Ethanol Recycle Paper

Converting Waste Paper into Ethanol

March 28, 2008

Outline U.T.C. Engineering Agricultural Comparison Papernol Process

Hydrolysis Fermentation Purification

Equipment Sizing and Cost Full Scale Outlook

Freshman Design

Heat & Mass Transfer Reactor

Design

Distillation

Process design

Unit Operations

Senior Papernol Project

Engineering Economics

Thermodynamics

Intro Chemical Process

UTC Papernol Team - 2008

How is Papernol Different?

Corn Switchgrass PaperLand x x

Fertilizer x Tilling x

Harvesting x xTransportation x xEnergy Input x x xProcessing x x x

Requirements for Each Source of Ethanol

Papernol Advantages Converts Waste Stream to Revenue Stream Resource from Local Community Improves Local Economy Minimal Transportation/Fuel Inputs No Cropland Requirement

Acid Hydrolysis:Dilute acid to generate glucose from cellulose

FreshH2O

Slurry Pump

Hydrolysis

ExpansionChamber

Rotary Filter

Paper Shredder

Solid wastes

Distillation

Paper

Mixer

Sulfuric Acid

Sodium Hydroxide

StorageHopper

H2O

Yeast Storage

Fermentation

YeastFilter

Molecular Sieves

CO2

Recycled H2O

Fermentation:Convert Glucose into Ethanol

Purification:Separate Ethanol from water

Preparation andHydrolysis

Fermentation Purification

Material Balances

FreshH2O

Slurry Pump

Hydrolysis

ExpansionChamber

Rotary Filter

Paper Shredder

Solid wastes

Distillation

Paper

Mixer

Sulfuric Acid

Sodium Hydroxide

StorageHopper

H2O

Yeast Storage

Fermentation

YeastFilter

Molecular Sieves

CO2

Recycled H2O

PAPER

10,000 lb/day

EtOH

500 gal/day

Preparation (Basis 10,000 lb paper/Day)

10,000 lb paper

150,000 lb H2O

160,000 lb slurry

*8,000 lb cellulose*

Research: 7% paper water mixture

80% paper is cellulose

Hydrolysis (Basis 10,000 lb paper/Day)

62,000 lb steam

1600 lb H2SO4acid

(98%)

230 lb steam

70% conversion

150,000 lb H2O

*5600 lb glucose*

160,000 lb slurry2,200 lb solid

waste

Evaporation - Fermentation (Basis 10,000 lb paper/Day)

150,000 lb H2O

*5600 lb glucose*

62,000 lb H2O

*5600 lb glucose*

62,000 lb H2O

*2850 lb EtOH*

2850 lb CO2

330,000 lb CW

860 lb yeast

80,000 lb steam

Purification (Basis 10,000 lb paper/Day)

65,000 lb EtOH–H2O

2,800 lb EtOH

62,200 lb H2O

500 gal EtOH

Energy Balances

FreshH2O

Slurry Pump

Hydrolysis

ExpansionChamber

Rotary Filter

Paper Shredder

Solid wastes

Distillation

Paper

Mixer

Sulfuric Acid

Sodium Hydroxide

StorageHopper

H2O

Yeast Storage

Fermentation

YeastFilter

Molecular Sieves

CO2

Recycled H2O

QIN = 49 million BTU/day QPRODUCT = 38 million

BTU/day

QADDED = 210 million BTU/day

QLOST = 49 million BTU/day

18.0210

38

milliion

million

Q

QoEnergyRati

ADDED

PRODUCT

Preparation

41,000 BTU/day

4.5 MM BTU/day

1.5 MM BTU/day

Total Daily Electrical Energy ~6 MM BTU

Hydrolysis

QIN=50 MM BTU/day

QIN=185,000 BTU/day

QIN=13,000 BTU/day

Total Daily Electrical Energy ~50.2 MM BTU

Evaporation - Fermentation

QOUT= 8 MM BTU/day

QIN=94 MM BTU/day

Purification

QIN= 66,000 BTU/day

QIN=60 MM BTU/day

QOUT= 41 MM BTU/day

QOUT= 223,000 BTU/day

Example of Sizing

Evaporator:Fxf = Lxlxf = current concentrationxl = desired concentration

L = F(xf/xl) = Liquid Exit Stream L/ρH2O = Volume of Evaporator

Equipment Size and CostEquipment Size(ft3) Quantity Total Cost($)

Storage Hopper 98 3 2,100

Shredder 1700 1 32,000

Mixer 1700 1 40,000

Hydrolysis Tank 2700 1 25,600

Expansion Chamber 1

Evaporator 100 1 1,500,000

Fermentation Vessel 800 4

Mixer fermentation 20 2

Distillation Column 400 1

Molecular Sieve 2

Equipment Size and CostEquipment Size(ft3) Quantity Total Cost($)

Slurry Pump 1 22,400

Slurry Heat Exchanger 2500 ft2 1 102,000

Acid Heat Exchanger 11 ft2 1 3,000

Conveyor N/A 2 22,000

Fermentation HE 1100 1

Stages of Project Development

LabProof ofConcept Medium

Small Demonstration

PilotIntegrated Processing

Full Scale UnitOrange Grove Center

Lab Scale – Proof of ConceptCurrently in Progress at UTCAvailable Budget: $500Restricted Testing

Medium Scale: 2008-2009Small Demonstration Budget: $150,000Tested Using UTC ENGR Labs

Pilot Scale: 2009-2010Integrated ProcessingUtilize TVA/UTC Chickamauga SiteEstimated Budget: $1,000,000

Orange Grove:

2010-2011Full Unit Skid-Mounted ModularEstimated budget: $3,000,000

Potential Orange Grove Site

Process 10,000 lb Paper =500 gal of Ethanol per day

=> Three Tractor Trailers

Current Work Toward our Preliminary Design:

Economics Environmental Aspects

(CO2 foot print) Utility Costs

Papernol Outlook

Cannot resolve the US energy dilemma Orange Grove = 500 gal/day max. Adds value to Orange Grove Competitive with Corn & Switchgrass A Renewable Ethanol Source

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