Scale up of lignocellulosic Fragmentation

Transcription

BioConSepT
From Plants to Plastic!
Scale-up of Lignocellulosic fragmentation and
the fermentations in BioConSepT
Presentation @ GreenPolymerChemistry
Gerd Unkelbach, Katja Patzsch, Moritz Leschinsky, Susanne Zibek
Cologne (Germany), March 21, 2013
KBBE-2011-5-289194
Funded by the 7th Framework Programme of the European Union, FP7 –
Knowledge based Bio-Economy, www.bioconsept.eu
The Fraunhofer pilot-plant center in
Leuna
n  Investment of 45 Million €
n  Construction period of 33 months
n  1600 m² of technical area
n  Inauguration on 2nd of October
n  Open for all interested parties
1
Challenges
n  Feedstock availability and
logistics
n  Feedstock composition
n  Feedstock pretreatment
n  Process development and
scale-up
Challenges
n  Resource efficiency and
recycling
n  Integration in value chains
n  Consumer acceptance
n  Manufacturing costs
From the laboratory to the industry
Enzyme
screening, design
& optimization
Feedstock
selection and
conditioning
Product
processing and
process integration
Industrial biotechnology and
material use of renewable
feedstocks within Fraunhofer
Bioprocess and
bioproduct
evaluation
Lab
Biotransformation
and bioprocess
development
Lab II
Bioproduct
manufacturing and
characterization
Pilot-scale
Process
simulation and
automation
Scale-up and process development
Full-scale
Integration of physical,
biotechnological, chemical and thermal
processes
Feedstock
Pretreatment
disintegration
extraction
pulping
Biotechnological
transformation
Chemical
transformation
Downstream
processing
Products
Equipment of the Fraunhofer CBP
–  5
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separate modules with pilot equipment:
Technical enzymes module
Lignocellulose fractionation module
Fermentation module
Separation module
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–  3
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Chemical processes module
laboratories
Biotechnology laboratory
Chemical laboratory
Analytical laboratory
Modular pilot plants for process
development
technical enzymes lignocellulose frac3ona3on fermenta3on high pressure extrak3on olefins offices 1. floor seminar-‐
room conference-‐ room recep3on laboratories workshops Funded by the 7th Framework Programme of the European Union, FP7 –
u3li3es BioConSepT
Integration of Bio-Conversion and Separation Technology for the production and
application of platform chemicals from 2nd generation biomass
BioConSepT
Integration of Bio-Conversion and Separation Technology for the production and
application of platform chemicals from 2nd generation biomass
BioConSepT
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Lignocellulose fractionation into glucose and xylose
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Scale up fermentation process into demo scale
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most promising processes from lab scale will be demonstrated
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microbial production of FDCA, itaconic acid, succinic acid or
long chain dicarboxylic acid
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or enzymatic conversion to epoxides
BioConSepT
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Lignocellulosic material – usage
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D 127 Mio. m³/a
72 Mio. m³/a for materials (57%)
55 Mio. m³/a for energy (43%)
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EU27 804 Mio. m³/a
458 Mio. m³/a for materials (57%)
346 Mio. m³/a for energy (43%)
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World 3,7 billion m³/a
1,8 billion m³/a for materials (49%)
1,9 bilion m³/a for energy (51%)
Lignocellulosic material - availability (D)
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Soft- and hardwood from forestry (39 Mio. t/a)
Bark (1,5 Mio. t/a), straw and other agriculture residues (60 Mio. t/a)
Industrial wood and sawmill residues from industrial processing (12 Mio. t/a)
Waste – used wood (5 Mio. t/a), food waste (7 Mio. t/a) and used paper (15
Mio. t/a)
Source: Mantau, FNR, DBFZ, VDP
Lignocellulose – composition
lignin
Main components
40-44 % cellulose
xylan
15-35 % hemicellulose
18-25 % lignin (hardwood)
25-35 % lignin (softwood)
cellulose
Source: L. Salmen, Kumar 2009, Pedersen 2010
glucomannan
Lignocellulose – composition
lignin
Main components
40-44 % cellulose
xylan
15-35 % hemicellulose
18-25 % lignin (hardwood)
25-35 % lignin (softwood)
cellulose
Source: L. Salmen, Kumar 2009, Pedersen 2010
