Separation and Purification: the Missing Link Between Biomass Deconstruction and Commercial Products
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1 Separation and Purification: the Missing Link Between Biomass Deconstruction and Commercial Products World Congress on Industrial Biotechnology May 12th John Bhatt Novasep Inc. 1
2 Industrial Purification Solutions Food Ingredients Functional Ingredients Bio-Industries Sugar Starch derivatives Dairy ingredients Specialty additives Pre-biotics Natural sweeteners Antioxidants Bulk antibiotics & amino-acids Organic acids Bio-based chemicals Over 400 systems & equipment installed, with ~40 new projects per year 2
3 Worldwide Industrial Biotech at Novasep S. M. de Beynost, FR Stravopol, RU Sales Office Process Development Pilot, Engineering Boothwyn PA, USA Sales, Engineering, R&D Bangalore, IN Sales Office Shanghai, CN Process Development Pilot, Engineering 3
4 Pure Chemicals from Complex Mixtures Biomass Hydrolysis Chemical or Enzymatic Catalysis Fermentation Cellulosic sugars Fermentation Broth Novasep Purification Technologies Bio Based Chemical Feed material Side products Salts Proteins Biomass Further valorization 4
5 Cost-efficient Processes for Industry Continuous chromatography Membrane filtration Ion exchange & Adsorption Evaporation & Crystallization Electrodialysis 5 Marketed products typically < $3/kg From kt/year
6 A Methodology from Lab to Commercial Screening studies Process Design & Optimization Pilot studies Supply of Equipment with Guaranteed Performances In-house Process Simulation Process Integration With Upstream & Side Stream Demo batch production 6
7 From an Ideal Concept Biomass Transformation Standardized Bio-based chemicals 7 Building materials Bio-fuel Specialty chemicals Plastic materials
8 to a Complex Reality Biomass (s) Transformation routes A B C D.G H Impurity profiles Crude? Standardized Bio-based chemicals 8 Building materials Bio-fuel Specialty chemicals Plastic materials
9 What you think you will get! What you actually get! >50% of bio-based chemicals production costs are dedicated to purification 9
10 «Thousands» of Impurity Profiles Biomass Source Paper pulp lignosulfonates Wheat straw Wheat straw Wheat straw Hardwood Wood Cane bagasse Hydrolysis type Bisulfite (MgHSO3)2 Organosolv Acid Enzymatic Enzymatic Acid Ionic liquid ph Monomer Sugar Polymers / Oligomers Ashe Suspended solids HMF Furfural Specific impurities % / DS % / DS % / DS % / DS , g/l % / DS 8.4 g/l SO4 9.7 g/l acetate + SO4 60 % ZnCl2 10
11 11 The Missing Link?
12 Industrial-Scale Purification Solutions Biomasses Transformation routes A B C D.G H Impurities profiles Crude Industrial Purification Solutions Standardized Bio-based chemicals 12 Building materials Bio-fuel Specialty chemicals Plastic materials
13 Cellulose Lignin Biomass Hemicellulose 13
14 Cellulose Energy Membrane filtration Specialty application (viscose) Bio-ethanol, Biofuel Carbon fibers Lignin Membrane filtration Biomass Phenolic resins Bulk polyphenols (coumaryl, sinapyl) Hemicellulose 14
15 Membrane Filtration Technologies Example for the biofuel treatment: Removal of suspended solids Separation of oil-water fractions Example for the lignin separation: Removal of suspended solids Classification/standardization of molecular weights Product before and after ultrafiltration 15 Standardization by molecular weight of carbon fibers (permeate)
16 Slide 15 NJH5 Dernières ligne: exemple de standardization du permeat pour 2 feed différents Nicolas-Julian HILBOLD, 4/30/2014
17 Industrial Scale CFF Solution Ceramic membranes Kerasep Modules Large range of geometries and cut-offs 99 membranes per modules at industrial scale High temperature operation and SIP (121 C) Compact, sanitary design Kerasep membrane designs 16
