Ethanol Production Ethanol Production from Wastepaperfrom Wastepaper

Ben DaltonBen DaltonMarie LabrieMarie LabrieCassia DavisCassia Davis Alex Alex SaputaSaputaJohn OzbekJohn OzbekSteve WildSteve WildMurat OzkayaMurat Ozkaya 4/15/094/15/09

OutlineOutline Project PurposeProject Purpose AssumptionsAssumptions Process FlowProcess Flow

Pre-TreatmentPre-Treatment Saccharification & FermentationSaccharification & Fermentation Distillation/PurificationDistillation/Purification

COCO22/H/H22O Footprint O Footprint Economics Economics SummarySummary

Project PurposeProject Purpose

Design a facility that converts wastepaper

into ethanol.

AssumptionsAssumptions 100 Tons of Waste Paper per Day100 Tons of Waste Paper per Day Waste Paper Contains 50% CelluloseWaste Paper Contains 50% Cellulose Target Purity: 99.5wt% EthanolTarget Purity: 99.5wt% Ethanol

PAPER

PRE-TREATMENT

WATER

YEAST &

ENZYME PRODUCTION

SACCHARIFICATION &

FERMENTATION

PURIFICATION

Ethanol

Pulp Preparation

Conveyor

Mixing Tank

Shredder Filter

P-2 P-3 P-4

Paper Water Acid

Enzymes-What are they?Enzymes-What are they? Proteins that catalyze reactions (increase Proteins that catalyze reactions (increase

the rate of)the rate of) Like catalysts, enzymes work by lowering Like catalysts, enzymes work by lowering

the activation energy for a reaction. This the activation energy for a reaction. This dramatically increases the rate of the dramatically increases the rate of the reaction.reaction.

Breaking up Cellulase Breaking up Cellulase (Saccharification) (Saccharification)

Breaking up cellulose requires three Breaking up cellulose requires three enzymes collectively called cellulases enzymes collectively called cellulases

How Do You Produce How Do You Produce Enzymes?Enzymes?

Trichoderma reeseiTrichoderma reesei (yeast)(yeast)

Secretes cellulasesSecretes cellulases One of the most One of the most

powerful secretors powerful secretors of cellulases known of cellulases known to dateto date

+

Producing Enzymes Producing Enzymes

Yeast Pre-Culture

190 gal30 °C

Yeast Enzyme Production

Culture4,800 gal

30 °C

Yeast Water

NutrientsWater Nutrients

2,400 gal/day Enzyme

160 gal/dayMixture

Non-Isothermal Continuous Saccharification and Fermentation

(NCSF)

CO2

Yeast

Enzyme

EthanolSlurry

Enzymatic Hydrolysis

Fermentation

NCSF Material Balance

20 Tons CO2

Yeast

Enzyme

400 Tons H2O

50 Tons Cellulose

50 Tons Lignin

40ºC45ºC50ºC 35ºC 30ºC 400 Tons H2O

21 Tons Cellulose

50 Tons Lignin

NCSF Energy Balance

40ºC45ºC50ºC 35ºC 30ºC

24.3 MBtu/Day

13.1 MBtu/Day

Cooling H2O

HPS

13.5 MBtu/Day

13.9 MBtu/Day

14.3 MBtu/Day

NCSF Reactor System Design81 % Conversion to Ethanol in 25 Hours

Tank Volume = 8,000 gal

T-101

TK-502

P-502

P-501

TK-501

L-501

Recycle

F

F

L-510

F

L-507

L-508

L-505

L-508

L-502

L-514

1

E-501

E-502

L-511

L-504

L-503

L-512

L-509

2

L-506

3

4

6

V-2

V-4

T-102

L-513

V-1

5

L-508

V-3

Feed

Distillate

Molecular Sieve

Product Storage

Distillation & Purification

Distillation: Material Distillation: Material BalanceBalance

FEEDF= 420 tons/dayXF= 0.050 wt% EtOHf= -0.102

DISTILLATED= 23 tons/dayXD= 0.906 wt% EtOH

BOTTOMSB= 400 tons/dayXB= 3x10-4 wt% EtOH

Distillation: Condenser Distillation: Condenser DutyDuty

CONDENSERQC= 110 MBTU/dayAHT= 2080 ft2

AgentHT= Cooling Water

QC

V L

Distillation: Reboiler Distillation: Reboiler DutyDuty

V L

QR

REBOILERQR= 195 MBTU/dayAHT= 2860 ft2

AgentHT= HPS

Distillation: McCabe Thiele Distillation: McCabe Thiele MethodMethod

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0.0 0.2 0.4 0.6 0.8 1.0x

y

N = 10 actual stages and the partial reboilerNf = 8

Program prepared by: Dr. J. R. Cunningham Mr. M. B. McGann

Distillation: Column Distillation: Column SpecificationsSpecifications

11 ft

Sieve tray

2 ft1 stage

40 ft20 stages

Column Height = 60 ft

Packing Diameter = 3.0 ft

Packing Height = 50 ft

Sieve Dimensions

23 Total Tons / Day

21 Tons EtOH

+

2 Tons H2O ~21 Tons EtOH

Adsorption Phase

11 Tons

Synthetic Zeolite

Regeneration Phase

7.1 MBtu/Day

6 Tons CO2/ Day

~ 6 Tons Hot CO2 +

2 Tons H2O Vapor

Per Day11 Tons

Synthetic Zeolite

Waste UtilizationWaste Utilization

SteamBoiler

Lignin

720 MBtu/Day

High-Pressure Steam

520 MBtu/Day

***120 tons of CO2 released per day

COCO22 Footprint Footprint COCO22 emissions require an operating emissions require an operating

permit……permit……

Papernol

Papernol ProducesPapernol Produces

55,000 tons CO55,000 tons CO22/year/year

HH22O FootprintO Footprint In the near future fresh water use In the near future fresh water use

will be as regulated as COwill be as regulated as CO22 emissions……..emissions……..

Grey Water

Papernol Plant Uses

7,000 tons/year

Papernol

Economic AnalysisEconomic AnalysisCapital CostsCapital Costs

Equipment Cost = $4.4M

Plant Heuristic x (2.4)

Total Capital Cost = $10.5M

Annualized Capital CostAnnualized Capital Cost

MillionA

MA

iiiPA N

N

4.2$

1)05.01()05.01(05.05.10

1)1()1(

5

5

MillionA

MA

iiiPA N

N

4.2$

1)05.01()05.01(05.05.10

1)1()1(

5

5

Annual Operating CostsAnnual Operating Costs Wastepaper Water Enzyme & Yeast Nutrients Electricity CoolingTotal Operating Cost

$300K

$200K

$33K

$1.3M

$1.4M

$21K

$3.8M

Production CostsProduction Costs Annualized Capital Cost

Annual Operating Cost

Annual Production

Production Cost

$2.4M

$3.8M

2.3M Gal

$2.70/Gal

Energy Energy

PapernolPlant1,300

MBtu/Day

500 MBtu/D

ay

SummarySummary Project PurposeProject Purpose AssumptionsAssumptions Process FlowProcess Flow

Pre-TreatmentPre-Treatment Saccharification & FermentationSaccharification & Fermentation Distillation/PurificationDistillation/Purification

COCO22/H/H22O Footprint O Footprint Economics Economics

ConclusionConclusion This design project is not This design project is not

economically feasible due to current economically feasible due to current market conditions.market conditions.

Future technology advances may Future technology advances may lower production costs.lower production costs.