Mats Galbe Dept. Chemical Engineering Lund University pretreatment Mats Galbe Dept. Chemical...
Transcript of Mats Galbe Dept. Chemical Engineering Lund University pretreatment Mats Galbe Dept. Chemical...
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Biomass pretreatment
Mats Galbe Dept. Chemical Engineering
Lund University
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SSF
Enzymatic
hydrolysis Ferment-
ation Distillation
Ethanol Pre-
treatment
Biomass
Lignin
• Steam pretreatment (water, acid or alkali)
• Fermentation of all sugars (incl. Pentoses)
• Ethanol, polymers & biogas
• Energy integration
• Integration with other processes
Research @ Chem Eng – Lund
Examples
Biogas
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Biorefinery concept
• A selection of potential products from lignocellulose
• Ranging from bulk to high-value chemicals
• Important to maximize the yield form the starting material • Prepare the material for
attack!
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Pretreatment What is THAT?
• Some kind of action before the treatment…
• Likely to be different for different raw materials and desired products
• Some steps also before pretreatment (Pre-pretreatment?)
• Washing/separation of inorganic matter, pebbles, etc. • Size reduction (grinding, milling, crushing…) • Separation of solubles (e.g., sucrose residues)
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Lignocellulosic materials rather recalcitrant
• Starchy materials mainly glucose units • Less severe conditions
needed
• Cane mostly sucrose – extractable
• Avoid drying of the lignocellulosic materials: pore shrinking, limits diffusion etc.
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Cellulose (42%)
Lignin (21%)
Hemicellulose (20%)
Extractives
O
OH
CH2OH
OH
OH
OH
glucose glucose
mannose
galactose
rhamnose
O
OH
CH2OH
OH
OH
OH
O
CH2OH
OH
OH
OHOH
OOH
OH
CH2OH
OH
OH
O
CH3
OH
OH OH
OH
xylose
arabinose
O
OH
OH
OH
OH
O
OH
OH
OH
HOH2C
glucurono-pyranose
galacturono-pyranose
O
OH
OHOH
COOH
H3CO
OOH
OH
OH
COOH
OH
ETHANOL
FURALDEHYDES
HMF
furfural
O CHO
O CHOCH2
OH
PHENOLICS OH
RR
R
EXTRACTIVES Terpenoids etc.
ALIPHATIC ACIDS
CH3COOH
acetic acid
HCOOH
formic acid
CH3COCH2CH2COOH
levulinic acid
FERMENTATION INHIBITORS
Products & By-products
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Hydrolysis of hemicellulose
High recovery of all carbohydrates
High digestibility of the cellulose in enzymatic hydrolysis
No or very limited amounts of sugar and lignin degradation products The pretreatment liquid should be possible to ferment without detoxification
High solids concentration and high concentration of sugars
Low energy demand or possible to re-use secondary heat
Low capital and operational cost
Pretreatment – desired features for fermentation
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Action of pretreatment
• Modification of the structure
• Increased surface area • Increased pore sizes • Partial hydrolysis of
hemicellulose
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Acid based methods,
i.e. at low pH using an acid (H2SO4, SO2, H3PO4, Acetic acid…))
Results in hydrolysis of the hemicellulose (HC) to monomer sugars
and minimize the need for hemicellulases
Methods working close to neutral conditions e.g. steam pretreatment and hydrothermolysis
Solubilise most of the HC (due to acetyl groups in HC acetic acid)
Do not usually result in total conversion to monomer sugars
Requires hemicellulases acting on soluble oligomers of the HC
Alkaline methods
Leaves a part of the HC in the solid fraction
(For ammonia fibre explosion, AFEX, almost all HC)
Requires hemicellulases acting both on solid and dissolved HC
Rough classification in terms of pH
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Physical methods Chemical & Physicochemicals Biological
Milling: - Ball milling - Two-roll milling - Hammer milling Irradiation: - Gamma-ray irradiation - Electron-beam irradiation - Microwave irradiation Others: - Hydrothermal - High pressure steaming - Extrusion - Pyrolysis
”Explosion”: - Steam, Ammonia, CO2, SO2 , Acids Alkali: - NaOH, NH3, (NH4)2SO3 Acid: - Sulfuric, Hydrochloric & Phosphoric acids Gas: - ClO2, NO2, SO2 Oxidizing agents: - Hydrogen peroxide - Wet oxidation - Ozone Solvent extraction of lignin: - Ethanol-water extraction - Benzene-water extraction - Butanol-water extraction Organosolv/ Ionic liquids
Fungi and actinomycetes (lignin peroxidase, manganese peroxidase, laccase…) White-rot & Brown-rot fungi
Classification of pretreatment methods
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Chipping, milling, grinding
• Particle size reduction to some microns
• Increased surface area • Some decrystallization
occurs improving enzymatic hydrolysis
For enzymatic hydrolysis very small particles required
Very high energy requirements
Extrusion combined with chemicals and heat an option
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Irradiation
Irradiation: • Gamma-ray irradiation • Electron-beam irradiation • Microwave irradiation (short penetration)
requires a liquid (or a wet mtrl), dilute solutions resulting
• Expensive! • Ultrasound?
