Post on 25-May-2015
Bio-Hydrogen Production in Pilot Scale
ERGOSTECH
-Founded as ¨Clean Energy Ltda¨ - Nov 2004
-Renamed into ¨Ergostech Ltda¨ - Nov 2007
-Capital: 1 Million R$
-Focus:-R&D Biomass Technology-IBB – Consulting-Investment Projects in Brazil and Angola
Estrada da Rhodia, Km 16 Barão Geraldo/ Campinas/ SP
Strategic Location
UnicampCPqD
LS
PauliniaReplan
www.randon.com.br/.../p_menu_10.htm
IBM
Bosch
Motorola
Green: Sugar Cane Plantation
Honda
Samsung
Sugarcane
Sugar
BoilerBoiler
Sugar production
Molasses
Ethanol fermentation
Bagasse, stover
Cane juice
Crushing
Hydrogen fermentation
Methane fermentation
Vinasse: Xylose, Lignin
Vinasse: residual sugars
Distillation
Sugar process
Ethanol process Ethanol
Hydrolysis
Hexose, Pentose, Lignin,
Residues
HydrogenMethane
Lignocellulose utilize process
Energy
Sugarcane
Sugar
BoilerBoiler
Sugar production
Sugar production
Molasses
Ethanol fermentation
Ethanol fermentation
Bagasse, stover
Cane juice
CrushingCrushing
Hydrogen fermentation
Hydrogen fermentation
Methane fermentation
Methane fermentation
Vinasse: Xylose, Lignin
Vinasse: residual sugars
Vinasse: Xylose, Lignin
Vinasse: residual sugars
DistillationDistillation
Sugar process
Ethanol process Ethanol
HydrolysisHydrolysis
Hexose, Pentose, Lignin,
Residues
HydrogenMethane
Lignocellulose utilize process
Energy
Sugar Cane
Crushing
Cane Juice
Sugar Process Molasses
Bagasse
Hydrolysate: Hexose, Pentose, LigninResidues: Ash, Char
Ethanol Fermentation
DistillationVinasse Biomass
Hydrogen Fermentation
Methane Fermentation
Hydrogen
Process E. Power
Methane
Process Steam
A
B
C
D
10,000 t/day(1 sugar Mill)
3.000 t/day(50% moisture)
Hexose 525 tPentose 315 tLignin 210 tResidues 450 t
Gas for industryRaw material
GasFuel
Overall Process Flow
Process
• Cascade Process
• Ethanol fermentation: already existing in Brazil
• Biodiesel
• Hydrogen fermentation
• Methane fermentation
Installations involved
• A reactor of 1m3 capacity, fully equipped with the control units (heating/temperature control, pH-adjusting, substrate addition, sterilization, pressure control, among others)
• A laboratory to perform the analysis and control the parameters of the process.
• This laboratory shall get the data for the industrial scale fermentation, for the different raw materials available for this process.
• The local and ground facility will be offered by ERGOSTECH
Hydrogen Production Pathway
Microbial strain• Patent microbe is owned by Sapporo Breweries
• Exploitation of the patent microbe: subject to agreement of intellectual-property-rights
• Deposited microorganisms: obtained from International Authority Depository (U.S.A. or Germany)
• Some deposited strains present hydrogen productivity near the Sapporo strain
• New strain screening: might be another Joint Research Project
• Although this method requires time, we can obtain the new excellent microbes.
Expected Benefits
• Optimization of the renewable resources utilization
• Introduce an alternative product to be used as biofuel, using the same agricultural resources
• Increment in the energy recovery of approximate 1.5 times (ca. 50% increase)
• Results in more energy and less waste release
• Alternative process to couple to other biofuel production process, including Biodiesel (oil production)
ERGOSTECH EXISTING BUILDING
PILOT PLANT
(19×9.8m)
Pilot Plant Placement
15 m19 m
MaterialIn
let
Homogenizer
③Bioreactor
②Nutrient Treatment & Adjustment Unit
N-S
ource Supplier
Raw
Material
Preparation T
ank
Cooler
④ Control Panel
⑦Portable Slurry Pump⑤Portable Vessel
400 L
⑥Portable Vessel 100 L
⑧Bacteria Propagation
Unit 30L
⑨Bacteria Propagation Unit 200L
⑩ Cooling Water Unit
⑬ Compressor
⑪Drum Lifter
⑫Stirer
Pilot Plant Layout(not final plan dated 09/05/12)
Doorway
Movable
Installed (Fix)
Installed Base
①Raw Material Treatment & Adjustment Unit
Raw Material Supplier
sieve
Raw Material Preparation Tank
WC
Sapporo is designing the detail of each equipment’s specification now.These layout, therefore, is possible to be changed according to their specs.If you have any opinions about this plan, please inform us.Refer to your opinions, Sapporo will modify this layout and specs.
