Process Integration in Biorefineries - Chalmers · 2013-03-20 · Process Integration in...

www.americanprocess.com

Process Integration in Biorefineries Lessons Learned from Pulp & Paper

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Process Integration Jubilee Symposium By Christos Sarigiannidis [email protected]


Who is American Process

Founded in 1995 as a process integration engineering consulting company Mission = “Maximize value from biomass” Realized as • More than 500 consulting engagement in more than 150 pulp and paper mills

with over $1 billion/y identified savings through process integration • Two biorefinery technologies to co-produce bioproducts, biofuels and

biochemicals • Two state of the art demonstration plants and current active plans to build

the first commercials

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Sugar is the New Crude®

3 CONFIDENTIAL MATERIAL


Sugars

Agricultural Residues

Forest Resources

Energy Crops/ Grasses

Biochemical & Chemical

Fermentation

Polyethylene

Diesel

Jet Fuel

Gasoline

Acetaldehyde

Acetic Anhydride

Ethanolamines

Polypropylene

Ethyl Acetate

Corn

Sugarcane

Ethanol

Ethylene Oxide

Gasoline additive

Ethylene glycol

Vinyl acetate

PET

Ethyl Ether

n-butanol

Ethylene

Fossil Crude

Chemistry

4


Sugars

Agricultural Residues

Forest Resources

Energy Crops/ Grasses

Biochemical & Chemical

Fermentation

Polyethylene

Diesel

Jet Fuel

Gasoline

Acetaldehyde

Acetic Anhydride

Ethanolamines

Polypropylene

Ethyl Acetate

Corn

Sugarcane

Ethanol

Ethylene Oxide

Gasoline additive

Ethylene glycol

Vinyl acetate

PET

Ethyl Ether

n-butanol

Ethylene

Fossil Crude

Chemistry

Area of American Process activities

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Cellulosic Sugars Value Proposition • Upgrading the value of biomass

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0%100%200%300%400%500%600%700%800%900%

1000%1100%1200%

Biomass White Pellets

Electricity Black Pellets

Non Cellulosic Ethanol

Cellulosic Ethanol

Pulp Ethanol + Acetic Acid

Chenmial + Acetic

Aic

Rela

tive

Reve

nue

per T

of b

iom

ass

Green Power+ Biorefinery Value Proposition

Chemical

Sugar is the New Crude®


Cellulosic sugar prices can be low & stable

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0,00

5,00

10,00

15,00

20,00

25,00

30,00

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

CORN SUGARSUGAR INTERNATIONALSORGHUM SUGARWOOD SUGAR

(Cen

ts/l

b) U

next

ract

ed S

ugar

Cos

t in

Biom

ass

Year

Annual Data per Sugar Type including INFLATION Factor

American Process Cellulosic Sugar Cash Costs

UNEXTRACED BIOMASS SUGARS


Two Sugar Technologies Because they address different market opportunities

GreenPower™ • Makes low cost sugars • ONLY from hemicelluloses • In co-production with pellets or power or pulp • From any biomass including softwood and sugarcane bagasse

• Advantages: Profitable at small scale

Small CAPEX barrier for first commercial operations Synergistic with biomass based renewable power, pellets, sugarcane plants

AVAP™ • Makes low cost sugars • From both the cellulose and the hemicelluloses • From any biomass including softwood and eucalyptus

• Advantages: Lowest cost sugars

Able to produce sugars at large scale

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Green Power+

Cellulose

Hemicelluloses

Lignin

Hemicelluloses

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Cellulose

HemicellulosesLignin

Cellulose

Hemicelluloses

AVAP


1. Green Power+ Technology Cellulosic sugar production from hemicelluloses ONLY in co-production mode

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Conventional Biomass Use

lignin

1 T biomass

Power Plant

Pellets

Pulp

Green Power+™ Biomass Use

1 T biomass

Power Plant

Pellets

Mild SulfuricHydrolysis

ResidueSeparation

Hot WaterExtraction

1+ T biomass

Chemicals

Pulp

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Green Power+ Cellulosic Sugars technology


Views of Alpena Biorefinery

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2. AVAP™ Technology Cellulosic sugar production from cellulose and hemicelluloses in stand alone facility

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Fractionation and Cellulose separation

Biomass

Was

hed

cellu

lose

Regenerated ethanol / SO2

Wash filtrate (hemicelluloses , sugars, ethanol, SO2, Lignin

Enzymatic Hydrolysis

Cellulose sugars Hemicelluloses sugars

Lignin Hemicelluloses Autohydrolysis

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Chemical Regeneration

AVAPTM process


AVAP Demonstration Facility

Converts various biomass to 2000 t/y of cellulosic sugars, C6 from cellulose, C5 and C6 from hemicelluloses; Sugars fermented to ethanol Startup Q1, 2013


What is process integration?

Integrating process streams • E.g. beer overheads to rectifier feed

Upgrade byproducts • Waste streams to acetic acid, furfural,

Reusing / recovering raw materials • E.g. recycle of enzymes *1

Integrating heat needs with waste heat • E.g. heat recovery schemes

Generating steam/heat “appropriately” • E.g. at the right pressure

Integrating many flowsheets / Co-production / Technology synergies • E.g. like a refinery - many co-products • E.g. Choose complimentary process steps

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What is process integration?