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Ionic liquids (IL)
• ILs are salts • A large organic cation • A small anion, usually inorganic
• Liquids at room temperature • Typically range 80 – 130°C • Chemically stable • Disrupts bonds between cellulose,
hemicellulose and lignin • Low degradation to by-products
• How to recycle the IL? • High cost • Are they safe?
1-Ethyl-3-methylimidazolium chloride [EMIM]Cl
1-Butyl-3-methylimidazolium bromide [BMIM]Br
1-Butyl-3-methylimidazolium acetate [BMIM]Oac
Examples
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Hydrothermal process
• Main principle is cooking in liquid hot water generally at 150-210 °C, 5-15 min.
• Autohydrolysis may occur due to organic acids in the mtrl. (mainly acetic acid)
• Hydrates cellulose • Small removal of lignin
• Best suited for agricultural or hardwood
• No addition of chemicals • Less requirements for
neutralization • Cheaper construction
materials • Applied in demo-scale by
Inbicon (Denmark)
• May result in dilute solutions • Oligo- and polymeric form
• A variation of hydrothermolysis is the wet-oxidation procedure , where air or oxygen is added
• Lignin is oxidized causing loss
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Alkali
• Treatment with alkaline solutions • Sodium hydroxide • Ammonia • Potassium hydroxide • Lime • …
• Soaking in alkali causes pore swelling
• Internal surface area increaes • More accessible carbohydrates
• Most efficient for agricultural crop low
in lignin • More severe cooking for woody
materials
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Organic solvents
• Organosolv • Methanol • Ethanol • Acetone • Glycols • Phenols
• Small addition of mineral acids
• Dissolves lignin in the organic phase • Recovery of solvent an absolute
requirement: • Economics • Enviromental reasons • May be act inhibiting on
organisms and enzymes • Best for agricultural materials • The Lignol process for fuel ethanol
• Pilot plant in Vancouver
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Biological pretreatment
• Pretreatment using microorganisms: • White-rot fungi breaks down lignin • Brown-rot fungi breaks down cellulose and
hemicellulose • Slow process! • Loss of material • Works at ambient conditions
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Physico-chemical methods
Methods that act both chemically and physically A bit of a grey zone…
• Steam pretreatment (steam explosion) • Ammonia-freeze explosion (AFEX) • Hydrothermolysis? • Wet-oxidation?
Steam pretreatment • Similar to dilute-acid hydrolysis
• Higher dry-matter content • 160-240°C, 1-20 min. • Rapid release of the pressure • Works well for many materials
in general, also softwood • Small amount of acid catalyst • Inherent acids OK with many
materials • Disruptive effect from
”explosion” not that important
AFEX • Operates at elevated pressure • Liquid ammonia • Around 100°C, 10-60 min • Results in polymeric carbohydrates • Interesting properties, such as water-
holding capacity and gel-formation • Best for agricultural materials • High amounts of NH3, e.g., 1.1 kg/kg
biomass
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Dilute-acid pretreatment
Is it pretreatment? Or is it actually hydrolysis? Or both? High DM: steam pretreatment Low DM: hydrolysis
• Addition of an acid, e.g., H2SO4 H3PO4, SO2, Hac, etc.