Flow Chart of Hydrogen Fermentation
Raw material preparationby Homogenizer
NOT FINAL PLAN
Raw material preparationby NaOH
Preparationby Enzyme
HydrogenFermentation
Separationby Sieve
Load Concentration
• Main components of the metabolite of hydrogen fermentation are organic acid
• About 10% of load decreases by hydrogen fermentation • Organic acid is the most desirable substrate of methane
fermentation• Effluent is used effectively and can maximize the energy
recovery from the biomass, if a rapid methane fermentation is coupled to use the organic acid (hydrogen fermentation effluent)
Fermentation Broth
• The load concentration before and after hydrogen fermentation (acid fermentation) is as follows:– At raw material concentration is 25 - 30 kg / m3
– COD of raw material broth is ca. 33,000 mg / liter– COD of effluent is ca. 30,000 mg / liter
01-1-1Tank for raw material preparation
01-1-2 Homogenizing devices for the raw material preparation
01-1-5 Raw material supplier No.201-1-3 Raw material
supplier No.1
01-1-7 Feed pump
01-1-4 Stirring device
01-1-6 Stirring device
01-1-8 Frame/piping
Item 01-1 Raw Material Treatment & Adjustment Unit
01-5 100L Vessel
01-6 400L Vessel01-7 Slurry pump
ToItem 01-3
NOT FINAL PLAN
Item 01-3 Bioreactor Unit
01-3-1 Bioreactor
FromItem 01-1
01-3-2 Circulation system
01-3-3 pH adjuster vessel
01-3-4 pH controller
01-3-5 pH probes
01-3-6 Flow monitor
01-3-7 Temperature detector
01-3-8 Frame/piping
NOT FINAL PLAN
Item 01-2 Nutrient Treatment & Adjustment Unit
01-2-1 Tank for raw material preparation
01-2-2 Stirring device
01-2-3 N-source supplier
01-2-4 Stirring device
01-2-5 Frame/piping
Items 01-8 Bacteria Propagation Unit 30L& 01-9 Bacteria Propagation Unit 200L
01-8-1 Automated Cultivator 30L
01-9-1 Automated Cultivator 200L
01-8-2 Stirring device01-9-2 Stirring device
01-10 Cooling Water Unit
01-11 Lifter & 01-12 Stirrer
01-13 Air compressor
NOT FINAL PLAN
Routine analysis process
• Generated gases: Gas Chromatography
• Generated organic acids: HPLC
• Total sugar: Phenol-sulfuric acid method
Model of Methane Fermentation Unit by UASB
(Up-flow Anaerobic Sludge Bed )
Model of Methane Fermentation Unit by Membrane
Membrane Methane Fermentation Unit
Bio-Gas
PreparationTank
MethaneReactor
MembraneSeparator
EffluentSystem
Generator
Boiler
Separator
Raw Material
Timeline of the ProjectActivity Semester 1 Semester 2 Semester 3 Semester 4 Semester 5 Semester 6 Sem. 7
Nov.28,’08
Mar.2,’09 –
Jul., ’09Aug., ’09 Oct., ’09 Dec., ’09 Mar., ’10 Jun., ’10 Sep., ’10 Dec., ’10 Mar., ’11 Jun., ’11 Sep., ’11
Dec., ’11 -Mar.2, ’12
Fermentation test (Year 1)
PreparationPre-
shipment inspection
Installation,
Commissioning
Continuous fermentation process for each type of raw materialN-source & C-sourceFermentation (Year 2)
Evaluation of the results of Year 1 and Preparation
Complementation of the remaining parametersSolution of problems and questioning Optimization of strain/inoculum vs. raw material typeFermentation (Year 3)
Preparation
Optimization of F/SCell concentration, rapid fermentation setupCost reduction, energy reduction
Progress Reports
Start up and Progress Meetings Jp Jp Br Jp Br Jp Br
Performance Report Submitted up to 90 days after the final Meeting Demonstration work
(in Japan)Kick off meeting
(in Japan)