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Process Integration in Biorefineries Lessons Learned from Pulp & Paper
1
Process Integration Jubilee Symposium By Christos Sarigiannidis csarigiannidis@americanprocess.com
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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
2
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Sugar is the New Crude®
3 CONFIDENTIAL MATERIAL
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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
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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
5
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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®
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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
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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
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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
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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
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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
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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
19
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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
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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
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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
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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
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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)
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