• Usually < 2%; commonly 0.2-0.5%
• Acid concentration depends on temperature & residence time
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Flash- vapour
Pretreated material
Computer
Steam
Biomass
Boiler
T
Reactor
Temp
Time
100 C
160 – 230 C 1–30 min
Steam pretreatment
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Steam pretreatment unit
Main purposes
Improve the enzymatic
hydrolysis of cellulose
Hydrolysis of hemicellulose
10 litre reactor
160 - 230 °C
Impregnation with
H2SO4, SO2 or alkali
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10 kg impregnation liquid
per kg straw
Soak for 30 – 60 min
Press to 40% DM
Soaking
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Spray acid to desired
concentration and DM of straw
Mix for 10 – 30 min
Small amount of acid
Spraying
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Impregnated
wood chips
Steam pretreated SO2, 210 C, 5 min
Contains potential inhibitors
Extractives
Sugar degradation products e.g. Furans and acids
Lignin degradation products (phenolic compounds)
Impregnation
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Scanning Electrone microscope Images
Steam pretreated spruce
Wiman et al., unpublished
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Straw Steam pretreated 0.2 % H2SO4, 190 C, 10 min
Impregnated material
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Reactor
Filter
Soli
ds
Liquid
Biomass
Conditions? Depend on purpose
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Reactor
Filter
Soli
ds
Liquid
Pulping Pulp
Enzymatic
hydrolysis
Ethanol
Butanol
Lactic acid
Other
Fermentation
Heat &
Power Electricity
Heat
Biomass
Conditions? Depend on purpose
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Reactor
Filter
Soli
ds
Liquid
Pulping Pulp
Enzymatic
hydrolysis
Ethanol
Butanol
Lactic acid
Other
Fermentation
Heat &
Power Electricity
Heat
Fermentation
Reaction
Separation
Furfural
Acids (levulinic, Formic etc)
Oligomers (Building blocks
for polymers)
Biomass
Conditions? Depend on purpose
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Reactor
Biomass
Example:
Fermentation of all carbohydrates
Yield of sugars
Concentration of sugars/product
Fermentability
Example:
Oligomers as building blocks
Molecular weight distribution
Structure (side groups etc)
Purity
etc
Requires subsequent steps
Enzymatic hydrolysis
Fermentation
SSF
Separation steps
Assessment? Depends on purpose
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Severity factor
• Severity increases with:
• Temperature
• Residence time
• Acid concentration
Poor improvement of
enzymatic hydrolysis!
Formation of by-products
inhibitory for fermentation!
Low severity High severity
]]75.14/exp[*[)( ref0 TTtLogRLog
The severity factor is a pseudo-first-order reaction that combines the treatment temperature (T) and residence time (t) in one value and provides an approximate indication of the treatment conditions.
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Acid hydrolysis of pine
1st acid-hydrolysis step: 180-200 °C
2nd acid-hydrolysis step: 200-225 °C
Time
Traditional two-step hydrolysis:
Cooling of substrate
Time
Consolidated two-step hydrolysis: Profile OR step-wise temperature change
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Improvement of temperature control in steam pretreatment
Control by pressure: Fast, requires pT-data
0
5
10
15
20
25
30
2.6 2.8 3 3.2 3.4 3.6 3.8 4
[g/1
00
g D
M]
Combined Severity
Glucose [g/100g]
Mannose [g/100g]
Xylose [g/100g]
Total C6 Sugars
Glucose [g/100g]2
Mannose [g/100g]2
Xylose [g/100g]
Total C6 Sugars
T
e
m
p
Time
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By-products after dilute-acid hydrolysis
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0
5
10
15
20
25
30
35
215 220 210 215 220 210 215 190 200 205 210 215 190 195 200 205 210 215 200 205
5 10 15 5 10 15
0 0.5
Temp. (°C)
Time (min)
Acid conc. (%)
Su
ga
r y
ield
(g
/10
0 g
Ba
rley
Hus
k)
Arabinose
Xylose
Glucose
Combined pretreatment and enzymatic
hydrolysis of Barley Husk
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Temp. (°C)
Time (min)
Acid conc. (%)
0
1
2
3
4
5
215 220 210 215 220 210 215 190 200 205 210 215 190 195 200 205 210 215 200 205
5 10 15 5 10 15
0 0.5
Co
nc
en
tra
tio
n (
g/l
)
HMF
Furfural
Acetic Acid
Combined pretreatment and enzymatic
hydrolysis of Barley Husk
0.3 g/l HMF
1 g/l Furfural
3 g/l Acetic acid
Rather low in inhibiting compounds
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Microwave pretreatment
Treatment vessel
Control unit
Rotor
Shell
Microwave oven
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Continuous pretreatment reactor Sekab E-technology
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Extraction of hemicellulose from
barley husks
Filtration - LAROX
filter press
Concentration
using UF
Steam
explosion
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0
10
20
30
40
50
60
