From Gram to Kilo, Scaling Up Green Chemical Technologies. IGCW, Mumbai, 7 th December Dr Mark Gronnow

Transcription

1 From Gram to Kilo, Scaling Up Green Chemical Technologies IGCW, Mumbai, 7 th December 2013 Dr Mark Gronnow

2 early Centre for Novel Agricultural Products late Biorenewables feedstock discovery and development early Green Chemistry Centre of Excellence Biorenewables process and product development late early late Biorenewables R+D scale up facilities early SMEs to multinationals Process and product development late

3 About us The BDC is a UK-based not-forprofit company providing industry with new processes to convert plants, microbes and biowastes into high-value products.

4 What we do Plants and microbes Genotyping and molecular marker development Antimicrobial studies DNA/RNA sequencing Fast-track plant breeding Microbial identification Toxicity testing Processes Demonstration and scale-up Product and process development / optimisation Custom manufacturing Materials analysis 4

5 Our facilities Scale-up Open-access Plug & play Modular State of the art Proof of concept 5

6 Pre-processing Equipment Granulator - Hammer Mill - Pelletiser Scaled to handle 100kg batches of straws, seeds and other dry biomass Macerator Scaled for 100kg batches of high moisture biomass such as sugar beet and fruit waste Oil Expeller Press Continuous oil seed pressing Up to150kg/hour Impact Huller Dehulling a wide range of seed types Up to kg/hr

7 Processing Equipment I Steam Explosion System 100 litre high pressure/temperature vessel for ligno-cellulosic biomass treatment Microwave Pyrolysis System 30kg/h continuous low temperature system Semi-Continuous Centrifuges Solid-liquid and liquid-liquid separator centrifuges Vacuum Filtration System 316 litre filter dryer

8 Processing Equipment II Process Scale Column Chromatography 5-120L/hr process chromatography skid with Easy-Pack Glass column Supercritical CO 2 System 2 x 5 litre sub- and super-critical CO 2 extraction and fractionation system Distillation Facilities Spinning cone and short path distillation equipment suitable for recovery of a range of plant extracts Glass Reactor System Versatile glass-lined reactor vessels up to 50 litres suitable for crystallisation and a wide range of chemical reactions

9 Microbiology and Analytical Suites Microbiology Suite 5 and 40 litre bioreactors located in a dedicated microbial laboratory Analytical Suite HPLC, GC, ICP-MS, NMR, Karl Fischer-moisture meter UV/visible spectrophotometer, Rancimat, and cold flow plug point instrumentation

10 Feedstock Development Opium poppy Sugar Cane Industrial Hemp Miscanthus Stevia Artemisia Maize Jatropha Aspergillus

11 Real-Time PCR System Capillary Electrophoresis DNA Analyzer Single Nucleotide Polymorphism detection system Ion Torrent Personal Genome Machine Fragment Analyzer CE System

12 Business Development Unit UK becomes a top 3 producer of high value chemicals from plants

13 Our progress to date Over 40 on-going projects Over 50 local businesses supported Team of 21 highly-qualified professionals 13

14 AJ Ethical Extractions Ltd Aptamer Diagnostics Limited Aptamer Solutions Limited Aqua Enviro Limited Biotec Ltd Brocklesby Limited Citration Technology Limited Citrefine International Limited Conrad Farm Energy Limited Eggleston Catering Services Limited Fresh Marketing Ltd Hallstone Composting Limited Higgins' Consultancy Limited Kepier & Company Limited Link2energy Limited Natures Laboratory Limited Newhay Feeds Limited Nugel Limited Pextenement Cheese Company Limited Richard Coppack Rolawn Limited Rudgate Engineering Ltd Specify Consulting Limited Sports Turf Research Institute (The) Strulch Limited The Heating Company (Northern) Ltd The National Non-Food Crops Centre TransWaste Treboom Limited UTO Environmental Products Limited Vertigro Limited W.T. Johnson & Sons (Huddersfield) Limited Wack's Wicked Plants Walker Resource Management Limited Wold Toppers Limited Advanced Extraction Technology Ltd Anthony Turnbull Apiceutical Research Centre Earth Supply Ltd Higgins' Consultancy Limited Kerfoot Ltd New Holland Extraction SupaPlants Terra Resource Investment

15 Technology Development : Microwaveassisted processing of biomass for energy products Microwave energy Continuous feed

16 Why MW? Advantages of MW Heating Rapid internal heating Uniform heating Instant control Acceleration of reaction rate Selective interaction with active groups

17 Microwave Treatment of Biomass Biomass Energy Microwave processor Low Temperature Extracted oil Pyrolysis Oil Char Wide range of feedstock Flexibility of Microwave Parameters (time, temperature, power) + = Wide range of products The preparation of high-grade bio-oils through the controlled, low temperature microwave activation of wheat straw. Bioresource Technology (2009) 100(23),

18 First Observations: Rape Seed Heat of combustion 30 kj g

19 Characteristics of MW Bio-Char High calorific value Good grindability Good hydrophobicity Co-firing with coal

20 Microwave oil characteristics 1. Low water content 2. Low acid content. 3. Low alkali metals content. 4. The high yields of fermentable sugars: - Levoglucosan (up to 50%) - Levoglucosanone (up to 25%)

21 Bio-Oil Yield Sample York Microwave Pyrolysis Products Yield (%) Bio-Char Aqueous Bio-Oil Liquid Flash pyrolysis Liquid yield (%) Bracken Wheat Straw Paper Wood Barley Dust Reed Grass Canary

22 Wood Microwave pyrolysis. Oil fractionation Fraction Temperature ( o C) Fraction Temperature ( o C)

23 Wheat straw MW decomposition. Semi-scale experiment. 1.5 of oil 18 kg of wheat straw = 6.7 kg of char of oil

24 Continuous microwave processor. 30 kg/h

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26 Case Study 2 Orange Peel Waste biorefinery 60% of Orange Peel was transformed to valuable products CHEMSUSCHEM, 2012, 5 (9),

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28 Some examples CH 3 CH 3 H 3 C CH 2 p-cymene H 3 C CH 3 Green Chemistry, 2011, 14, CH 3 CH 3 SO 3 H H 3 C CH 3 HO alpha-terpineol H 3 C CH 3 Catalysis Today, 2012, 190,

29 p-cymene as a platform molecule? CH 3 CH 3 CH 3 CH 3 HNO 3 NO 2 Cu(I) CN CN H 2 /Pd NH 2 H 3 C CH 3 H 3 C CH 3 H 3 C CH 3 H 3 C CH 3 H 2 O CH 3 O CH 3 O NH 2 H 2 O OH H 3 C CH 3 H 3 C CH 3

30 Carbonylation of d-limonene M. Bahr, A. Bitto, R. Mulhaupt, Green Chemistry, 2012, 14,

31 Chemicals from Apples Graph showing formation of HMF from apple pomace under microwave conditions using citric acid catalyst MSc Project by Matthew Evans, University of York September 2010

32 Future Development: Hydrothermal MW treatment. MW biorefinery of orange peel waste Valorisation of Orange Peel Residues: Waste to Biochemicals and Nanoporous Materials. hemsuschem (2012) 5(9),

33 Case Studies : Micro-breweries

34 Grain

35 Hops

36 Yeast

37 The Heating Company (Northern) Ltd. Straw Wheat straw Barley straw Oat straw Rape straw PELLETS spent grain High moisture content! (>70%) High calorific value 37

38 Connect with us online www biorenewables-development-centre