Incorporating Conversion R&D and Testing Adaptation in an Existing Facility Gary Welch and Michael Ladisch Aventine Renewable Energy and Laboratory of Renewable Resources Engineering Purdue University Presented at International Energy Agency Meeting Golden, CO April 25, 2007 Acknowledgements Rollo Everett Nate Mosier Jerry Weiland Rick Hendrickson Andy Aden Larry Russo Joan Goetz Kelly Ibsen Nancy Ho Young Mi Kim Linda Liu Mira Sedlek Rich Dreschel Ryan Warner
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P8 - Incorporating Conversion R&D and Testing Adaptation ... · aldehydes that inhibit both bacterial and yeast fermentations ... (a physical change) ... Concentration (g/L) Glucose
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Incorporating Conversion R&D and Testing Adaptation in an Existing Facility
Gary Welch and Michael Ladisch
Aventine Renewable Energyand
Laboratory of Renewable Resources EngineeringPurdue University
Presented at International Energy Agency MeetingGolden, CO
Fiber : Water Ratiodry basis = 0.16 : 1 (160 g / L)
Temperature, pH, pressure, and Hold Time160 C, pH > 4, 150 psig, 15 -20 min
Separate liquid from solid (centrifuge)Liquid to fermentor, solid to feed drier
SEM of Fiber before Pretreatment
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SEM of Pretreated Fiber
Comparison of Pretreatment Liquid and Stillage
0
20000
40000
60000
80000
100000
120000
140000
0 2 4 6 8 10 12 14
Time (min.)
Res
po
nse
(m
V)
Pretreatment10x Dilute
Stillage10x Dilute
Oligosaccharides
Glucose Glycerol
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Controlled pH Liquid Hot Water Pretreatment
Conditions 160 C, 20 min
pH control through buffer capacity of liquid
Minimal fermentation inhibitors, no wash stream
Minimize hydrolysis to monosaccharides thereby minimizing degradation
4 ½ ”
Swagelok Fittings and Endcap
1” Stainless Steel Tubing
33.75 mL Working Volume
Pretreated Corn Fiber (Enzyme Hydrolysis)
100%1.3%Yield2
(%)
0.420.0043Glucose1
(g/g fiber)
Cellulase10 FPU/g biomass
(Celluclast + Novozyme188)
Amylase80 U α Amylase + 6.3 kU
Amyloglucosidase per g biomass
1 – grams of free glucose per gram of pretreated fiber
2 – based on analysis of pretreated fiber by 4% acid hydrolysis
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Corn Fiber
After 4 days of enzyme treatment (20 FPU/gram dry fiber)
After 1 day of enzyme treatment (20 FPU/gram dry fiber)
Pretreated Corn Fiber
160oC, 20 min.
FermentabilityHydrolyzed Pretreatment Liquid
0
5
10
15
20
25
30
35
40
45
0 2 4 6 8 10 12 14
Time (hrs)
Co
nce
ntr
atio
n (g
/L)
Glucose
Ethanol
Data from Nacy Ho and Miroslav Sedlak, LORRE, Purdue University
Fermentability confirmed by Bruce Dien, USDA-NCAUR
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Process DescriptionPretreat Fiber and Liquid/Solid Separation
Fiber Pretreat
Centrifuge
To Fermentation
Solids
LiquidStillage(Water)
To drier or hydrolysis
Pretreatment Flow Diagram
Recycle
43 gpm
Stillage Liquid
Steam
Centrifuge
Hold Tank
X
CakeFiber from Vetter press Back-
pressure Regulator
1
2
3
4
5
Heat Exchanger
Pump
E
A
D
B C
41.5 gpm
50 lbm/min
w/dissolved solids
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Process Steps After Pretreatment
1. Separate liquid from solids with centrifuge2. Process liquid stream
Add cellulase, other enzymes. Combine with liquified starch stream.Add yeast. Hydrolyze, ferment in the same tank.
3. Process solids from pretreatmentDry and sell as co-product feed.
Pump
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“Snake-coil” Plug Flow Pretreatment Coil
Williams Bioenergy
Pekin, IL
Pretreatment Coil (Insulated)
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Hold Tank
Grain
Milling Cooking
Water Enzymes
Ferment
CO2
Distillation / Dehydration
Ethanol
eDG
eDDGSBackset
Pretreat
Hydrolyze
Enzymes
Dry Mill (Dry Grind) Process with Cellulose Conversion
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Processing Experiments Show
Conversion of Corn Fiber and Corn Stover gives fermentable sugars
Pretreatment requiredWater is an effective pretreating agentpH control minimizes monosaccharide
formationIndustrial pretreatment development and
pilot research being underway
Next Steps
Complete evaluation of process modificationsContinuous processing run Tighten material and energy balancesObtain operational data and test:
equipment operation materials handling process robustness
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Potential Impacts
Introduce existing corn to ethanol plants to conditions and equipment required for cellulose processing,
Enable cellulose conversion processes to derive economic benefits from existing fermentation, ethanol distillation, waste treatment, and power generation facilities.
This technology, while specific for existing ethanol plants, is also cross-cutting in that it could introduce ethanol producers to various types of cellulosic biomass for ethanol conversion.