Biorefining Biorefining Chemical Engineering Team Chemical Engineering Team Tejas Patel, John Truong, Tony Tran, Trenika Iland, Tejas Patel, John Truong, Tony Tran, Trenika Iland, Bambo Ibidapo- -Obe, Jeremy Constantino, Adam Adler, Obe, Jeremy Constantino, Adam Adler, Bambo Ibidapo Blake Adams Blake Adams
Presentation Outline Presentation Outline Purpose Purpose – What is What is biorefining biorefining – Plant Design Plant Design – Fermentation processes Fermentation processes – – Purification processes Purification processes – – Utilities Utilities – – Waste Waste – – Economics of each process Economics of each process – Business Plan Proposal – – Mathematical Model Mathematical Model Business Plan Proposal – Model Description Model Description – – Inputs into the Model Inputs into the Model – – Results of Model Results of Model – – Sensitivity and Risk of Model Sensitivity and Risk of Model –
Overview of Biorefining Overview of Biorefining What is a bio based product? What is a bio based product? – Made from renewable resources Made from renewable resources – – Plant material as main ingredient Plant material as main ingredient – – Biodegradable Biodegradable – Why bio- -refining? refining? Why bio – National and local policies promote bio National and local policies promote bio- -refining refining – – Strict environmental regulations Strict environmental regulations – Increased cost of products made from fossil fuels Increased cost of products made from fossil fuels – Extraction, processing, disposal Extraction, processing, disposal – – Advantages Advantages – Rural economic development, lower economic costs, Rural economic development, lower economic costs, environmentally safe environmentally safe http://www.pnl.gov/biobased/docs/prodplas.pdf
Scope of Project Scope of Project Figure 1: Chemicals, Microorgansims, and End Products of Fermentation Processes Each of these acids are generated using nearly identical fermentation processes with different bacteria which dictate the end result
Scope of Process Scope of Process http://www.pnl.gov/biobased/docs/prodplas.pdf
Market Analysis / Demand Market Analysis / Demand www.the-innovation-group.com/ChemProfiles.htm
Market Demands for Products Market Demands for Products Years 2005- -2025 2025 Years 2005 8000 7000 6000 m ) Acetic Acid 5000 6 lb Citric Acid Fumaric Acid Mass (10 4000 Succinic Acid Lactic Acid Ethanol 3000 Propionic Acid 2000 1000 0 2005 2010 2015 2020 2025 Year Assumptions: -growth due to environmental profile -industrial applications increase due to biodegradable advantages
Price Projections for Products Price Projections for Products Years 2005- -2025 2025 Years 2005 3 2.5 m ) Price per Unit Mass (US$/lb 2 Acetic Acid Citric Acid Fumaric Acid 1.5 Succinic Acid Lactic Acid Ethanol Propionic Acid 1 0.5 0 2005 2010 2015 2020 2025 Year Assumptions: -an increase in demand will result in over capacity and competition among suppliers -as a result, a reduction of prices with a corresponding increase in the amount of sales is expected -more competition will drive prices down and supply up
Process Description Process Description Simulations for Fermentation/Purification Simulations for Fermentation/Purification – Model Descriptions Model Descriptions – Fermentation Fermentation – Formation of each acid Formation of each acid – – Bacteria Considerations Bacteria Considerations – Conversions Conversions Simulations Simulations – Outline of Fermentation Outline of Fermentation – – Outline of Purification Processes Outline of Purification Processes –
Models Models Citric Acid Citric Acid Succinic Acid Succinic Acid Propionic Acid Propionic Acid Fumaric Acid Fumaric Acid Acetic Acid Acetic Acid
Fermentation Fermentation Acid Similar processes Similar processes Glucose + Water Formation Formation Fumaric Acid Propionic Acid Acetic Acid Citric Acid Succinic Acid – 10:1 mass ratio of water to 10:1 mass ratio of water to – Bacteria glucose glucose Clostridium thermocellum Anaerobiospirillum Propionibacterium Aspergillus niger Rhizopus Our Scope – Heat sterilization Heat sterilization succiniciproducens acidipropionici – – Compressed Air Compressed Air – – Ammonia Ammonia – Bacteria Name Yield Product Bacteria Name Yield Product – Batch Reaction Batch Reaction – Clostridium thermocellum Clostridium thermocellum 100% 100% Acetic Acid Acetic Acid Aspergillus niger Aspergillus niger 66.7% 66.7% Citric Acid Citric Acid Anaerobiospirillum succiniciproducens succiniciproducens 87% Succinic Acid Anaerobiospirillum 87% Succinic Acid Ethyl Lactate Subgroup Propionibacterium acidipropionici acidipropionici 66.7% Propionic Acid Propionibacterium 66.7% Propionic Acid Rhizopus Rhizopus 69% 69% Fumaric Fumaric Acid Acid Saccharomyces cerevisiae cerevisiae 66.7% Ethanol Saccharomyces 66.7% Ethanol Lactobacillus delbrueckii delbrueckii 95% Lactic Acid Lactobacillus 95% Lactic Acid
