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Ethanol Production from Wastepaper

Ethanol Production from Wastepaper. Ben Dalton Marie Labrie Cassia Davis Alex Saputa John Ozbek Steve Wild Murat Ozkaya 4/15/09. Outline. Project Purpose Assumptions Process Flow Pre-Treatment Saccharification & Fermentation Distillation/Purification Energy Utilization/Usage

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Ethanol Production from Wastepaper

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  1. Ethanol Production from Wastepaper Ben Dalton Marie Labrie Cassia Davis Alex Saputa John Ozbek Steve Wild Murat Ozkaya 4/15/09

  2. Outline • Project Purpose • Assumptions • Process Flow • Pre-Treatment • Saccharification & Fermentation • Distillation/Purification • Energy Utilization/Usage • CO2/H2O Footprint • Economics • Summary

  3. Project Purpose Design a facility that is: • State-of-the-art • Flexible • Adaptible • Bio-chemical processing plant • Optimizing Ethanol production

  4. Project Purpose Optimizing includes: • Water usage • Energy usage • CO2 • Waste Stream Utilization/Cogeneration • Return on investment

  5. Assumptions • 100 Tons of Waste Paper per Day • Waste Paper Contains 50% Cellulose • 81% Conversion of Cellulose to Ethanol in 24 hours • Target Purity: 99.5wt% Ethanol

  6. WATER PAPER PRE-TREATMENT PURIFICATION YEAST & ENZYME PRODUCTION Ethanol SACCHARIFICATION & FERMENTATION

  7. Pre-Treatment Undesirables

  8. Enzymes-What are they? • Enzymes are catalysts that are biological molecules • Like all catalysts, enzymes dramatically increase the rate of reaction

  9. Breaking up Cellulose (Saccharification) • Breaking up cellulose requires three enzymes collectively called cellulases

  10. Where Do You Get Enzymes? • Trichoderma reesei (yeast) • Secretes cellulases • One of the most powerful secretors of cellulases known to date

  11. + Producing Enzymes Water Yeast Nutrients Water Nutrients Yeast Enzyme Production Culture 600 lbs 20 lbs/day Mixture 300 lbs/day Enzyme Yeast Pre-Culture 25 lbs

  12. Saccharification by Enzymatic Hydrolysis Enzymes Cellulose C6H12O6 (Glucose)

  13. Fermentation 2C2H5OH Yeast C6H12O6 + 2CO2

  14. Non-Isothermal Continuous Saccharification and Fermentation (NCSF) Enzyme CO2 Slurry Ethanol Yeast Enzymatic Hydrolysis Fermentation

  15. NCSF Material Balance Enzyme 20 Tons CO2 400 Tons H2O 50 Tons Cellulose 50 Tons Lignin 400 Tons H2O 21 Tons Ethanol 59 Tons Undigested Paper 50ºC 45ºC 40ºC 35ºC 30ºC Yeast

  16. NCSF Energy Balance 55 MMBtu/Day 50ºC 45ºC 40ºC 35ºC 30ºC Cooling H2O 40 MMBtu/Day HPS

  17. Distillation & Purification

  18. Distillation: Material Balance DISTILLATE D= 20 tons/day QC= 110 MMBtu/day XD= 90.6 wt% EtOH FEED F= 420 tons/day XF= 5.0 wt% EtOH BOTTOMS B= 400 tons/day QR= 200 MMBtu/day

  19. Distillation: Column Specifications Sieve tray 1 stage 2 ft 40 ft 20 stages 11 ft

  20. Water Adsorption by a Molecular Sieve 21 Tons EtOH + 2 Tons H2O 11 Tons Synthetic Zeolite ~21 Tons EtOH

  21. Regeneration of the Molecular Sieve ~ 6 Tons Hot CO2 + 2 Tons H2O Vapor Per Day 11 Tons Synthetic Zeolite 6 Tons CO2/ Day 7.1 MMBtu/Day

  22. Waste Stream Utilization Flue Gases 200 MMBtu/Day Steam Boiler Undigested Paper 720 MMBtu/Day High-Pressure Steam 520 MMBtu/Day

  23. Energy: Ethanol from Wastepaper Cogenerated Electricity Papernol Plant 200 MMBtu/Day Ethanol 500 MMBtu/Day

  24. Energy: Ethanol from Corn Corn Based Ethanol Plant Fossil Fuels Ethanol 500 MMBtu/Day 450-550 MMBtu/Day

  25. CO2 Footprint Papernol Produces 120 tons CO2 / day Papernol Average CO2 released by vehicles in Chattanooga = 3,300 tons per /day

  26. H2O Footprint Papernol Papernol Plant Uses 20 tons/day Grey Water

  27. Capital Costs • Reactor Vessels $1.5M • Steam Boiler $1.0M • Enzyme Tanks $1.0M • Shredder/Conveyer $500K • Distillation Column $240K • Prep Tank $90K • Molecular Sieve $70K • Total $4.4 Million

  28. Economic AnalysisCapital Costs Equipment Cost = $4.4M Plant Heuristic x (4.7) Total Capital Cost = $20M

  29. Annual Operating Costs • Wastepaper $300K • Water $200K • Electricity $120K • Nutrients $86K • Enzyme & Yeast $33K • Cooling Water $21K • Total$1.2 Million

  30. Production Costs $4M $1.2M 2.3M Gal $2.56/Gal • Annual Capital Cost • 5 Year Payback • Annual Operating Cost • Annual Production • Production Cost

  31. Return On Investment 10 Year ROI 5 Year ROI $2.56/gal $1.66/gal

  32. Summary • Project Purpose • Assumptions • Process Flow • Pre-Treatment • Saccharification & Fermentation • Distillation/Purification • Energy Utilization/Usage • CO2/H2O Footprint • Economics

  33. Conclusion • Facility Produces 21 tons of Ethanol Daily • Net Energy Usage is (+)700 MMBtu/day • Return on Investment of 5 Years • Gives a Cost = $2.56/gallon

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