18 Cellulose Energy Membrane filtration Specialty application (viscose) Bio-ethanol, Biofuel Carbon fibers Lignin Membrane filtration Biomass Phenolic resins Wood panels adhesives Bulk polyphenols (coumaryl, synaryl) Adsorption Hemicellulose 17
19 Novasep s Adsorption Solutions Solvent regeneration / cleaning Polyphenols and impurities Stationary phase (resin) Impurities Adsorption Resin Solvent + clean polyphenols Evaporation for solvent recovery ATEX Industrial Unit (1600L resin) 18
20 Cellulose Energy Membrane filtration Specialty application (viscose) Bio-ethanol, Biofuel Carbon fibers Lignin Membrane filtration Biomass Phenolic resins Wood panels adhesives Bulk polyphenols (coumaryl, synaryl) Adsorption Sugars Hemicellulose Demineralization solutions 19 HMF Furfural
21 Novasep s Electrodialysis and IEX Solutions Electrodialysis High desalting efficiency No chemical consumption Electricity-driven technology Ion exchange High desalting efficiency Chemicals consumption (limited by the combination with ED) Cyclic behavior operated in columns 20 Chromatography Alternative solution with no chemical consumption Valorization of HMF/Furfural
22 Cellulose Energy Membrane filtration Specialty application (viscose) Bio-ethanol, Biofuel Carbon fibers Lignin Membrane filtration Biomass Phenolic resins Wood panels adhesives Bulk polyphenols (coumaryl, synaryl) C5 sugars (xylose) Adsorption Sugars SSMB Hemicellulose Demineralization solutions C6 sugars 21 HMF Furfural
23 Purification of Sugars with Batch Chromatography Separation of C5/C6 by batch chromatography Two fractions are recovered Raffinate (low affinity) = C6 sugars Extract (high affinity) = xylose 22
24 Principles of Simulated Moving Bed Principle of Moving Bed : Simulation of a counter current flux to separate more easily the different fractions Simulated Moving Bed = continuous chromatography (SSMB) SSMB = Sequential simulated moving bed Several cells in series: Simulation of a counter current flux by switching injection and recovering points 23 Discontinuous injection and recovery of extracts and raffinate
25 SMB Profile Evolution 24 High purity fractions Low water usage Very low chemicals consumption
26 Cellulose Energy Membrane filtration Specialty application (viscose) Bio-ethanol, Biofuel Carbon fibers Lignin Membrane filtration Biomass Phenolic resins Wood panels adhesives Bulk polyphenols (coumaryl, synaryl) C5 sugars (xylose) Adsorption Xylitol EG/PG Sugars SSMB C5 chemistry 25 Hemicellulose Demineralization solutions HMF Furfural C6 sugars Bio-ethanol Polyols Organic acids
27 Cellulose Energy Carbon fibers Membrane filtration Specialty application (viscose) Bio-ethanol, Biofuel Specialty chemicals (aromatics) Lignin Membrane filtration LPLC/HPLC Biomass Phenolic resins Wood panels adhesives Bulk polyphenols (coumaryl, synaryl) C5 sugars (xylose) Adsorption Xylitol EG/PEG 26 Hemicellulose For very high value added products Sugars IEX, chromato Electrodial. HMF Furfural SSMB Switch to high performance liquid chromatographyc6 to sugars ensure excellent resolution C5 chemistry Bio-ethanol Polyols Organic acids
28 Conclusions Industrial purification solutions are the missing link between biomass deconstruction and valorization into final products Multiple transformation routes, multiple impurity profiles: the purification process cannot be improvised and needs to be adapted, driven by the user objectives The scale-up from lab to industrial units requires a clear methodology 27
29 Slide 27 NJH10 Dernières ligne: exemple de standardization du permeat pour 2 feed différents Nicolas-Julian HILBOLD, 4/30/2014
30 Thank you! Here s to your success! Any questions? John Bhatt John.Bhatt@novasep.com 28
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