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Experiences from the PDU Mats Galbe Department of Chemical Engineering Lund University

Experiences from the PDU Mats Galbe Department of Chemical Engineering Lund University. Process Development Unit (PDU). PDU: lab and process equipment Research in bench-scale, i.e., max size 100 litre fermentor vessel

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Experiences from the PDU Mats Galbe Department of Chemical Engineering Lund University

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  1. Experiences from the PDUMats GalbeDepartment of Chemical EngineeringLund University

  2. Process Development Unit (PDU) • PDU: lab and process equipment • Research in bench-scale, i.e., max size 100 litre fermentor vessel • National facility placed at Lund University,mainly financed by the Swedish Energy Agency • Commissioned work for companies and universities • Internal research

  3. Research Increasedknow-howTests of new ideasCreate models… Development Test of process configs.OptimisationProducts & By-products Verification EvaluationTest of methodologyFinal optimisationData for scale-up Purpose of a Process Development Unit • Lab scale • PDU • Pilot scale • Industrial scale

  4. Process Development Unit (PDU) Steam pretreatment unit 10 litre reactor 160 - 230 °C Impregnation with H2SO4 or SO2 or other catalysts Main purposes Hydrolysis of hemicellulose Improve the enzymatic hydrolysis of cellulose Success: A number of units constructed & sold

  5. Pretreatment unit (small) • 4-litre capacity • Jacket for less heat losses • Improved control of temperature • Surface-coated flash-off vessel Implemented in large reactor

  6. Steam pretreatment or acid hydrolysis? • What do we actually mean? • Steam pretreatment renders a material suitable for further processing (e.g, by enzymatic hydrolysis) • With or without catalyst (acid or base) • Acid hydrolysis (strong or dilute) ideally produces monomers that can be used without further treatment

  7. Dilute-acid hydrolysis • Dilute-acid hydrolysis: • Concentrations typically less than 2% • Temperatures 180-220°C • Residence time usually < 15 min • One- or two-step hydrolysis • Advantage: rather fast and simple • Drawback: results in degradation products -> may be difficult to ferment • Pentose sugars -> furfural • Hexose sugars -> HMF, formic and levulinic acid

  8. Acid hydrolysis of spruce One-step at two temperatures

  9. By-products in one-step acid hydrolysis using a temperature profile

  10. Steam pretreatment • Addition of a catalyst during pretreatment • Milder conditions than in acid hydrolysis • Acid results in hydrolysis of the hemicellulose • H2SO4, H3PO4, SO2 • Alkali mainly oligo- and polymers • NaOH, NH3 • Enzymatic hydrolysis (SHF) or simultaneous saccharification and fermentation (SSF)

  11. Different materials behave……differently • Agricultural materials • Wheat straw • Corn stover • Sugar cane bagasse • Sorghum (sweet/fibre) • Arundodonax • Rice straw • Hemp • Barley straw • Paja Brava • Forest materials • Spruce • Pine • Poplar • Cypress • Salix

  12. PDU – International partner • Borregaard, Norway: Steam pretratment • Chemtex, Italy: SSF, steam pretreatment • Cargill, Germany: Steam pretreatment • Mitsui Engineering & Shipbuilding, Japan: SSF • Nagurjana Hills, India: SSF • NBE Sweden: Hydrolysis, analysis, fermentation • SGCC (State grid of China): Project and cooperation • SEKAB: SSF, analysis • Taurus: Pretreatment and fermentation • … • CTH • KTH • Brazil-EU: Partner in Cane Biofuel • NILE (EU): SSF, pretreatment (Partner) • University of Florida • University of Georgia • National Renewable Energy Labs (NREL), USA • … Currently building full-scale plant in Italy

  13. High-WIS applications(WIS: Water-Insoluble Solids) • High WIS is good… • Potentially higher sugar concentrations-> Higher ethanol concentrations-> Less energy requirements • …(or is it?) • Increased viscosity • Higher inhibitor concentrations • Less available liquid-> unfriendly environment • Heat transport affected! • pH control initially difficult • OPTIMISATION!

  14. Higher dry-matter concentrations • Terrafors(originally for solid-state fermentations) • Difficult to control pH • Mixing less efficient with increased liquefaction

  15. High-WIS hydrolysis quick tests Rotating with steel balls for mixing

  16. High-WIS (SHF or SSF)Test of equipment

  17. First test of enzymatichydrolysis of spruce

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