Niklas Berglin, Innventia

Transcription

1 New 2G process for ethanol from wood Niklas Berglin, Innventia 1

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4 Energy density is a key issue for biofuels Chips 0.8 Wood pellets 3 Torrefied wood & Lignin powder 5 Ethanol 6 Slash 0.4 Our focus 4

5 Production (million m 3 /yr) Biodiesel Ethanol Biofuels: Potential growth % per year (Data from F.O. Licht, 2006, quoted by and REN Renewables Global Status Report: 2009 Update 5

6 Outline Driving forces Process concept Large scale trial Conclusions 6

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 7

8 Process routes Wood F R A C T I O N A T I O N Cellulose Hemicellulose Lignin Extractives Waste Hydrolysis/Fermentation Hydrolysis/Fermentation Gasification /Synthesis Esterification Anaerobic digestion Ethanol Ethanol Methanol DME FT fuels Hydrogen FAME (Biodiesel) Biogas 8

9 Process routes 90 EUR/t 500 EUR/t (250 EUR/t wood) Cellulose EUR/t ( EUR/t wood) Ethanol Wood Hemicellulose Lignin Extractives Ethanol Methanol DME FT fuels Hydrogen FAME (Biodiesel) Waste Biogas 9

10 Wish list Several value-added products Robust with respect to raw material Minimize capital expenditure Closed cycle Minimize waste Profit from integration 10

11 Alkaline route from wood to ethanol Forestry Residues Alkaline fractionation Hydrolysis, Fermentation & Distillation Ethanol + biogas CO 2 Chemicals Recovery Lignin Separation Sulphur-Free Lignin Energy Recovery Electric Power 11

12 Process concept with gasification Forestry Residues Alkaline fractionation Hydrolysis, Fermentation & Distillation Ethanol + biogas Chemicals Recovery Gasification Energy Recovery Synthesis Methanol /DME 12

13 Results from system study Mostly known and well proven technology Possible to produce liters of ethanol per tonne of wood Possible production in typical mill, ca m 3 /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 13

14 Will it work in practice? Project to test the concept in mill and pilot scale trials 14

15 Distillation Simplified process layout (modelled in WinGEMS) Mill trial in Norrsundet Steam turbine Electricity Lignin fuel HP Steam Lime kiln Feed Alkaline frac. Evaporation Lignin separation Recovery boiler Caustisizing Pilot plant trial in Örnsköldsvik Water Enzymes Yeast CO 2 Ethanol Acid ph adj Cooking liquor Pre- Hydrolysis Simultaneous Saccharification and Fermentation (SSF) Combustible solids Dewatering Liq.-phase To evap. & then to power boiler 15

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 16

17 Mill trial Digester 5 Temperature, time and alkali charge adjusted Blow tank 5 Oxygen bleachplant Storage O2-bleached pulp Cellulose removed at a consistency of 4% Extraction liquor Pulp to bleachplant Storage of low S liquor NaOH Pulp transportation to the Ethanol Pilot Plant Blow tank 4 Fresh NaOH charged instead of normal white liquor Immediately trucked to the Ethanol pilot 17

18 HS - in extraction liquor (mol/l) Results mill trial 70 tonnes of soda pulp produced 0,30 Planned digester stop 0,25 0,20 Low S liquor to storage 0,15 0,10 0,05 0,00 06:00 08:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 00:00 Reached a low of nearly zero sulphidity 18

19 Kappa number Results mill trial Kappa after blow tank Kappa before O2 Kappa before bleach plant Delignification to a kappa number of < 20 (i.e. lignin content < 3 %) 19

20 Pilot plant trial 40 m 3 of cellulose suspension used in the trial Two enzyme cocktails Two levels of enzyme charge in SSF 700 litres of ethanol produced 20

21 Etanol [g/l] Results pilot plant trial 16,00 14,00 12,00 10,00 8,00 6,00 1: Novozymes låg 2: Novozymes hög 3: Roal hög 4: Roal låg; 1 5: Roal låg; 2 4,00 2,00 0,00 0,00 10,00 20,00 30,00 40,00 50,00 60,00 70,00 80,00 Tid [h] About 48 hours to complete SSF 21

22 Etanolutbyte (% av teoretiskt maximum) Results pilot plant trial Lund SEKAB % of theoretical yield Novozymes låg Novozymes hög Roal låg Roal hög 22

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. 23

24 Thank you for your attention! 24