Introduction to a Disruptive Bio-butanol Technology

Transcription

1 BIT s 3rd Annual World Congress of Bioenergy-2013 Nanjang, China, April Introduction to a Disruptive Bio-butanol Technology Alex Tong Vice President and General Director GEL/ ITRI Copyright 2013 ITRI 工業技術研究院 1

2 Introduction to ITRI Non-profit research organization with more than 6,000 researchers generating over 1,000 US patents a year Global leading organization in developing new businesses and technologies Won six R&D 100 Awards in 2012 Copyright 2012 ITRI 工業技術研究院 2

3 Market in need of Advanced Bio-fuel US Renewable Fuel Standard (RFS) caps corn ethanol at 15 bgy due to limited GHG reduction (~20%) EU Renewable Energy Directives (RED) requires GHG Savings >35%, and 50-60% by 2017 GHG reduction requirement Advanced Biofuel: 50% Cellulosic Biofuel: 60% Copyright 2012 ITRI 工業技術研究院 3

4 Advanced Bio-fuels Still in Small-Scale Trial Cellulosic ethanol stalled at the moment US Actual production significantly below allotment: 8.65 Mgal vs. 500 Mgal in 2012 Gevo cut back its iso-butanol production and instead produced more ethanol on its demo plant in Luverne, Minnesota Copyright 2012 ITRI 工業技術研究院 4

5 ITRI s Solution ButyFix --Highest carbon yield worldwide-- Lignocellulose Pretreatment Sugars Butyric Product Butanol Fermentation Hydrolysis Acid Recovery Hydrolysis Eco-solvent: lower processing cost High reaction rate: lower equipment cost Mild operation condition: less energy consumption Fermentation No CO 2 release : fully-utilized feedstock and better GHG reduction Immobilized cell: easy to operate and reduce pre-culture cost C5 and C6 sugars fermentable: lignocellulose feedstock Less heat and gas generation: easy to scale-up Copyright 2012 ITRI 工業技術研究院 5

6 Challenges of Lignocellulose Pretreatment Cellulose (38-50%) Extend of reaction Inhibitor formation Lignin degradation Detoxification needed Wastewater treatment Reactor design for high loading Lignin (15-25%) Hemicellulose (23-32%) Pretreatment/ Conditioning Cellulose & Lignin (Solid Phase) Hydrolysis C5 Sugars solution (mainly from hemicellulose) Feedstock selective Enzyme Slow reaction Sugar yield Lignin suspend in the solution ~10% sugar syrup result in ~5% EtOH Fermentation Fermentation Copyright 2012 ITRI 工業技術研究院 6

7 Challenges of Enzymatic Hydrolysis Process Require different pretreatment for different feedstock Control of cellulose de-crystallization and lignin degradation Enzyme activity and Inhibitors (HMF, FF, Phenol) Pretreatment Hydrolysis Xylose Glucan Glucose Xylose Cellulase Enzyme Active site Typical composition of biomass Component Percent Dry Weight Glucan Lignin Glucan Cellulose 40-60% Hemicellulose 20-40% Lignin 10-25% Lignin Enzyme Active site Copyright 2012 ITRI 工業技術研究院 7

8 ITRI s Eco-Solvent Process Eco-solvent: lower processing cost Homogeneous reaction: high reaction rate and lower equipment cost Mild operation condition: less energy consumption Esterification RCOOH + heat, metal salt cat. Soluble + H 2 O The crystalline structure of cellulose is destroyed by forming soluble ester Hydrolysis + RCOOH Using organic acid to hydrolyze ester to glucose Copyright 2012 ITRI 工業技術研究院 8

9 Typical Experiment Results 10 wt.% of microcrystalline cellulose tested Hydroxymethylfurfural (HMF) concentration lower than 0.03 g/l Total sugar yield determined by using 3,5-dinitrosalicylic acid (DNS) method (a) (b) Optical microscope images of cellulose (100x): (a) before dissolving, (b) after dissolving Cellulose in ionic solution (II) Ionic solution Metal salt /organic acid Esterification Temp. ( ) Time (hr) Water content (%) Hydrolysis Temp. ( ) Time Total sugar yield (wt.%) (hr) Copyright 2012 ITRI 工業技術研究院 9

10 Benchmarking of Hydrolysis Tech. Advantages of ITRI hydrolysis technology: Fast hydrolysis High total sugar yield >95% (including sugar oligomers) Low cost of pretreatment Items Enzyme hydrolysis H 2 SO 4 hydrolysis HCl hydrolysis Biomass 17% corn stover 14.6% straw 10% wood Pretreatment Hydrolysis 6% H 2 SO 4 (aq), 6 atm, 158, 3~7 min 70% H 2 SO 4 (aq), 1 20 mg protein/g cellulose, 48, reaction time 84 hr atm, 60-80, 1 min 43% H 2 SO 4, , total reaction time 2-6 hr 39% HCl(aq), 1 atm, 20-50, reaction time 8-16 hr ITRI Ionic Solution 10% sugarcane bagasse Salt/organic acid, 1 atm, 55, 3 hr 100, reaction time~2hr Total Products sugar >90% 95% 3 Yield Glucose 2 86% 70-80% >50% 68% Xylose 2 80% 60-70% 90% 83% 1. Wt%. 2. Mole% 3. Theoretical yield 111 wt%, ex.: glucan glucose, 180/162=111% Copyright 2012 ITRI 工業技術研究院 10

