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Sustainability assessment for the production of bio based products - - PowerPoint PPT Presentation

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Session XIII: Biofuels & Biobased Products Sustainability assessment for the production of bio based products using by product streams derived from the pulp and paper industry Anestis Vlysidis, D. Ladakis, M. Alexandri, I. Kookos, A.

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Agricultural University of Athens, Greece

Anestis Vlysidis, D. Ladakis, M. Alexandri, I. Kookos, A. Koutinas Session XIII: Biofuels & Biobased Products

Department of Food Science and Human Nutrition Agricultural University of Athens Greece 23rd – 25th June 2016 Limassol, Cyprus

Sustainability assessment for the production of bio‐based products using by‐product streams derived from the pulp and paper industry

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Agricultural University of Athens, Greece

Our Research Group

Biorefinery development based on renewable resources

Valorisation of renewable resources Industrial wastes and by‐ product streams Biorefinery development Added‐value products Food waste and by‐products

Food Feed Antioxidants Chemicals Biofuels Biopolymers Heat Biomaterials

  • White biotechnology
  • Bioprocess / biorefinery engineering
  • Bioprocess / biorefinery design
  • Βioprocess optimisation

Agricultural crops and residues

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Agricultural University of Athens, Greece

Fermentation cases of Agricultural wastes integrated in biorefinery schemes

A.A. Koutinas, Chem. Soc. Rev., 2014,43, 2587‐2627

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Agricultural University of Athens, Greece

Bioprocess optimisation Techno-economic evaluation Life Cycle Analysis

The BRIGIT Project: Valorising SSL from pulp and paper mills

SSL

Fermentation

Succinic acid production Succinic acid Separation and Purification Polybutylene succinate

Phenolic Extract

Phenolic Extraction with Ethyl acetate Ultrafiltration N2

LS

Fireproof biopolymers

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Agricultural University of Athens, Greece

SSL Characterisation Value St Dev pH 2.7 Density (g/mL) 1.277 0.007 Viscosity (cP) 552 167 Dry Matter (g-DM/L) 816.5 0.6 Lignosulphonates (g/L) 458.8 2.7 Ash % (g/g-DM) 8.62 0.55 Phenolics % (g/g-DM) 1.55 0.04 Carbohydrates (g/L) 176.41 Xylose (g/L) 128.08 0.59 Galactose (g/L) 21.47 5.50 Glucose (g/L) 19.27 0.39 Mannose (g/L) 7.41 1.30 Arabinose (g/L) 0.18 0.05 Acetic Acid (g/L) 6.91 0.49

SSL Production in Pulp and Paper Industry

BLOW TANK WOOD CHIPS WATER

CELLULOSE FIBRES

THIN LIQUOR 1 2 3 4 5 6 7 THICK LIQUOR COOKING CHEMICALS SO2/MeHSO3 (Me: Ca, Mg, Na, NH4)

SSL

DIGESTER WASHER

SO2 RECOVERY

MULTIPLE EVAPORATION PROCESSES

Sugars are destroyed during precipitation after the addition of calcium or sodium hydroxide

Current uses

Plasticizers for concrete production among others +NaOH +Ca(OH)2

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Agricultural University of Athens, Greece

Worldwide production quantity of bleached sulphite pulp in the last decade

  • Global annual production of bleached sulphite pulp: 3,570,476 t/yr (FAO, 2012) 14% increase since 2009

− Annual production in United States of America: 989,074 t/yr (FAO, 2012)  21% increase since 2009 − Annual production in South America: 211,000 t/yr (FAO, 2012)  74% increase since 2009 − Annual production in European region: 2,056,902 t/yr (FAO,2012)  0,01% increase since 2009

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Agricultural University of Athens, Greece

Formation of Sugars & Inhibitors During the Process

Lignin

Phenolic compounds Lignosulphonates

Cellulose Hemicellulose

glucose xylose arabinose galactose mannose Furfural 5‐HMF Acetic acid Formic acid Levulinic acid

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Agricultural University of Athens, Greece

Detoxification / Pretreatment and fermentation of SSL

SSL

Ultrafiltration N2

Fermentations

  • A. succinogenes
  • B. succiniciproducens

Phenolic Extraction with Ethyl acetate

5 10 15 20 25 30 35 40 45 20 40 60 80 100 120 140

Concentration (g/L) Time (h) Total sugars Succinic acid

 0.63 g‐SA/g yield  Low by‐product formation  SA productivity 0.31 g/L/h (0.5 g/L/h @ 50 h)  ~ 40 g/L final SA

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Agricultural University of Athens, Greece

Process Design of the SA production & purification of SA from SSL

Concentrated Detox SSL from WP2 Water I

V-102

(Yeast Extr.)