glucomannan
LC-Pretreatment with alcohols
REACTOR
Lignocellulose
Solvent
MeOH, EtOH,
propanol or
glycerol
Water
Catalysts
(H2SO4, NaOH)
Cellulose
Temperature: 170 - 200°C
Pressure: 20 - 35 bar
Extract
Time: 2 - 4 h
pH: 2 - 4, 13 - 14
Examples:
EtOH-water-Treatment
(OrganoSolv at CBP)
Alcell process
Organocell process
MEA process
Recycling of
solvents
Organosolvlignin,
C5-Zucker,
furfural
Saccarification: Treatment with enzymes
REACTOR
Lignocellulose
Temperature: 40 - 60°C
(pretreated)
Pressure: 1 atm.
HydrolysisLignin
Time: 12 - 48 h
pH: 5 - 6
Enzymes
Examples:
Water
Enzymatic saccharification
with cellulases, xylanases,
esterases
Sugars
Lignocellulose biorefinery pilot plant
ethanol/water
Digester
Plant capacity:
400 L
200°C
ethanol/
Feedstock
water
properties:
wood chips
OrganoSolv pulping:
tank farm
pulping
fiber
fraction
Final products:
(calculated)
fiber washing
mother
liquor
315 kg dry wood per week
Wood chips of residual wood (P 100, with 50%
water content), 42 % cellulose, 29 % hemicelluloses, 24 % lignin, 5 % others
Ethanol/Water mixture (50/50); xylose fraction
T = 180 °C, t = 2 h, p = 18 bar, catalyst
Wood
lignin : solvent ratio = from 1 : 6 to 1 : 4
organosolv lignin
Glucose:
122 kg
lignin precipitation/
hydrolysis lignin
C5-Sugar:
31
kg
solvent recovery
dewatering
lignin
lignin washing
Lignin:
drying 81 kg
Residue*hydrolysis
81 kg
residue
(*acetic acid, inorganic compounds, thermal
glucose
degradation
products of sugarsconc.
andglucose
lignin,solution
solution
oligomers …, non precipitable lignin compounds)
dewatering
enzymatic
hydrolysis
concentration
Operations :
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Wood pulping with ethanol and water
Disintegration, washing and dewatering of pulp
Precipitation, filtration, washing and drying of lignin
Enzymatic hydrolysis of cellulose
Concentration of glucose syrup
Solvent recovery
BioConSepT
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Fermentation cascade and downstream
processing
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Bioreactors for various fermentation scales (upstream processing) of
10 L, 100 L, 300 L, 1 m³ and 10 m³
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Separator for cell separation
Homogenizer for cell breakdown
Micro/ultrafiltration plant for concentrating
Crystallization tank
Chromatography column for further product purification
Dry freezer and spray dryer for product preservation
Integrated microbiology labs, which permit the cultivation of
microorganisms for seeding the fermenters
processing
processing
Lignocellulose chain Process development in lab scale
Project cooperation
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Sugar à Itaconic acid (TNO , Ingenza, Lucite ,Clariant, GTVT)
Sugar à Succinic acid (Designer-Energy, GTVT, Applicon)
HMF à furan dicarboxylic acid FDCA (Bird, TNO)
Sugar à HMF (Biochemize)
FDCA/HMF à diamines, diamides (Taminco ,ICT)
Oil chain –
Process development in lab scale
Project cooperation
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Fatty acid à long chain dicarboxylic acid à diamines
(Novamont , VTT, IGB, ICT)
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Oils, fatty acid à Epoxides (IGB, Eucodis, Clea)
Glycerol à glycerolcarbonate (Sunilei, Vito)
Oil à Biosurfactant (IGB, Leitat)
Conclusions
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BioConSepT: A project with high potential in oil and lignocellulose as
2nd generation raw material for chemical industry
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Combined organosolv and enzymatic pretreatment method for
fractionating lignocellulose
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Fermentation cascade up to 10 m3 with a wide range of downstream
processing possibilities
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Integrated pilot plant at Fraunhofer CBP
Thank you
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BioConSepT consortium
Team Industrial Biotechnology at Fraunhofer IGB
Team Fraunhofer CBP
Prof. Thomas Hirth (Director)
Funding by the European Union
Contact Susanne Zibek Group manager Industrial Biotechnology Phone +49 711 970-‐4167 susanne.zibek@igb.fraunhofer.de Contact Moritz Leschinsky Group leader Pretreatment and FracJonaJon of Renewable Feedstocks Phone +49 3461 43 9102 moritz.leschinsky@cbp.fraunhofer.de Funded by the 7th Framework Programme of the European Union, FP7 –

Scale up of lignocellulosic Fragmentation

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