Preliminary Design for Cellulosic Ethanol Production Facility

Capable of Producing 50 MMgal/yr

The goal of this project was to develop a complete preliminary design for a
cellulosic ethanol facility with a capacity of 50 MMgal/yr of ethanol.
The main components of the facility were first approximated by scaling
down the design prepared by the National enewable !nergy "aboratory for a #0
MMgal/yr cellulosic ethanol facility $%&. 'hile preparing the preliminary design for
this process a better understanding of the re(uirements for the facility was
developed) allowing for the enhancement of detail for the saccharification)
fermentation) and separations sections. *re+treatment design was solely based
upon re(uired residence times.
,orn stover was initially considered as the raw material of choice) as
re(uested by the ,lient- although) attention was given to incorporating another
possible feedstoc. /wheat straw0. ,entral location of the plant to the raw
material) while balancing the factors involving product transportation) was to be
optimi1ed. 2n analysis of the environmental impact of removing corn stover from
fields to use as a feedstoc. was also re(uested to be included in the completed
design.
2 final economic analysis of the cellulosic facility was to be based upon as
%34 after+tax rate of return over 30 years) with 5+year M2,5 depreciation.
'or.ing capital was to be assumed to be 504 of the first+year cost of
manufacturing without depreciation /COM
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0) with 1ero salvage value. 2ny
available subsidies offered by the government were also to be included in the
economic analysis. ,ases including and not including the subsidies were
re(uested to be presented in the final deliverable.
Results
2 bloc. flow diagram for the overall process is given in 6igure %. 2 brief
description of the important processes is given below.
Feed Handling: Figure 2
The corn stover or wheat straw is ta.en from storage) washed) and
shredded. The wash water is condensate from the separations section /7nit
28000. The used wash water is sent to a clarifier and the remaining solids are
disposed. 2 portion of the used wash water is sent bac. to a storage tan. for
reuse.
Pretreatment and Conditioning: Figure 3
The feedstoc. is then steamed and reacted in the acid hydrolysis reactor
trains. 2fterwards) the product is sent to the blowdown tan. to remove the solids
and li(uid components. The resulting slurry is then sent to solid/li(uid separations
where the excess acid is neutrali1ed and the gypsum is removed. The
hydroly1ate is then sent to saccharification and fermentation /7nit 29000.
Saccharification and Fermentation: Figure 4
:n this bloc.) the hydroly1ate is reacted with bacteria grown in the seed
train reactors. The resulting ethanol mixture is sent to separations for distillation
and the waste gas is sent to the scrubber in the same section.
Separations
:n this section) the ethanol is distilled in the rectification section /6igure 50)
purified of excess water in the dehydration /6igure ;0 and evaporation sections
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/6igure #0) and sent to storage/blending /7nit 2#000. The solids are removed
from the slurry and sent to the boiler to be combusted and the waste gases are
sent through the scrubber. !xcess condensate is sent to wastewater treatment
/7nit 2;000.
Storage
>ere) the ethanol is blended with gasoline and stored. 5ome corn steep
li(uor is fed into the process to aid in bacteria production. This is also the location
where purchased en1yme and sulfuric acid are stored and pumped to their
respective destinations.
Burner/Boiler ur!ogenerator
>ere) methane gas from wastewater treatment) leftover syrup) and solids
from separations are combusted to produce process steam and electricity. The
blowdown steam from the turbine is sent to wastewater treatment.
"ast#ater reatment
>ere) wastewater and excess condensate are combined with nutrients
and put through aerobic and anaerobic digestion. ,arbon dioxide and other
waste gases are vented to the atmosphere and the treated water is sent to
utilities /7nit 2=000 to be recycled.
$tilities
Treated wastewater is collected here to be sterili1ed and recycled. 2ir is also
dried here before being put into the process.
%conomics
Table % shows the important results of the economic analysis.
