Ethanol Recycle Paper Converting Waste Paper into Ethanol March 28, 2008

Outline  U.T.C. Engineering  Agricultural Comparison  Papernol Process Hydrolysis Fermentation Purification  Equipment Sizing and Cost  Full Scale Outlook

Freshman Design Heat & Mass Transfer Reactor Design Distillation Process design Unit Operations Senior Papernol Project Engineering Economics Thermodynamics Intro Chemical Process

UTC Papernol Team

How is Papernol Different?

Papernol Advantages  Converts Waste Stream to Revenue Stream  Resource from Local Community  Improves Local Economy  Minimal Transportation/Fuel Inputs  No Cropland Requirement

Acid Hydrolysis: Dilute acid to generate glucose from cellulose Fermentation: Convert Glucose into Ethanol Purification: Separate Ethanol from water Preparation and Hydrolysis FermentationPurification

Material Balances PAPER 10,000 lb/day EtOH 500 gal/day

Preparation (Basis 10,000 lb paper/Day) 10,000 lb paper 150,000 lb H 2 O 160,000 lb slurry *8,000 lb cellulose* Research: 7% paper water mixture 80% paper is cellulose

Hydrolysis (Basis 10,000 lb paper/Day) 62,000 lb steam 1600 lb H 2 SO 4 acid (98%) 230 lb steam 70% conversion 150,000 lb H 2 O *5600 lb glucose* 160,000 lb slurry 2,200 lb solid waste

Evaporation - Fermentation (Basis 10,000 lb paper/Day) 150,000 lb H 2 O *5600 lb glucose* 62,000 lb H 2 O *5600 lb glucose* 62,000 lb H 2 O *2850 lb EtOH* 2850 lb CO 2 330,000 lb CW 860 lb yeast 80,000 lb steam

Purification (Basis 10,000 lb paper/Day) 65,000 lb EtOH–H 2 O 2,800 lb EtOH 62,200 lb H 2 O 500 gal EtOH

Energy Balances Q IN = 49 million BTU/day Q PRODUCT = 38 million BTU/day Q ADDED = 210 million BTU/day Q LOST = 49 million BTU/day

Preparation 41,000 BTU/day 4.5 MM BTU/day 1.5 MM BTU/day Total Daily Electrical Energy ~6 MM BTU

Hydrolysis Q IN =50 MM BTU/day Q IN =185,000 BTU/day Q IN =13,000 BTU/day Total Daily Electrical Energy ~50.2 MM BTU

Evaporation - Fermentation Q OUT = 8 MM BTU/day Q IN =94 MM BTU/day

Purification Q IN = 66,000 BTU/day Q IN =60 MM BTU/day Q OUT = 41 MM BTU/day Q OUT = 223,000 BTU/day

Example of Sizing  Evaporator: Fxf = Lxl xf = current concentration xl = desired concentration L = F(xf/xl) = Liquid Exit Stream L/ρ H2O = Volume of Evaporator

Equipment Size and Cost EquipmentSize(ft 3 )QuantityTotal Cost($) Storage Hopper9832,100 Shredder ,000 Mixer ,000 Hydrolysis Tank ,600 Expansion Chamber1 Evaporator10011,500,000 Fermentation Vessel8004 Mixer fermentation 202 Distillation Column4001 Molecular Sieve2

Equipment Size and Cost EquipmentSize(ft 3 )QuantityTotal Cost($) Slurry Pump122,400 Slurry Heat Exchanger2500 ft ,000 Acid Heat Exchanger11 ft 2 13,000 ConveyorN/A222,000 Fermentation HE11001

Stages of Project Development Lab Proof of Concept Medium Small Demonstration Pilot Integrated Processing Full Scale Unit Orange Grove Center Lab Scale – Proof of Concept Currently in Progress at UTC Available Budget: $500 Restricted Testing Medium Scale: Small Demonstration Budget: $150,000 Tested Using UTC ENGR Labs Pilot Scale: Integrated Processing Utilize TVA/UTC Chickamauga Site Estimated Budget: $1,000,000 Orange Grove: Full Unit Skid-Mounted Modular Estimated budget: $3,000,000

Potential Orange Grove Site Process 10,000 lb Paper =500 gal of Ethanol per day => Three Tractor Trailers

Current Work Toward our Preliminary Design: Economics Environmental Aspects  (CO 2 foot print) Utility Costs

Papernol Outlook  Cannot resolve the US energy dilemma  Orange Grove = 500 gal/day max.  Adds value to Orange Grove  Competitive with Corn & Switchgrass  A Renewable Ethanol Source

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