Bacteria Bacteria All the fermentation processes are catalyzed by All the fermentation processes are catalyzed by the appropriate bacteria the appropriate bacteria They are grown along with inoculum inoculum seeds in seeds in They are grown along with small laboratory vessels small laboratory vessels Once the nutrients and inoculum inoculum seeds are seeds are Once the nutrients and grown sufficiently, they form a slurry which is grown sufficiently, they form a slurry which is transferred to the fermentors transferred to the fermentors Cost of using bacteria was found to be $0.80 Cost of using bacteria was found to be $0.80 per ton per ton
Process Description Process Description Fermentor Capacity: 350,000L Blending/Storage Sterilizer Citric Acid Units: 5 Citric Acid Capacity: 21,000 gal Units: 3 Rotary Drum 27 bacteria Cost: $1.2 Million + → + + 2 C H O O C H O 6 CO 8 H O Units: 3 Cost: $200,000 Capacity: 65 m 2 6 12 6 2 6 8 7 2 2 2 Cost: $110,000 Units: 2 Throughput: 80m 3 /hr Cost : $ 115,250 Exit Stream Mass % Nutrients waste Water – 1249786 kg/batch Byproducts – 7.1% Glucose – 0.4 Stream to Purification Water – 85.9 Citric Acid – 3.78 Ammonia: 62489.3 kg/batch Flowrate – 1,400,000 kg/batch Air: 6242930 kg/batch Ion Exchange Column Cost: $75,000 Glucose – 112480.7 kg/batch, 89.9%mass Salts – 12525 kg/batch, 10.1%
Purification Processes Purification Processes Citric Acid Citric Acid Succinic Acid Succinic Acid Propionic Acid (Sodium Propionate) Propionic Acid (Sodium Propionate) Fumaric Acid Fumaric Acid Acetic Acid Acetic Acid
Citric Acid Citric Acid Capacity: 30,000L Water: 100,000 kg/batch Water: 10,000 kg/batch Units: 1 Citric Acid: 56975.4 kg/batch Cost: $35,000 Capacity: 47 m 2 Water: 75236.6 kg/batch Calcium Citrate: Units: 2 80363.9 kg/batch Cost: $91,200 Sulfuric Acid: 75000 kg/batch Air: 237.1 kg/batch 48.06 % Sulfuric Acid: 32061.7 kg/batch Water: 155303 kg/batch Ca Citrate: 4018.2 kg/batch Citric Acid: 54268.7 kg/batch Ca(OH) 2 : 35000 kg/batch 23.2 %mass Ca(OH)2 waste: 20.36% Gypsum: Product Precipitation Capacity: 27,500 L Water: 79.64% 40146.5 kg/batch Capacity: 65 m 3 Citric Acid Product: Capacity: 35,000L Units: 3 Total 18125.5 kg/batch 45.4 mass% Units: 2 54268.7 kg/batch Units: 7 Cost: $323,000 Gypsum Formation Cost: $115,250 Cost: $364,200
Acetic Acid Acetic Acid Acetic Acid: 64.7 lbmol/hr Water: 333 lbmol/hr Water: 333 lbmol/hr EtAc: 777.9 lbmol/hr EtAc: 777.9 lbmol/hr Acetic Acid: 1780 kg/hr Water: 1591 kg/hr EtAc: 68600 lb/hr Units: 1 Water: 2500 lb/hr Trays: 10 Cost: $95,000 Units: 1 Cost: $60,000 Water: 30.2 lb/hr Acetic Acid: 2.23 lb/hr Acetic Acid: 64.4 lbmol/hr Water: 2.33 lbmol/hr 96.5% Purity
Citric Acid Citric Acid FCI vs Capacity 160 y = 1.6241x + 4.3017 140 R 2 = 0.9955 120 100 FCI (MM 80 60 40 20 0 0 10 20 30 40 50 60 70 80 90 Capacity (MM lb)
Annual Operating Cost Annual Operating Cost Citric Acid Citric Acid Capacity Capacity 35 MM lb 35 MM lb Raw materials Raw materials 12.68 12.68 Operating labor 1.34 Operating labor 1.34 Utilities 3.01 Utilities 3.01 Maintenance and repairs Maintenance and repairs 4.43 4.43 Operating supplies Operating supplies 1.01 1.01 Total ($ MM) Total ($ MM) 22.50 22.50 Operating cost breakdown Raw materials Maintenance Supplies 5.5 % Operating labor 19.7 % 56 % 5.9 % 13.4 % Utilities
Citric Acid Citric Acid Operating cost vs Production 30 y = 0.31x + 0.652 25 Operating cost (MM $ 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 Capacity (MM lb/yr)
Model Considerations Model Considerations Acetic Succinic Citric Acetic Succinic Citric Acid Acid Acid Propionic Acid Acid Acid Acid Propionic Acid Fermentation Fermentation 4.83 4.24 3.79 2.97 4.83 4.24 3.79 2.97 Broth Mass (%) Broth Mass (%) Final Conversion Final Conversion 63.3 59.9 66.0 48.1 63.3 59.9 66.0 48.1 to Sell(%) to Sell(%)
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