%0
%0
+able 1 Economic ,nalysis
?ase ,ase
!lectricity
@ No
5ubsidies
?est ,ase
!lectricity @
5ubsidies
No
!lectricity
@ No
5ubsidies
No
!lectricity
@
5ubsidies
A,6B =.8;4 %;.#84 5.8<4 %8.8;4
A** %= yr ;.% yr N2 ;.<
N*C
/millions of D0
+33.55 8;.## +8<.5% 30.<%
FC&
'
/millions of D0 %85.< %85.< %%<.0 %%<.0
,BM
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/millions of D0 5=.; 5=.; #0.< #0.<
Minimum !thanol
*rice /D/gal0
%.#33 N2 %.<;3 N2
4 of Monte ,arlo
5cenarios giving a
A,6B E %34
;9.3 ==.% 9#.5 =<.5
FA** G Aiscounted *aybac. *eriod
FF ?est case based on probability of ma.ing the most profit
2 basic layout for the storage lots is shown in 6igure <. This figure
illustrates the general arrangement of storage lots situated around the facility.
The facility will be built near a rail road. The facility has four e(ually si1ed
storage lots for feed stoc.. The general arrangement of bales in these lots is
also shown.
%%
%%
Figure - .ayout of %torage .ots in Relation to Facility /0ot to %cale1
%3
%3
Fermentation Section and Mathematical Model
:t was necessary to find an accurate mathematical model for the
conversion of xylose and glucose to ethanol using the bacterium) ()momonas
mo!ilis) as well as a continuous method of production. These bacteria are
produced onsite to be fed into the fermentor. The bacteria are produced in a five+
tan. seed train in order to simulate a continuous process. This ensures a
continuous stream of inoculate is available for fermentation.
2fter conducting research on the bacterium) a model specific to this
problem was found $3&. This model was tested for accuracy by using a computer
algebra system. The results from the simulation were compared to experimental
data recorded for the same bacterium $9&.
The model correlated with the experimental data fairly well. >owever)
there was room for improvement. The model predicted glucose consumption and
conversion into ethanol and biomass very well but deviated significantly for
predictions of xylose consumption and conversion. :n order to correct this) the
model parameters were examined. 2fter determining which parameters had the
most effect on the modelHs predictions) a multivariable optimi1ation was
conducted to match the experimental data more closely. 2 more accurate model
was generated by changing parameters associated with xylose metabolism
including biomass growth rate while feeding on xylose) the specific substrate
utili1ation rate) the specific ethanol production rate) the substrate inhibition
constant) and the maximum ethanol concentration. Iraphical illustrations of the
model before and after optimi1ation as well as the mathematical model used can
%9
%9
be found in 2ppendix 2J 6ermentation Model.
Ilucose and xylose concentrations were then optimi1ed for the model to
produce the highest concentration of ethanol over the shorter time period. ?y a
trial+and+error method) the most productive concentrations for glucose and xylose
were found to be %;8.9 g/" and 83.= g/") respectively. This yielded
approximately #0.5 g/" of ethanol at =54 yield. This conversion was chosen due
to the asymptotic nature of the ethanol production model. The residence time for
this yield was close to 38 hours. To increase the yield) significantly longer
residence times were re(uired. This increased the si1e and number of reaction
tan.s re(uired for the process.
The chemical compositions of corn stover and wheat straw were used to
determine the re(uired feedstoc. flow rate to reach the target production (uota of
50 million gallons per year $8&. :t was determined that approximately 3)#35 tonne
of feed stoc. were re(uired per day to reach the desired capacity.
'heat straw was used to determine the re(uired reaction tan. si1es due
to the higher concentration of hemi+cellulose in it compared to corn stover. 2
longer time is re(uired for wheat straw because the extra hemi+cellulose and
subse(uently produced xylose ta.e longer to ferment. The fermentation volume
re(uired was calculated based on the total volume of 38 hours worth of reactor
feed. The reactor feedHs volume was based on the amount of water re(uired to
reach the target glucose and xylose concentrations for the 3#35 tonne per day
feedstoc. flow rate. :t was determined that roughly %.< million gallons of reaction
volume would be re(uired to hold the fermentation mixture for the re(uired
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residence time.
The most economical configuration for the fermentation reaction consisted
of a single large tan. with agitators for power. >owever) it was decided to split
the volume into two e(ually si1ed tan.s to help ensure that enough agitation
power was supplied per unit volume to maintain a well+mixed system. 2 larger
agitator in the single tan. could have supplied the re(uired power) but the higher
shear rate could have damaged the bacteria needed for fermentation.
Saccharification
The saccharification section of the facility decomposes cellulose into
glucose. The glucose from the saccharification reactor moves into the
fermentation section to be converted into ethanol. The conversion from cellulose
to glucose ma.es use of a novel en1yme developed by :ogen $8&. The en1yme is
of a class of en1ymes .nown as cellulases. These en1ymes wor. to degrade the
cellulose into glucose by LcuttingM the glycosidic bond in the cellulose chains.