100 120 140 160 180 200 220
Temperature
Yie
ld (
% o
ligo
- a
nd
po
lys
ac
ch
ari
de
s)
0
5000
10000
15000
20000
25000
30000
35000
40000
MwYield
Mw
0
5
10
15
20
25
30
35
40
45
2 4 6 8 10 12 14
pH
Yie
ld (
% o
lig
o-
an
d
po
lys
ac
ch
ari
de
s)
0
10000
20000
30000
40000
50000
60000M
wYield
Mw
(After impregnation)
Impregnation with
water (pH 6,5)
Res. time: 5 min
Temperature: 200°C
Res. time: 5 min
Alexandra Andersson, Henrik Stålbrand
Biochemistry, LU
Extraction of Arabinoxylan from Barley husks
Screening with microwave oven
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Autohydrolysis (barley husks)
0
10
20
30
40
50
2.0 2.5 3.0 3.5 4.0
Yield
MwMole
cula
r m
ass (
kD
a)
Severity factor
Xyla
n Y
ield
(%)
0
10
20
30
40
50
0
5
10
15
20
25
30
3.0 3.2 3.4 3.6 3.8 4.0 4.2X
yla
n y
ield
(%
)
Severity factor
15-20% yield is possible to acchieve without removing the acetyl groups or significantly decreasing the molecular mass
Microwave irradiation Steam pretratment
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0
10
20
30
40
50
3.6 3.7 3.8 3.9 4.0 4.1 4.2
Wheat straw
1 wt%
2 wt%
3 wt%
Xyla
n y
ield
(%
)
Severity factor
Steam pretreatment with NaOH
25-35% yield possible to reach when using modest concentrations of NaOH
0
10
20
30
40
50
3.6 3.7 3.8 3.9 4.0 4.1 4.2
Barley straw
1 wt%
1.5 wt%
2 wt%
Xyla
n y
ield
(%
)
Severity factor a
0
10
20
30
40
50
3.6 3.7 3.8 3.9 4.0 4.1 4.2 4.3
1.0 wt%
0.5 wt%Xyla
n y
ield
(%
)
Severity factor
Barley husks
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0
20
40
60
80
100
4 5 6 7 8 9 10 11 12
Barley
Wheat
Pe
rcen
tag
e o
f a
rab
ino
xyla
n >
5 k
Da
pH after steam pretreatment
If pH decreases, the molceular mass decreases
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Which condition is optimal?
Only water
•Acetyl groups remains
•No costs for chemicals
•Lower maximum yield
With NaOH
•Higher maximum yield
•De-Acetylation occurs
•Chemical costs
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Tengborg et al Enzyme & Microbial Technol (2001)
Test procedure – effect of pretreated slurry on enzymatic hydrolysis
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Tengborg et al Enzyme & Microbial Technol (2001)
Effect of pretreated slurry on enzymatic hydrolysis at low enzyme dosage
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High enzymatic
digestibility
Hemi
in liquid
Pretreatment
step 1
Pretreatment
step 2
180-190°C
Low severity
210°C
High severity
Two-step steam pretreatment
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Two-step pretreatment of spruce (Yields of some sugars)
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Tb
Ta
time
Separation and Washing
Step-wise increase between two temperatures
Linear increase in temperature
Two-step dilute acid pretreatment
Improved One-step pretreatment of spruce
Temperature: 190 - 226 °C
Total residence time: 5 -12 min
2.5% (w/w) SO2
Monavari S. et al Biotechnol. Progr. 2010 26(4), 1054-1060
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0
5
10
15
20
25
30
2 5 10 2 5 10 2 5 10
Enzymatic hydrolysisPretreatment: oligoPretreatment: mono
Over
all
yie
ld o
f x
ylo
se
(g/1
00g
dry
str
aw)
Pretreatment conditions
190 200 210 ºC
min
Maximum theoretical
Linde et al (2006)
Pretreatment of wheat straw (Xylose yield)
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0
10
20
30
40
50
2 5 10 2 5 10 2 5 10
Enzymatic hydrolysisPretreatment
Over
all
yie
ld o
f glu
cose
(g/1
00g
dry
str
aw)
Pretreatment conditions
190 200 210 ºC
min
Maximum theoretical
Linde et al (2006)
Pretreatment of straw (Glucose yield)
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• Several pretreament methods available
High sugar yields for agricultural residues
• Dilute acid pretreatment /steam pretreatment
High sugar yields for most biomass
• Several pilot/demo plants using pretreatment are in
operation
• Abengoa – Salamanca (E)
• Chemtex – Tortona (I)
• Inbicon – Kalundborg (DK)
• SEKAB – Örnsköldsvik (S)
Finally…
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• Assessment of pretreatment difficult
- Process configuration
- Process conditions (the whole process)
- Type of catalyst (affects downstream)
- Impregnation method
- Type of enzymes (and dosage)
- Type of fermentation organism
• Technical-economical evaluation of the
whole integrated process
…
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Building for Demo scale
Pretreatment Unit
Bottom of reactor
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Research/pilot plant
- Two-steps dilute acid- and enzymatic hydrolysis
- Capacity: 2 tons of dry substance per 24 hours
- Complete plant with recirculation of process streams
- Investment 22 million Euro
- Inauguration: May 26 2004
Plan Demo plant 2010/11
Industrial scale 2014
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Problems in pilot plant (deposits)
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Problems in pilot plant (leakage)