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

Energy Utilization/UsageEnergy Utilization/Usage COCO22/H/H22O Footprint O Footprint Economics Economics SummarySummary

Project PurposeProject Purpose

Design a facility that is:Design a facility that is: State-of-the-artState-of-the-art FlexibleFlexible AdaptibleAdaptible Bio-chemical processing plantBio-chemical processing plant Optimizing Ethanol productionOptimizing Ethanol production

Project PurposeProject Purpose

Optimizing includes:Optimizing includes: Water usageWater usage Energy usageEnergy usage COCO22

Waste Stream Utilization/CogenerationWaste Stream Utilization/Cogeneration Return on investmentReturn on investment

AssumptionsAssumptions

100 Tons of Waste Paper per Day100 Tons of Waste Paper per Day Waste Paper Contains 50% Waste Paper Contains 50%

CelluloseCellulose 81% Conversion of Cellulose to 81% Conversion of Cellulose to

Ethanol in 24 hours Ethanol in 24 hours Target Purity: 99.5wt% EthanolTarget Purity: 99.5wt% Ethanol

PAPER

PRE-TREATMENT

WATER

YEAST &

ENZYME PRODUCTION

SACCHARIFICATION &

FERMENTATION

PURIFICATION

Ethanol

Pre-Treatment

Conveyor

Mixing Tank

Shredder Filter

P-2 P-3 P-4

Paper Water Acid

Undesirables

Enzymes-What are they?Enzymes-What are they? Enzymes are catalysts that are biological Enzymes are catalysts that are biological

moleculesmolecules Like all catalysts, enzymes dramatically Like all catalysts, enzymes dramatically

increase the rate of reactionincrease the rate of reaction

Breaking up Cellulose Breaking up Cellulose (Saccharification) (Saccharification)

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

Where Do You Get Where Do You Get 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

25 lbs

Yeast Enzyme Production

Culture600 lbs

Yeast Water

NutrientsWater Nutrients

300 lbs/day Enzyme

20 lbs/dayMixture

Saccharification Saccharification by by

Enzymatic HydrolysisEnzymatic Hydrolysis

CelluloseCelluloseEnzymes

CC66HH1212OO66

(Glucose)(Glucose)

FermentationFermentation

CC66HH1212OO66

Yeast

2C2C22HH55OHOH

++

2CO2CO22

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 Ethanol

59 Tons Undigested Paper

NCSF Energy Balance

40ºC45ºC50ºC 35ºC 30ºC

40 MMBtu/DayCooling H2O

HPS

55 MMBtu/Day

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= 5.0 wt% EtOH

DISTILLATED= 20 tons/dayQC= 110 MMBtu/dayXD= 90.6 wt% EtOH

BOTTOMSB= 400 tons/dayQR= 200 MMBtu/day

Distillation: Column Distillation: Column SpecificationsSpecifications

11 ft

Sieve tray

2 ft1 stage

40 ft20 stages

21 Tons EtOH

+

2 Tons H2O

~21 Tons EtOH

Water Adsorption by a Molecular Sieve

11 Tons

Synthetic Zeolite

7.1 MMBtu/Day

6 Tons CO2/ Day

~ 6 Tons Hot CO2 +

2 Tons H2O Vapor

Per Day11 Tons

Synthetic Zeolite

Regeneration of the Molecular Sieve

Waste Stream UtilizationWaste Stream Utilization

SteamBoiler

Undigested Paper

720 MMBtu/Day

High-Pressure Steam

520 MMBtu/Day

Flue Gases

200 MMBtu/Day

Energy: Ethanol from Energy: Ethanol from WastepaperWastepaper

PapernolPlant

200 MMBtu/Da

y

500 MMBtu/D

ay

Cogenerated Electricity

Ethanol

CornBased

EthanolPlant

500 MMBtu/D

ay

Ethanol

450-550 MMBtu/D

ay

Fossil Fuels

Energy: Ethanol from Energy: Ethanol from CornCorn

COCO22 Footprint Footprint

Papernol

Papernol ProducesPapernol Produces

120 tons CO120 tons CO2 2 / day/ day

Average CO2 released by vehicles in Chattanooga = 3,300 tons per /day

HH22O FootprintO Footprint

Grey Water

Papernol Plant Uses

20 tons/day

Papernol

Capital CostsCapital Costs

Reactor Vessels $1.5M Steam Boiler $1.0M Enzyme Tanks $1.0M Shredder/Conveyer $500K Distillation Column $240K Prep Tank $90K Molecular Sieve $70K Total $4.4 Million

Economic AnalysisEconomic AnalysisCapital CostsCapital Costs

Equipment Cost = $4.4M

Plant Heuristic x (4.7)

Total Capital Cost = $20M

Annual Operating CostsAnnual Operating Costs

•Wastepaper $300K

•Water $200K

•Electricity $120K

•Nutrients $86K

•Enzyme & Yeast $33K

•Cooling Water $21K

•Total $1.2 Million

Production CostsProduction Costs

Annual Capital Cost 5 Year Payback

Annual Operating Cost

Annual Production

Production Cost

$4M

$1.2M

2.3M Gal

$2.56/Gal

Return On InvestmentReturn On Investment

$2.56/gal

5 Year

ROI

$1.66/gal

10 Year

ROI

SummarySummary

Project PurposeProject Purpose AssumptionsAssumptions Process FlowProcess Flow

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

Energy Utilization/UsageEnergy Utilization/Usage COCO22/H/H22O Footprint O Footprint Economics Economics

ConclusionConclusion

• Facility Produces 21 tons of Ethanol Daily

• Net Energy Usage is (+)700 MMBtu/day

• Return on Investment of 5 Years

Gives a Cost = $2.56/gallon