This reaction is shown in !(uation %.

?ased on data from :ogenHs patent $%0&) a 30+hour residence time was
re(uired to convert approximately <04 of the cellulose into glucose. The
remainder of the cellulose is used to generate steam and electricity for the
facility. The re(uired reaction volume for the residence time was determined to
be approximately %.# million gallons. 2gain) this volume was split into two
%5
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e(ually si1ed tan.s to help maintain a well+mixed system.
,ellulase activity is measured in an obscure unit .nown as filter paper units
/6*70J
L2 unit of filter paper activity is defined as the number of
micromoles of sugar produced per minute. The activity is
calculated using the amount of en1yme re(uired to produce
3 mg of sugar. 2 sample of :ogenHs cellulase was found to
have %80 filter paper units per m".M $8&
To achieve the <04 conversion in the 30+hour residence time) 0.85 m"/g
feedstoc. and 0.93 m"/g feedstoc. must be used for corn stover and wheat
straw respectively $8&.
%;
%;
Cited References
$%& 2den) 2. et al. "ignocellulosic ?iomass to !thanol *rocess Aesign and
!conomics 7tili1ing ,o+,urrent Ailute 2cid *rehydrolysis and !n1ymatic
>ydrolysis of ,orn 5tover. National enewable !nergy "aboratories)
3003. N!"/T*+5%0+9398<.
$3& "e.sawasdi) Noppol et al. Mathematical modelling of ethanol production
from glucose/xylose mixtures by recombinant ()momonas mo!ilis*
?iotechnology "etters. 300%. Col. 39. *g %0<#+%0=9.
$9& Nompala) Ahina.ar et al. ,haracteri1ation of >eterologous and Native
!n1yme 2ctivity *rofiles in Metabolically !ngineered ()momonas
mo!ilis 5trains Auring ?atch 6ermentation of Ilucose and Oylose
Mixtures. 2pplied ?iochemistry and ?iotechnology. 3003. Cols. =<+%00.
*g 98%+955.
$8& 6oody) ?rian. *retreatment *rocess for ,onversion of ,ellulose to 6uel
!thanol. 7nited 5tates *atent ;0=05=5. :ssued to :ogen ,orporation on
Puly %<) 3000
2ther References
7.5. !nergy *ricesJ ?ase ,ase. !nergy Butloo. for 300#. Aepartment of
!nergy. httpJ//www.eia.doe.gov/emeu/steo/pub/8tab.html
Ilasner) Aavid 2. et al. ,orn 5tover ,ollection *roject. ?io!nergy H=<J
!xpanding ?io!nergy *artnerships. *gs %%00 Q %%%0.
Turton) ichard et al. 2nalysis) 5ynthesis) and Aesign of ,hemical *rocesses
3
nd
!d. 3009. *rentice >all) 7pper 5addle iver) NP.
'omach) Pasper and Racobucci) ?rent. "909;=J 6uel !thanolJ ?ac.ground
and *ublic *olicy :ssues. National ,ouncil for 5cience and the !nvironment.
'ashington) A,. 7pdated March 33) 3000.
?N56 ailways. httpJ//www.bnsf.com
Ias Taxes. httpJ//gaspricewatch.com/usgastaxes.asp 7pdated Panuary %9)
3005.
Settapac. www.1ettapac.com/molecular+sieve+details.html. 2ccessed 6eb
%%) 300#
,ommercial "and ,osts in Mendota) :". 7pdated March =) 300#
httpJ//www.loopnet.com/xNet/Main5ite/"isting/*rofile/*rofile5!.aspxT
%#
%#
":AG%5035=09@lin.codeG%0<50@sourcecodeG%lww3t00;a0000%
National 2gricultural 5tatistics 5erviceJ :llinois eports and 5tatistics. etrieved
March 39) 300#. httpJ//www.nass.usda.gov/5tatisticsUbyU5tate/:llinois/index.asp
%<
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2ppendix 2 Q 6ermentation Model
Figure ,'1 2ptimi3ed Fermentation Model 444444444444444444444444444444444444444444444444 ,'1
Figure ,'! 2riginal Fermentation Model 4444444444444444444444444444444444444444444444444444 ,'!
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