P-101 E-101 R-101 E-102 lps (160 oC) 140 oC 20 oC 37 oC 130 oC 37 oC

Medium Mixing tank Sterilization Fermentor

2 1 E-103 140 oC CO2 C-101

CO2 compressor Medium Mixing tank

V-101 72.9 oC 20 oC 4 20 oC

Inoculum Mixing tank

V-103

TSB Water II

E-104 E-105 140 oC 130 oC E-106 140 oC lps (160 oC)

Sterilization Inoculum Reactor

3

To Area 200

A-101 R-102

Small scale plant Annual Capacity of SSL: 15 kt Hourly rate of 2.14 t/h

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Agricultural University of Athens, Greece

CR-201 4 6 AC-201

3‐Phase Evaporator

V-202 8

Biomass residues

AREA 100

5 IER-201

Wastes

7 F-201 SD-201

Fluidized bed Dryer

9 E-201 37 oC 130 oC E-202 Air C-102 Air compressor

Succinic Acid Crystals

Process Design of the SA production & purification of SA from SSL (cont’)

2 ktons of SA / year Hourly rate: 300 kg/h

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Agricultural University of Athens, Greece

Fermentation Downstream

Using process simulation software UNISIM Simulation of SA production & purification

Triple effect Evaporator

Cell mass removal Activated carbon Resins Crystallizer Spray drier

Heat Integration

  • Combine hot and cold stream
  • Energy minimization
  • 65% less consumption of steam
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Agricultural University of Athens, Greece

Techno‐economic evaluation of SA bioprocess

Sizing of the equipment and we find their characteristic values Calculation of the equipment cost through empirical costing equations Conversion to 2015 prices by using the CEPCI (CHEMICAL ENGINEERING PLANT COST INDEX) Calculation of the installation cost (CBM) via installation factors FBM Calculation of the fixed capital investment FCI=1.6*CBM Development of the Process Flow Diagrams

  • CBM= M$ 9.7
  • 47% Triple effect evaporator
  • 37% the three fermenter
  • Together with their agitators
  • FCI = M$ 15.6
  • Utility Cost was remarkable
  • High requirements for steam
  • M$ 0.85 per year

The Total Production Cost: TPC = M$ 11.1 per year 5.39 $/kg‐SA produced Current prices: 2.94 for biobased SA * 2.5 for petroleum derived SA *

 

WT UT RM OL woD

C C C C FCI TPC      23 . 1 73 . 2 18 .

* E4tech (UK) Ltd

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Agricultural University of Athens, Greece

System boundaries

LCA for the production and purification of SA

Materials Energy Emissions Wastes “Gate to gate” approach

Concentrated Detox SSL from WP2

2 1 4 3 4 6 8 5 7 9

Succinic Acid Crystals
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Agricultural University of Athens, Greece

LCA of SA bioprocess

Gabi software from PE International

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Agricultural University of Athens, Greece

Environmental Impact UNITS GWP 6.33 kg‐CO2 Eq/kg of SA produced ADP (MJ) 136.06 MJ /kg of SA produced Energy Demand (MJ) 155.22 MJ /kg of SA produced

Identification of “hot spots”: SA Production and Recovery

0,00% 20,00% 40,00% 60,00% 80,00% 100,00% 120,00%

Activated Carbon Carbon Dioxide Requirements for fermentation Process steam for evaporation Process steam for sterilisation Regenaration of Resins with sulphuric acid Power for Agitation in the fermentor New resin for downstream process Total of SA Primary energy demand from ren. and non ren. resources (gross cal. value) MJ CML2001 ‐ Apr. 2015, Abiotic Depletion (ADP fossil) MJ GWP (100 years), excl biogenic carbon kg‐CO2 eq Abiotic resource depletion includes depletion of nonrenewable resources, i.e. fossil fuels, metals and minerals. Global warming potential (GWP) is calculated as a sum of emissions of the greenhouse gases (CO2, N2O, CH4 and VOCs)

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Agricultural University of Athens, Greece

Main Conclusions & Future recommendations

  • SSL is a by-product of the pulp and paper industry that can be used as a

substrate in microbial fermentations

– Needs to be pretreated first (remove the inhibitors) – Extract LS by nanofiltration – Extract phenolic compounds by solvent extraction

  • Succinic acid can be produced in high yields and adequate productivities

and final SA concentrations

  • Techno-economic evaluation gave a higher TPC of SA from current SA

costs

– 5.3 instead of 2.9 $/kg – Under the same order of magnitude – Scale up designs (21050 ktons) will significantly decrease the TPC

  • The carbon footprint of the SA process showed a 6.3 kg-CO2 Eq./kg-SA

– Mainly due to the downstream process – The LCA results will be compared with petrochemical SA production

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Agricultural University of Athens, Greece

The AUA team

Thank you for your attention

The research leading to these results has received funding from the European Union’s Seventh Framework Program for research, technological development and demonstration under grant agreement no 311935

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Agricultural University of Athens, Greece

Phenolic compounds

Determination of the main phenolic compounds in the extracts by HPLC ‐ DAD

Phenolic compound (mg/L) pH =2 ratio 1:3 v/v pH =3.4 ratio 1:3 v/v Gallic acid 1038 525 Isorhamnetin 41 21 Syringic acid 252 106 Syringaldehyde 32 127 Vanillic acid 50 17.8 Acetosyringone 16 ‐ Lariciresinol 142 ‐ Ellagic acid 1165.5 534 Caffeic acid 3.2 4 Vanillin 115 120 Catechin 127.6 53