Assessment of Conversion Technologies for Bioalcohol Fuel ...

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SEKAB Group, Ormskoldsvik, Sweden Organizational Background–SEKAB Group, newly-reorganized in 2006, is a Swedish industrial consortium consisting of the following four established and new companies: SEKAB E-Technology -- research and development of industrial processes for cellulose-based biofuels in biorefineries SEKAB Industrial Development -- industrial development and construction of ethanol production facilities SEKAB International Project -- organization for international investment in production plants SEKAB BioFuels & Chemicals -- provision, refinement and marketing of bioethanol as fuel and chemicals SEKAB BioFuels and Chemicals (formerly Svensk Etanolkemi AB) is one of the largest existing producers of ethanol in Northern Europe. SEKAB E-Technology (formerly Etek Etanolteknik AB) has, since 1999, pursued development of biochemical processes for producing ethanol from cellulosic biomass materials. Since 2004, the company has operated a pilot facility in Ornskodsvik to test these processes, in cooperation with several Swedish universities and research institutes. Technology Characteristics– SEKAB’s biomass-to-ethanol technology development (begun as Etek), has involved both a dilute acid hydrolysis process and an enzymatic hydrolysis process. The technology is based on hydrolyzing the cellulose and hemicellulose, whereupon the sugar is fermented to ethanol, which is then distilled. In weak acid hydrolysis, sulfuric acid or sulfur dioxide is used as a catalyst at temperatures of around 200ºC. In enzymatic hydrolysis, the material is first treated with a mild weak acid hydrolysis after which enzymes hydrolyze the remaining cellulose in a third stage. Development Status–Both the weak acid and enzymatic processes are currently being evaluated at SEKAB’s pilot plant, which has a capacity of 300-400 liters of ethanol per day using 2,000 kilograms (dry weight) of feedstock. The initial feedstock tested has been fir wood chips. The plant is said to be extremely flexible with significant feedback possibilities in the process flow. In the four fomenters, it is possible to ferment with fed-batch or continuous technology. SEKAB’s pilot facility is said to operate 24 hours per day, and the project has a total staff of about 20 people. Air emissions and wastewater effluents have reportedly been measured, with energy balance determinations in process. Project staff members have delivered various technical papers and presentations on their technology development, including at the Sixteenth International Symposium on Alcohol Fuels in Rio de Janeiro, Brazil in November 2006. Future Development Plans–In parallel with operation of its pilot facility, SEKAB is planning a larger demonstration and reference plant in the northern part of Sweden, 98
construction of which could begin in 2007. The company is also studying two more biorefineries having an ethanol capacity 500 to 700 times higher than the existing pilot facility. Other products besides ethanol will be produced at these biorefineries: electricity, lignin pellets, district heating, and high-grade chemicals. Testing of other feedstocks besides fir wood chips is also planned. SEKAB sees its current development activities as steps in a sequence of long-term industrial investment in cellulose-based ethanol and the international development of production plants. The aim is to develop an industrial structure for providing knowledge and equipment and for building production plants in Sweden and the rest of the world. Iogen Corp., Ottawa, Ontario, Canada Organizational Background–Iogen Corporation was established in 1974 with three employees (then Iotech Corp.) as a commercial manufacturer of enzymes for use in industries such as pulp and paper, textiles, and animal feeds. Today, the company operates a 30,000 square feet enzyme manufacturing plant and employs nearly 200 people. For most of its history, Iogen has also been pursuing biomass-to-ethanol production technology, based on the company’s own development of special enzymes for converting cellulosic materials into sugars. Iogen’s supporting partners for its biomass-to-ethanol process development have included the Canadian Government, Goldman Sachs and Co., Petro Canada, and the Royal Dutch/Shell Group, which owns a 22 percent equity share of Iogen. The company has been seeking to build upon experience achieved with its existing biomass-to-ethanol demonstration facility in Otawa and construct a “commercial prototype” plant. In February 2007, Iogen received a U.S. DOE grant of up to $80 million to co-fund such a project in the State of Idaho. Technology Characteristics– Iogen’s patented technology, shown in Figure A16, incorporates a multi-stage enzymatic hydrolysis process. Four steps are involved in the complete biomass-to-ethanol production process, described as follows: (1) Feedstock Pretreatment–using a modified steam explosion process to increase the surface area of the biomass feedstock accessible to the enzymes (2) Enzyme Production–high-eficiency enzymes are made using