Bio-Hydrogen Production in Pilot Scale

Bio-Hydrogen Production in Pilot Scale

ERGOSTECH

-Founded as ¨Clean Energy Ltda¨ - Nov 2004

-Renamed into ¨Ergostech Ltda¨ - Nov 2007

-Capital: 1 Million R$

-Focus:-R&D Biomass Technology-IBB – Consulting-Investment Projects in Brazil and Angola

Estrada da Rhodia, Km 16 Barão Geraldo/ Campinas/ SP

Strategic Location

UnicampCPqD

LS

PauliniaReplan

www.randon.com.br/.../p_menu_10.htm

IBM

Bosch

Motorola

Green: Sugar Cane Plantation

Honda

Samsung

Sugarcane

Sugar

BoilerBoiler

Sugar production

Molasses

Ethanol fermentation

Bagasse, stover

Cane juice

Crushing

Hydrogen fermentation

Methane fermentation

Vinasse: Xylose, Lignin

Vinasse: residual sugars

Distillation

Sugar process

Ethanol process Ethanol

Hydrolysis

Hexose, Pentose, Lignin,

Residues

HydrogenMethane

Lignocellulose utilize process

Energy

Sugarcane

Sugar

BoilerBoiler

Sugar production

Sugar production

Molasses

Ethanol fermentation

Ethanol fermentation

Bagasse, stover

Cane juice

CrushingCrushing

Hydrogen fermentation

Hydrogen fermentation

Methane fermentation

Methane fermentation

Vinasse: Xylose, Lignin

Vinasse: residual sugars

Vinasse: Xylose, Lignin

Vinasse: residual sugars

DistillationDistillation

Sugar process

Ethanol process Ethanol

HydrolysisHydrolysis

Hexose, Pentose, Lignin,

Residues

HydrogenMethane

Lignocellulose utilize process

Energy

Sugar Cane

Crushing

Cane Juice

Sugar Process Molasses

Bagasse

Hydrolysate: Hexose, Pentose, LigninResidues: Ash, Char

Ethanol Fermentation

DistillationVinasse 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 tPentose 315 tLignin 210 tResidues 450 t

Gas for industryRaw material

GasFuel

Overall Process Flow

Process

• Cascade Process

• Ethanol fermentation: already existing in Brazil

• Biodiesel

• Hydrogen fermentation

• Methane fermentation

Installations involved

• A reactor of 1m3 capacity, fully equipped with the control units (heating/temperature control, pH-adjusting, substrate addition, sterilization, pressure control, among others)

• A laboratory to perform the analysis and control the parameters of the process.

• This laboratory shall get the data for the industrial scale fermentation, for the different raw materials available for this process.

• The local and ground facility will be offered by ERGOSTECH

Hydrogen Production Pathway

Microbial strain• Patent microbe is owned by Sapporo Breweries

• Exploitation of the patent microbe: subject to agreement of intellectual-property-rights

• Deposited microorganisms: obtained from International Authority Depository (U.S.A. or Germany)

• Some deposited strains present hydrogen productivity near the Sapporo strain

• New strain screening: might be another Joint Research Project

• Although this method requires time, we can obtain the new excellent microbes.

Expected Benefits

• Optimization of the renewable resources utilization

• Introduce an alternative product to be used as biofuel, using the same agricultural resources

• Increment in the energy recovery of approximate 1.5 times (ca. 50% increase)

• Results in more energy and less waste release

• Alternative process to couple to other biofuel production process, including Biodiesel (oil production)

ERGOSTECH EXISTING BUILDING

PILOT PLANT

(19×9.8m)

Pilot Plant Placement 　

15 ｍ19 ｍ

MaterialIn

let

Homogenizer

③Bioreactor

②Nutrient Treatment & Adjustment Unit

N-S

ource Supplier

Raw

Material

Preparation T

ank

Cooler

④ Control Panel

⑦Portable Slurry Pump⑤Portable Vessel

　４００ L

⑥Portable Vessel　１００ L

⑧Bacteria Propagation

Unit 30L

⑨Bacteria Propagation Unit 200L

⑩ Cooling Water Unit

⑬ Compressor

⑪Drum Lifter

⑫Stirer

Pilot Plant Layout(not final plan dated 09/05/12)　

Doorway

Movable

Installed (Fix)

Installed Base

①Raw 　 Material Treatment & Adjustment Unit

Raw Material Supplier

sieve

Raw Material Preparation Tank

WC

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.

Flow Chart of Hydrogen Fermentation

Raw material preparationby Homogenizer

NOT FINAL PLAN　

Raw material preparationby NaOH

Preparationby Enzyme

HydrogenFermentation

Separationby Sieve

Load Concentration

• Main components of the metabolite of hydrogen fermentation are organic acid

• About 10% of load decreases by hydrogen fermentation • Organic acid is the most desirable substrate of methane

fermentation• 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)

Fermentation Broth

• The load concentration before and after hydrogen fermentation (acid fermentation) is as follows:– At raw material concentration is 25 - 30 kg / m3

– COD of raw material broth is ca. 33,000 mg / liter– COD of effluent is ca. 30,000 mg / liter

01-1-1Tank for raw material preparation

01-1-2 Homogenizing devices for the raw material preparation

01-1-5 Raw material supplier No.201-1-3 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 Vessel01-7 Slurry pump

ToItem 01-3

NOT FINAL PLAN　

Item 01-3 Bioreactor Unit 　

01-3-1 Bioreactor

FromItem 01-1

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　

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 device01-9-2 Stirring device

01-10 Cooling Water Unit

01-11 Lifter & 01-12 Stirrer

01-13 Air compressor

NOT FINAL PLAN　

Routine analysis process

• Generated gases: Gas Chromatography

• Generated organic acids: HPLC

• Total sugar: Phenol-sulfuric acid method

Model of Methane Fermentation Unit by UASB

(Up-flow Anaerobic Sludge Bed )

Model of Methane Fermentation Unit by Membrane

Membrane Methane Fermentation Unit

Bio-Gas

PreparationTank

MethaneReactor

MembraneSeparator

EffluentSystem

Generator

Boiler

Separator

Raw Material

Timeline of the ProjectActivity Semester 1 Semester 2 Semester 3 Semester 4 Semester 5 Semester 6 Sem. 7

Nov.28,’08

Mar.2,’09 –

Jul., ’09Aug., ’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)

PreparationPre-

shipment inspection

Installation,

Commissioning

Continuous fermentation process for each type of raw materialN-source & C-sourceFermentation (Year 2)

Evaluation of the results of Year 1 and Preparation

Complementation of the remaining parametersSolution of problems and questioning Optimization of strain/inoculum vs. raw material typeFermentation (Year 3)

Preparation

Optimization of F/SCell concentration, rapid fermentation setupCost 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 Demonstration work

(in Japan)Kick off meeting

(in Japan)