Integrating and upscaling pretreatment, enzymatic hydrolysis and fermentation processes DATE: October 17 th, 2017 AUTHOR: Irantzu Alegria, CENER
ButaNexT s Scheme WP4 Integration & upscaling- CENER
WP4-Integration & upscaling Objective: Validate the technical performance of the integrated process in a pilot facility covering the whole process from feedstock handling to product recovery Approach: Integrate the individual conversion processes and biocatalysts (enzymes and microbes) developed in WPs 2 & 3. Mechanical & thermocahemical pretreatment Fermentation & pervaporation Enzymes & enzymatic hydrolysis Microorgsnisms
ButaNexT s Jigsaw WP2 WP2 WP2 WP3 WP3 WP4
Upscaling ButaNext s process ButaNext process 2-step pretreatment Enzymatic hydrolysis Fermentation (PV)
Upscaling ButaNext s process ButaNext 2-step Pretreatment 1 st Milling (0,5mm) 2 nd Thermochemical pretreatment Flexible Easy to adapt Variables
Upscaling ButaNext s process ButaNext 2-step Pretreatment 2 nd Thermochemical pretreatment Flexible Easy to adapt Variables: Temperature Catalyst Residence time Initial moisture Discontinuous testing assays Continuous production
Upscaling ButaNext s process ButaNext 2-step Pretreatment 2 nd Thermochemical pretreatment Selection of best TC pretreatment conditions: LAB - Solubilized sugars (HENZ) - Low inhibitors generation
Upscaling ButaNext s process ButaNext 2-step Pretreatment Continuous production: Pilot 50 kg/day 2 nd Thermochemical pretreatment >250kg/week scale
Upscaling ButaNext s process ButaNext process 2-step pretreatment Enzymatic hydrolysis Fermentation (PV)
Upscaling ButaNext s process ButaNext Enzymatic hydrolysis Slurry Hydrolysate Enzymes
Upscaling ButaNext s process ButaNext Enzymatic hydrolysis LAB 30-40 g/assay 10% total solids Incubator (temp+agitation) Pilot scale 100-120 kg up to 3000kg/assay 20%-25% total solids more?? Reactor Key factors: ph Temperature Agitation
Upscaling ButaNext s process ButaNext Enzymatic hydrolysis LAB Pilot scale Similar conversion yields
Upscaling ButaNext s process ButaNext process 2-step pretreatment Enzymatic hydrolysis Fermentation (PV)
Upscaling ButaNext s process ButaNext Fermentation Biofuel Bacteria
Upscaling ButaNext s process ButaNext Fermentation LAB Inoculum ready to activate Seed train 200ml-2L-40L Enviroment (lab to pilot) Pilot scale Vial SEED 1 200 ml SEED 2 2000 ml REACTOR 100L
Upscaling ButaNext s process ButaNext Fermentation LAB Pilot scale Synthetic media real media Batch feed batch continuous Stress factors: Inhibitors Sugar conc. ABE conc.
Upscaling ButaNext s process ButaNext Fermentation + PV unit LAB Stress factors: Inhibitors Sugar conc. ABE conc. Pilot scale
Conclusions: from lab to pilot scale 2-step pretreatment Reduce inhibitors & increase glucan availability Enzymatic hydrolysis Increase yields & sugar concentration Fermentation (PV) Increase productivities & sugar consumption
CENER s Resources and Facilities
Resources & Facilities CB2G-overview The Second generation Biofuel Centre consist of a Process Development Units (PDUs) for 2 nd generation biofuels on a pilot scale level as an intermediate step towards the industrial scale-up of these technologies The CB2G constitutes an integrated trial and demonstration platform designed to develop: processes, equipment and specific components, new biofuels bio-refinery concepts. 21
Resources & Facilities CB2G Process Units Pretreatment Unit: Capacity: 2MWt - 500 Kg Biomass/h Chipping for woody biomass. Chopping for herbaceous biomass Drying Torrefaction Milling. Pelletizing In operation from 2008 Thermo-Chemical Unit: Gasification unit: Capacity 2 MWt-500 Kg Biomass/h Gasification Island Thermal Oxidizer and Flue gases treatment In operation from 2012 Biochemical Process Unit: Capacity: Up to 1.500 kg biomass / week Pretreatment. Solid / Liquid Fractionation Biological Processes (Enzymatic Hydrolysis & fermentation). In operation from 2013 22
23 2. Resources & Facilities CB2G - Torrefaction and pelletization pilot plants Torrefaction pilot plant with a production capacity of 150-350 kg/h based on a internaly rotating saft indirectly heated reactor using thermal oil (250-300ºC): Very flexible regarding raw material particle size distribution (0,25-40 mm) and bulk density (50-500 kg/m 3 ) including agricultural biomass like straw. Excellent mixing and agitation minimizing internal temperature gradients, easy temperature control, being able to cope with feedstock with exothermal heat of reaction, producing a extremely homogeneous product. VIDEO pilot plant in operation: HTTPS://WWW.YOUTUBE.COM/WATCH?V=QSZEXORNTNQ Pelletizing pilot plant with a production capacity of 200-350 kg/h: Hammer mill: screen size 2-12 mm Mixer with 2 m 3 : moisture content adjustment and additive feeding Mill press of 30 kw: Ad Hoc die designs: pellets diameter, compression ratio, number of holes, etc New roller design
2. Resources & Facilities CB2G - Gasification Unit Main features: Bubling Fluidized Bed Nominal power: 2 MWt (500 kg/h) Operation pressure: 0,3 barg Temperature : 650-1000ºC Operation modes: Air gasification Steam + O 2 gasification Inertization: CO 2 24
2. Resources & Facilities CB2G Biochemical Unit Pilot Plant Pretreatment Enzymatic Hydrolysis Fermentation Continuous horizontal reactor: 5Kg/h up to 14.5bar & 200ºC Stirred tank reactor (75 l) able to develop high consistency EH Bioreactor fully monitored. (40 l) 25
3. Resources & Facilities CB2G Biochemical Unit Semi-Industrial Plant Main equipment includes: Enzymatic hydrolysis(2 x 3 m 3 ) Biorreactors (1, 3 and 6 m 3 ) 26
27 3. Resources & Facilities Laboratory Process development area - Fractionation: 3 pressurized stirred tank reactors (from 100ml to 4L) - Enzymatic hydrolysis: process parameters optimization in microplates, erlenmeyers y bioreactors (2-5 L) - Fermentation: process parameters optimization in microplates, erlenmeyers y bioreactors (2-5 L)
ACKNOWLEDGEMENTS The construction of the CB2G has been funded by the Government of Navarre (Navarre Plan 2012), the Spanish Ministry of Science and Innovation (National Program for Scientific- Technological Infrastructures) and the European Fund for Regional Development (FEDER)
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