Process Integration is the science and art of

converting a bench scale discovery to

a financially viable industrial process

CAPEX and OPEX AND enhanced LCA

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Design with Process Integration in mind

Not an after thought Pulp and Paper has grown organically How would it look if one started from a blank paper? • Would it have that chemistry? • That chemical recovery?

• That one product emphasis?

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Reference basis for biorefinery yields often ignore energy

Even if biomass is converted to bioproduct at theoretical yield – something must be used for

energy

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Without Process Integration - Zero sum Game

-

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

Total N

o Proc

ess In

t.

Avail

able i

n EtO

H+Lig

nin

Need

ed wi

th Pro

cess In

t.

Used

in Co

rn EtO

H Proc

ess

Energ

y in lig

nin

in 1 ga

llon E

tOH

Btu/ga

llon

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Process Integration for co-production

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Biomass Energy Content

Flue gases Heat Losses Process Cooling needs

Energy in product

Heat in gaseous effluents Heat in effluents

$

Most important – Look at the overall process or site

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Heat in byproducts


Use process simulation and pinch technology

To understand: • Real energy needs • Interaction between processes • Generation of by-products • Energy requirements / Energy recovery • Potential for co-product • Indentify integration opportunities

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Do not ignore by-products

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Basic biorefinery energy intensive process steps in sugar based platforms

• High Temperature biomass processing • Liquor evaporation • Liquor cooling • Solid separation / washing • Bioconversion T control • Distillation • Biomass / Lignin burning • Steam generation configuration

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Biorefinery energy governing streams

Biorefinery “Hot” Streams • Need to be cooled or can be cooled

• Hydrolysis stock • Feed to bio-conversion (enzymes or fermentation) • Beer bottoms

Biorefinery “Cold” Streams • Need to be heated

• Biomass and chemicals to hydrolysis • Evaporation / chemical recovery • Lignin / solids washing / concentration

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PINCH

TEM

PERA

TURE

HEAT FLOW Max Heat Recycle Excess Heat

Streams that need heating

Streams that need cooling

Heat Pump


Design an optimum heat recovery network

1

3

STEAM

210ºF B 2

∆H 277

B

HOT STREAMS

4 COLD STREAMS

∆H 23

∆H 83

265ºF 175ºF

ABOVE THE PINCH BELOW THE PINCH

COOLING

375ºF

195ºF

∆H 157

1.5

90ºF

120ºF

1.5

COOLING ∆H 75

1 120ºF

2

MCP (Heat capacity

flow rate)

360ºF

292ºF

∆H 83

∆H 97

∆H 157

A

A

∆Tmin=20oF


Conclusions

Process Integration is ESSENTIAL to design viable biorefineries It should not be an afterthought • We have an opportunity to get it right the first time in

the emerging biorefinery industry

Use process integration techniques (simulation and pinch technology) early in the process design and revisit constantly • Pay attention to energy usage, water usage and LCA

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Thank you

29 CONFIDENTIAL MATERIAL


PINCH

TEM

PERA

TURE

HEAT FLOW Min Heat Needed Max Heat Recycle Excess Heat

Streams that need heating

Streams that need cooling

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Company History • Conducted over 400 projects, in USA, Canada, Brazil, Europe, Australia • In more than 150 forest industry plants • Performed O&M services

1995 - 2010

• Designed EPC and operated power cogeneration facilities “across the fence” • Have JV with Swedish biomass boiler manufacturer with over 1000 installations • Designed projects for mill shutdown installations

1999 – 2010

• Invested in biorefinery R&D – Over 22 patents pending 4 allowed • Two technologies AVAP™ and Green Power+™ • Built one of the first demonstration cellulosic ethanol plant in GA • Recipient of DOE and Michigan State grants

2005 – 2010

• Starting up Alpena biorefinery • Expansion and partnerships worldwide • Financing

2012

• Over 80 man-years years experience in design and operation of ethanol plants • Design and built large Greenfield projects in pulp and paper and ethanol fields • Design and startup “first of kind” processes in pulp and paper and ethanol field • API personnel have over 2,000,000 man-hours of project experience • API personnel have over $2 billion of project implementation experience • API personnel have over 500,000 man-hours of operating and mill startup experience

API Experience

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Advanced E 1,411,000 l/d Sugarcane 3 MMt/y in 180 days

2304 t/D(2) Cogen

Baseline

Green Power+ application in sugarcane ethanol plants can increase ethanol output by 15% as cellulosic

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Cellulosic E 240,000 l/d

Advanced E 1,411,000 l/d

Sulfuric / Lime

(Acetic A cid)

Cogen

Green Power+

Sugarcane

Hot water Hemicelluloses

Bagasse 2,304 t/D(2) 1,964 t/D(3)

1,869 t/DO(4)

Process Integration in Biorefineries - Chalmers · 2013-03-20 · Process Integration in...

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Transcript of Process Integration in Biorefineries - Chalmers · 2013-03-20 · Process Integration in...