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Ethanol Production from Wastepaper

Ethanol Production from Wastepaper. Ben Dalton Marie Labrie Cassia Davis Alex Saputa John Ozbek Steve Wild Murat Ozkaya 4/15/09. Outline. Project Purpose Assumptions Process Flow Pre-Treatment Saccharification & Fermentation Distillation/Purification CO 2 /H 2 O Footprint

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Ethanol Production from Wastepaper

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  1. Ethanol Production from Wastepaper Ben Dalton Marie Labrie Cassia Davis Alex Saputa John Ozbek Steve Wild Murat Ozkaya 4/15/09

  2. Outline • Project Purpose • Assumptions • Process Flow • Pre-Treatment • Saccharification & Fermentation • Distillation/Purification • CO2/H2O Footprint • Economics • Summary

  3. Project Purpose Design a facility that converts wastepaper into ethanol.

  4. Assumptions • 100 Tons of Waste Paper per Day • Waste Paper Contains 50% Cellulose • Target Purity: 99.5wt% Ethanol

  5. WATER PAPER PRE-TREATMENT PURIFICATION YEAST & ENZYME PRODUCTION Ethanol SACCHARIFICATION & FERMENTATION

  6. Pulp Preparation

  7. Enzymes-What are they? • Proteins that catalyze reactions (increase the rate of) • Like catalysts, enzymes work by lowering the activation energy for a reaction. This dramatically increases the rate of the reaction.

  8. Breaking up Cellulase (Saccharification) • Breaking up cellulose requires three enzymes collectively called cellulases

  9. How Do You Produce Enzymes? • Trichoderma reesei (yeast) • Secretes cellulases • One of the most powerful secretors of cellulases known to date

  10. + Producing Enzymes Water Yeast Nutrients Water Nutrients Yeast Enzyme Production Culture 4,800 gal 30 °C 160 gal/day Mixture 2,400 gal/day Enzyme Yeast Pre-Culture 190 gal 30 °C

  11. Non-Isothermal Continuous Saccharification and Fermentation (NCSF) Enzyme CO2 Slurry Ethanol Yeast Enzymatic Hydrolysis Fermentation

  12. NCSF Material Balance Enzyme 20 Tons CO2 400 Tons H2O 50 Tons Cellulose 50 Tons Lignin 400 Tons H2O 21 Tons Cellulose 50 Tons Lignin 50ºC 45ºC 40ºC 35ºC 30ºC Yeast

  13. NCSF Energy Balance 13.1 MBtu/Day 13.5 MBtu/Day 13.9 MBtu/Day 14.3 MBtu/Day 50ºC 45ºC 40ºC 35ºC 30ºC Cooling H2O 24.3 MBtu/Day HPS

  14. NCSF Reactor System Design 81 % Conversion to Ethanol in 25 Hours Tank Volume = 8,000 gal

  15. Distillation & Purification

  16. Distillation: Material Balance DISTILLATE D= 23 tons/day XD= 0.906 wt% EtOH FEED F= 420 tons/day XF= 0.050 wt% EtOH f= -0.102 BOTTOMS B= 400 tons/day XB= 3x10-4 wt% EtOH

  17. Distillation: Condenser Duty QC CONDENSER QC= 110 MBTU/day AHT= 2080 ft2 AgentHT= Cooling Water V L

  18. Distillation: Reboiler Duty V L REBOILER QR= 195 MBTU/day AHT= 2860 ft2 AgentHT= HPS QR

  19. Distillation: McCabe Thiele Method

  20. Distillation: Column Specifications Sieve tray 1 stage 2 ft 40 ft 20 stages 11 ft

  21. Sieve Dimensions Column Height = 60 ft Packing Diameter = 3.0 ft Packing Height = 50 ft

  22. Adsorption Phase 23 Total Tons / Day 21 Tons EtOH + 2 Tons H2O 11 Tons Synthetic Zeolite ~21 Tons EtOH

  23. Regeneration Phase ~ 6 Tons Hot CO2 + 2 Tons H2O Vapor Per Day 11 Tons Synthetic Zeolite 6 Tons CO2/ Day 7.1 MBtu/Day

  24. Waste Utilization Steam Boiler Lignin 720 MBtu/Day High-Pressure Steam 520 MBtu/Day ***120 tons of CO2 released per day

  25. CO2 Footprint • CO2 emissions require an operating permit…… Papernol Produces 55,000 tons CO2/year Papernol

  26. H2O Footprint • In the near future fresh water use will be as regulated as CO2 emissions…….. Papernol Papernol Plant Uses 7,000 tons/year Grey Water

  27. Economic AnalysisCapital Costs Equipment Cost = $4.4M Plant Heuristic x (2.4) Total Capital Cost = $10.5M

  28. Annualized Capital Cost

  29. Annual Operating Costs • Wastepaper • Water • Enzyme & Yeast • Nutrients • Electricity • Cooling • Total Operating Cost $300K $200K $33K $1.3M $1.4M $21K $3.8M

  30. Production Costs $2.4M $3.8M 2.3M Gal $2.70/Gal • Annualized Capital Cost • Annual Operating Cost • Annual Production • Production Cost

  31. Energy Papernol Plant 1,300 MBtu/Day 500 MBtu/Day

  32. Summary • Project Purpose • Assumptions • Process Flow • Pre-Treatment • Saccharification & Fermentation • Distillation/Purification • CO2/H2O Footprint • Economics

  33. Conclusion • This design project is not economically feasible due to current market conditions. • Future technology advances may lower production costs.

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