Iogen’s proprietary technology for use in the hydrolysis step (3) Enzymatic Hydrolysis–using a multi-stage process in an Iogen-developed reactor, Iogen’s celulase enzymes convert the celulosic material to glucose sugars (4) Ethanol Fermentation and Distillation–fermentation is done using recombinant yeasts and microbes tailored to Iogen’s specific process. Lignin byproduct, said to have 80 percent of the energy content of common coal, is also produced in the process for use as boiler fuel. Iogen’s process is said to produce about 340 liters of ethanol and 250 kilograms of lignin per tonne of fibrous cellulosic feedstock processed. To date, Iogen’s main focus has been on processing of wheat straw, a common agricultural residue in the Ontario region. Other cereal grain straws, such as oat and barley straw are also adaptable, and various other potential feedstocks of interest include corn stover, switchgrass, miscanthus, sugarcane 99
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Northern California Rice field Asse
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APPENDIX 1. TECHNOLOGY DEVELOPER PR
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LIST OF TABLES Table 1-Categories o
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INTRODUCTION The State of Californi
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EXECUTIVE SUMMARY This report provi
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distributed production of bioalcoho
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from corn, sugarcane and other suga
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Table 1-Categories of Biomass Conve
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SECTION 2 - PAST CALIFORNIA BIOMASS
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the technological approach was too
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conversion technology at NREL, prep
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will use matching funds from the U.
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Report: Feasibility Study for Rice
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Environmental issues Market issues
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Presentation: Collins Pine Cogenera
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Syngas Production The thermochemica
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Alcohol Synthesis The direct synthe
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SECTION 4 - BIOCHEMICAL TECHNOLOGIE
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Feedstock Pretreatment There are a
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Achieving such cost reductions woul
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Another novel approach to bioalcoho
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have been run for a sufficient time
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concerns. This evaluation determine
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The data in Table 5 are based upon
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Thermochemical System (Electricity)
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SECTION 8 - OPPORTUNITIES AND CHALL
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Page 55 and 56: The above CEC and CBC inventories o
Page 57 and 58: Economic and Institutional Challeng
Page 59 and 60: SECTION 9 - GOVERNMENT ROLES AND IN
Page 61 and 62: SECTION 10 - CONCLUSIONS AND RECOMM
Page 63 and 64: initial attractive application may
Page 65 and 66: SECTION 11 - REFERENCES Barrett, J.
Page 67 and 68: Collaborative, California Energy Co
Page 69 and 70: CATEGORY 1-THERMOCHEMICAL PROCESSES
Page 71 and 72: and CO at the compression stage. Th
Page 73 and 74: Range Fuels, Inc., Denver, Colorado
Page 75 and 76: CATEGORY II-THERMOCHEMICAL PROCESSE
Page 77 and 78: Figure A4. Enerkem Process Diagram
Page 79 and 80: The slag leaves the gasifier and is
Page 81 and 82: Figure A6. Thermogenics, Inc., Tech
Page 83 and 84: CATEGORY VIII-BIOCHEMICAL PROCESSES
Page 85 and 86: Figure A8. BlueFire Arkenol Technol
Page 87 and 88: Figure A9. BEI Process Celunol Corp
Page 89 and 90: support systems and using the conve
Page 91 and 92: several years ago, HFTA has been wi
Page 93 and 94: Figure A11. Losonoco Wood-to-Ethano
Page 95 and 96: OxyNol process. TVA is decommission
Page 97 and 98: Technology Characteristics-The biom
Page 99 and 100: Figure A14. PEC Biomass-to-Ethanol
Page 101 and 102: CATEGORY IX - BIOCHEMICAL PROCESSES
Page 103: Richland Washington, with U.S. DOE
Page 107 and 108: Figure A16. Iogen Biomass-to-Ethano
Page 109 and 110: commercialize a biomass-to-ethanol
Page 111 and 112: developed by CBE, is used to separa
Page 113 and 114: Figure A19. DuPont Process BioGasol
Page 115 and 116: Technology Characteristics-The Swan
Page 117 and 118: CATEGORY X-OTHER BIOLOGICAL PROCESS
Page 119 and 120: CATEGORY XI-INTEGRATED BIOREFINERY
Page 121 and 122: CATEGORY XII-FERMENTATION OF SYNGAS
Page 123 and 124: APPENDIX 2. CALIFORNIA ETHANOL PROD
Page 125: Proposed Advanced Technology (Cellu
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