11 Fermentation Proprietary technology fixes carbon in the product during fermentation World-leading carbon conversion efficiency to butyrate 94% from glucose 61% from xylose Regulation of metabolic pathway Copyright 2012 ITRI 工業技術研究院 11

12 Carbon Fixation 13 C 13 C Lactate Pyruvate 12 C-acetate 13 CO 2 13 C-acetate Acetate Acetyl-CoA Butyrate 12 C-butyrate H m/e = C-butyrate Copyright 2012 ITRI 工業技術研究院 12

13 World-Leading Yield 30% increase in solvent yield over cutting-edge technology Butyrate/Butanol Carbon yield (%) Solvent Yield (g/g-sugar) Current Status Theoretical Maximum Reference ITRI UCLA UCB OSU 94% 0.70 g Butyrate 57% 0.35 g-butanol 45% 0.28 g-butanol 62% 0.50 g-butyrate 100% 67% Nature, % Nat Chem Biol., % DOE Program Commercial ABE Process 34% 0.21 g-butanol 67% Current Opinion in Biotech., 2011 Copyright 2012 ITRI 工業技術研究院 13

14 Enable Technology to Meet RFS2 GHG emissions (g CO 2 eq./mj) GHG Reduction 71 (24.3%) 57.6 (38.6%) Gasoline Fuel Distribution Conversion Feedstock transport Feedstock Production -1.3 (101.4%) -20 Ref: 1. M. Q. Wang et al., biomass and bioenergy, 2011, 35, M. Q. Wang et al., The Lifecycle Carbon Footprint of Biofuels, Proceedings of a conference January 29, 2008, in Miami Beach, FL. 3. J. Sheehan et al., 2003, V.7, No. 3 4, 117. Copyright 2012 ITRI 工業技術研究院 Gasoline Corn EtOH ITRI Corn BuOH ITRI Cellulosic BuOH 14

15 Levelized Cost ($/GJ) Cost Projection Corn: $6.5/Bu (25.6 cent/kg) Corn stalk: 6.45 cent/kg Operation Capital cost Feedstock cost 0 Corn EtOH ITRI Corn BuOH ITRI Cellulosic BuOH Copyright 2012 ITRI 工業技術研究院 15

16 Value Proposition 1. Reference: SRI PEP Report, Capacity: 150,000 MT/y 3. Project life: 20 yrs 4. Ethanol price 2.5 $/gal, Butanol price $/gal,plant life 20yrs, Federal tax 35%, 200% declining balance 5. Interest: 1% Copyright 2012 ITRI 工業技術研究院 16

17 Summary The mega trend in biofuel development is on non-food feedstock, improved GHG savings and drop-in fuel quality; Cost competitiveness against petro-fuel is the ultimate goal. None of cellulosic bio-fuel facilities have reached healthy operation at the moment. ITRI proprietary ButyFix technology, with world-leading carbon conversion efficiency, can be a winner. Copyright 2012 ITRI 工業技術研究院 17

18 Thank you for your attention Copyright 2012 ITRI 工業技術研究院

19 Backup Slides Copyright 2013 ITRI 工業技術研究院 19

20 Cost Estimation Baseline Baseline: Capacity:150,000 metric ton/a Butyric acid conc. In fermentor:5 wt% Carbon yield from glucose to butyric:94.0% Carbon yield from C5 sugar to butyric:61.0% Butyric yield ( kg butyric/ kg sugar) :0.70 (corn), 0.61 (corn stover) Fermentation time:6.6 hrs/batch Yield of Methyl Butyrate:98 mole% Yield of Butanol via hydrogenation:99 mole% Aspen plus simulation based on cost in 2012 dollar Corn Butanol Process Starch content:62 wt% Sugar yield:1.103 kg sugar/kg starch Ref: SRI PEP Report 149A (2008) Copyright 2012 ITRI 工業技術研究院 Corn-stover Butanol Process Corn stover:cellulose 50.3wt%, Hemicellulose 24.4 wt%,lignin 19.7wt% Hydrolysis yield:cellulose 90wt%, Hemicellulose 90 wt% (Total sugar yield: 0.67kg sugars/kg stover) Corn stover in hydrolysis tank:20 wt% Butyric yield from sugars:61wt% Lignin combustion for steam generation 20