450 t Gas for industry Raw material Gas Fuel
  5. 6. Process <ul><li>Cascade Process </li></ul><ul><li>Ethanol fermentation: already existing in Brazil </li></ul><ul><li>Biodiesel </li></ul><ul><li>Hydrogen fermentation </li></ul><ul><li>Methane fermentation </li></ul>
  6. 7. Installations involved <ul><li>A reactor of 1m 3 capacity, fully equipped with the control units (heating/temperature control, pH-adjusting, substrate addition, sterilization, pressure control, among others) </li></ul><ul><li>A laboratory to perform the analysis and control the parameters of the process. </li></ul><ul><li>This laboratory shall get the data for the industrial scale fermentation, for the different raw materials available for this process. </li></ul><ul><li>The local and ground facility will be offered by ERGOSTECH </li></ul>
  7. 8. Hydrogen Production Pathway
  8. 9. Microbial strain <ul><li>Patent microbe is owned by Sapporo Breweries </li></ul><ul><li>Exploitation of the patent microbe: subject to agreement of intellectual-property-rights </li></ul><ul><li>Deposited microorganisms: obtained from International Authority Depository (U.S.A. or Germany) </li></ul><ul><li>Some deposited strains present hydrogen productivity near the Sapporo strain </li></ul><ul><li>New strain screening: might be another Joint Research Project </li></ul><ul><li>Although this method requires time, we can obtain the new excellent microbes. </li></ul>
  9. 10. Expected Benefits <ul><li>Optimization of the renewable resources utilization </li></ul><ul><li>Introduce an alternative product to be used as biofuel, using the same agricultural resources </li></ul><ul><li>Increment in the energy recovery of approximate 1.5 times (ca. 50% increase) </li></ul><ul><li>Results in more energy and less waste release </li></ul><ul><li>Alternative process to couple to other biofuel production process, including Biodiesel (oil production) </li></ul>
  10. 11. ERGOSTECH EXISTING BUILDING
  11. 12. PILOT PLANT (19×9.8m) Pilot Plant Placement  
  12. 13. 15 m Pilot Plant Layout(not final plan dated 09/05/12)   Sapporo is designing the detail of each equipment’s specification now. These layout, therefore, is possible to be changed according to their specs. If you have any opinions about this plan, please inform us. Refer to your opinions, Sapporo will modify this layout and specs. 19 m 10 m Material Inlet Homogenizer ③ Bioreactor ② Nutrient Treatment & Adjustment Unit N-Source Supplier Raw Material Preparation Tank Cooler ④ Control Panel ⑦ Portable Slurry Pump ⑤ Portable Vessel  400 L ⑥ Portable Vessel  100 L ⑧ Bacteria Propagation Unit 30L ⑨ Bacteria Propagation Unit 200L ⑩ Cooling Water Unit ⑬ Compressor ⑪ Drum Lifter ⑫ Stirer Doorway Movable Installed (Fix) Installed Base ① Raw   Material Treatment & Adjustment Unit Raw Material Supplier sieve Raw Material Preparation Tank WC
  13. 14. Flow Chart of Hydrogen Fermentation Raw material preparation by Homogenizer NOT FINAL PLAN   Raw material preparation by NaOH Preparation by Enzyme Hydrogen Fermentation Separation by Sieve
  14. 15. Load Concentration <ul><li>Main components of the metabolite of hydrogen fermentation are organic acid </li></ul><ul><li>About 10% of load decreases by hydrogen fermentation </li></ul><ul><li>Organic acid is the most desirable substrate of methane fermentation </li></ul><ul><li>Effluent is used effectively and can maximize the energy recovery from the biomass, if a rapid methane fermentation is coupled to use the organic acid (hydrogen fermentation effluent) </li></ul>
  15. 16. Fermentation Broth <ul><li>The load concentration before and after hydrogen fermentation (acid fermentation) is as follows: </li></ul><ul><ul><li>At raw material concentration is 25 - 30 kg / m 3 </li></ul></ul><ul><ul><li>COD of raw material broth is ca. 33,000 mg / liter </li></ul></ul><ul><ul><li>COD of effluent is ca. 30,000 mg / liter </li></ul></ul>
  16. 17. 01-1-1Tank for raw material preparation 01-1-2 Homogenizing devices for the raw material preparation 01-1-5 Raw material supplier No.2 01-1-3 Raw material supplier No.1 01-1-7 Feed pump 01-1-4 Stirring device 01-1-6 Stirring device 01-1-8 Frame/piping Item 01-1 Raw Material Treatment & Adjustment Unit 01-5 100L Vessel 01-6 400L Vessel 01-7 Slurry pump NOT FINAL PLAN   To Item 01-3
  17. 18. Item 01-3 Bioreactor Unit   01-3-1 Bioreactor 01-3-2 Circulation system 01-3-3 pH adjuster vessel 01-3-4 pH controller 01-3-5 pH probes 01-3-6 Flow monitor 01-3-7 Temperature detector 01-3-8 Frame/piping NOT FINAL PLAN   From Item 01-1
  18. 19. Item 01-2 Nutrient Treatment & Adjustment Unit 01-2-1 Tank for raw material preparation 01-2-2 Stirring device 01-2-3 N-source supplier 01-2-4 Stirring device 01-2-5 Frame/piping Items 01-8 Bacteria Propagation Unit 30L& 01-9 Bacteria Propagation Unit 200L 01-8-1 Automated Cultivator 30L 01-9-1 Automated Cultivator 200L 01-8-2 Stirring device 01-9-2 Stirring device 01-10 Cooling Water Unit 01-11 Lifter & 01-12 Stirrer 01-13 Air compressor NOT FINAL PLAN  
  19. 20. Routine analysis process <ul><li>Generated gases: Gas Chromatography </li></ul><ul><li>Generated organic acids: HPLC </li></ul><ul><li>Total sugar: Phenol-sulfuric acid method </li></ul>
  20. 21. Model of Methane Fermentation Unit by UASB (Up-flow Anaerobic Sludge Bed )
  21. 22. Model of Methane Fermentation Unit by Membrane Membrane Methane Fermentation Unit Bio-Gas Preparation Tank Methane Reactor Membrane Separator Effluent System Generator Boiler Separator Raw Material
  22. 23. Timeline of the Project Demonstration work (in Japan) Kick off meeting (in Japan) Activity Semester 1 Semester 2 Semester 3 Semester 4 Semester 5 Semester 6 Sem. 7 Nov.28,’08 Mar.2,’09 – Jul., ’09 Aug., ’09 Oct., ’09 Dec., ’09 Mar., ’10 Jun., ’10 Sep., ’10 Dec., ’10 Mar., ’11 Jun., ’11 Sep., ’11 Dec., ’11 - Mar.2, ’12 Fermentation test (Year 1) Preparation Pre-shipment inspection Installation, Commissioning Continuous fermentation process for each type of raw material N-source & C-source Fermentation (Year 2) Evaluation of the results of Year 1 and Preparation Complementation of the remaining parameters Solution of problems and questioning Optimization of strain/inoculum vs. raw material type Fermentation (Year 3) Preparation Optimization of F/S Cell concentration, rapid fermentation setup Cost reduction, energy reduction Progress Reports Start up and Progress Meetings Jp Jp Br Jp Br Jp Br Performance Report Submitted up to 90 days after the final Meeting

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