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Making Biorefineries Competitive: PRO.E.SA TM The only sugar platform available today. Guido Ghisolfi. June 8, 2012. Three points that will change the industry:. Commercial-scale cellulosic ethanol plant, Q3 2012: 20 million gallons, Crescentino (13 to start) Cellulosic costs less
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Making Biorefineries Competitive: PRO.E.SATM The only sugar platform available today Guido Ghisolfi June 8, 2012
Three points that will change the industry: • Commercial-scalecellulosic ethanol plant, Q3 2012: 20 million gallons, Crescentino (13 to start) • Cellulosic costs less • No subsidies required
M&G Group: Biomass Technology & Experience Engineering Division $3B per year #2 producer of PET Technology for biomass to sugars
PRO.E.SATM Technology Step by Step • 2006 – 2008 • Scouting of technologies; • Generation of key inventions; • Proof of UNIT OPERATION in the labs. • 2009 – 2010 • Pilot plant construction & start up (June 2009); • Pilot plant operation and data gathering; • Test of plant flexibility using multiple biomasses. • 2011 – 2012 • Crescentino unit; • Technology licensing.
PRO.E.SATM Technology YEAST BIOMASS C6 Sugar PRO.E.SATM Technology Separation Fermentation ETHANOL C5 Sugar LIGNIN ( Energy Generation) Ready solution for industrial production of 2G Ethanol A Total Project Solution based on: Agronomy: Field experimentation and best energy crops identified and characterized; Biomass Pre-Treatment and Viscosity Reduction: Continuous process developed and piloted to produce cost-effective and clean fermentable sugars; Hydrolysis and Fermentation: Unique hybrid SSCF process scheme yielding high ethanol concentrations.
PRO.E.SATM Technology: From Biomass to Sugar • Without use of chemicals; • Optimizing C5 and C6 sugar extraction; • Minimizing the formation of by-products/inhibitors; • Using continuous equipment enabling design for large scale plant; • Minimizing CAPEX and OPEX.
The Continuous Pilot Plant: How it operates… • Biomass agnostic; • No biomass drying / grinding required; • Low level of inhibitor (lower then in P.O.C.); • No use of chemicals (only steam is added); • Reduced enzyme loads; • Rapid liquefaction of the solid material; • High solid concentration (>40%) in the hydrolysis step.
Biomass: Our Experience at Pilot Plant • PRO.E.SATMtechnology is flexible in feedstock supply: possibility to treat worldwide crops; • Several biomasses were evaluated and tested as potential feedstock for the PRO.E.SATM technology: Internal analysis according to Chemtex methods
Pre-Treatment Section: Biomass Type High feedstock flexibility • Energy crops: • Arundodonax (giant reed); • Miscanthusgiganteus; • Panicumvirgatum (switchgrass). • Agricultural and industrial residues: • Wheat straw; • Rice straw; • Sugarcane bagasse. • Woody species: • Eucalyptus; • Poplar, Internal data tests at pilot scale • Differences in yield (4 to 5 tons dry biomass/tons EtOH) index mainly depends on feedstock composition; • It is possible to reduce the yield variability optimizing the process condition.
Hydrolysis and Fermentation High solid concentration enzymatic hydrolysis is needed to guarantee the economics of ethanol recovery through distillation M&G solution Available solution
LCA – Full Scale Projection • The lifecycle performances of bioethanol produced through Chemtex technology at a full industrial scale have also been estimated by means of the GREET model; • Scale benefits will allow a further improvement of the bioethanol environmental profile. - 84% - 91%
Baseline Process Scheme 2G Bioethanol Plant TECHNOLOGY IS READY! Biomass 2G BIOETHANOL THOSE INTERMEDIATES REPRESENT A STARTING POINT FOR A NEW GREEN CHEMISTRY BASED ON RENEWBLES
How to exploit PRO.E.SATM Technology ENZYMES ETHANOLOGEN …? …? …? • We can adapt the composition of the sugar stream to various fermentations: • With / without lignin; • Higher / lower sugar concentration; • Free from inhibitory compounds.
How to exploit PRO.E.SATM Technology JET FUEL ETHANOL BUTANOL GREEN DIESEL 1,4 BDO ACETIC ACID EG ADIPIC ACID PE PX FATTY ALCOHOLS THE BIOMASS SUGAR PLATFORM