Making Biorefineries Competitive: PRO.E.SA TM The only sugar platform available today Guido Ghisolfi June 8, 2012.

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Presentation transcript:

Making Biorefineries Competitive: PRO.E.SA TM The only sugar platform available today Guido Ghisolfi June 8, 2012

Commercial-scale cellulosic ethanol plant, Q3 2012: 20 million gallons, Crescentino (13 to start) Cellulosic costs less No subsidies required Three points that will change the industry:

$3B per year #2 producer of PET Engineering Division Technology for biomass to sugars M&G Group: Biomass Technology & Experience

2006 – 2008 Scouting of technologies; Generation of key inventions; Proof of UNIT OPERATION in the labs – 2010 Pilot plant construction & start up (June 2009); Pilot plant operation and data gathering; Test of plant flexibility using multiple biomasses – 2012 Crescentino unit; Technology licensing. PRO.E.SA TM Technology Step by Step

Ready solution for industrial production of 2G Ethanol PRO.E.SA TM Technology BIOMASS C 5 Sugar C 6 Sugar Fermentation YEAST ETHANOL LIGNIN Separation ( Energy Generation) A Total Project Solution based on: 1.Agronomy: Field experimentation and best energy crops identified and characterized; 2.Biomass Pre-Treatment and Viscosity Reduction: Continuous process developed and piloted to produce cost-effective and clean fermentable sugars; 3.Hydrolysis and Fermentation: Unique hybrid SSCF process scheme yielding high ethanol concentrations. PRO.E.SA TM Technology

Crescentino Plant

PRO.E.SA TM Technology: From Biomass to Sugar Without use of chemicals; Optimizing C 5 and C 6 sugar extraction; Minimizing the formation of by-products/inhibitors; Using continuous equipment enabling design for large scale plant; Minimizing CAPEX and OPEX.

The Continuous Pilot Plant: How it operates… Biomass agnostic; No biomass drying / grinding required; Low level of inhibitor (lower then in P.O.C.); No use of chemicals (only steam is added); Reduced enzyme loads; Rapid liquefaction of the solid material; High solid concentration (>40%) in the hydrolysis step.

Biomass: Our Experience at Pilot Plant PRO.E.SA TM technology is flexible in feedstock supply: possibility to treat worldwide crops; Several biomasses were evaluated and tested as potential feedstock for the PRO.E.SA TM technology: Internal analysis according to Chemtex methods

Pre-Treatment Section: Biomass Type High feedstock flexibility Energy crops: Arundo donax (giant reed); Miscanthus giganteus; Panicum virgatum (switchgrass). Agricultural and industrial residues: Wheat straw; Rice straw; Sugarcane bagasse. Woody species: Eucalyptus; Poplar, Internal data tests at pilot scale Differences in yield (4 to 5 tons dry biomass/tons EtOH) index mainly depends on feedstock composition; It is possible to reduce the yield variability optimizing the process condition.

Hydrolysis and Fermentation High solid concentration enzymatic hydrolysis is needed to guarantee the economics of ethanol recovery through distillation Available solution M&G solution

LCA – Full Scale Projection E100Gasoline CO 2 emissions[g/km]15169 GHG emissions[g CO2 eq /km] % - 84% The lifecycle performances of bioethanol produced through Chemtex technology at a full industrial scale have also been estimated by means of the GREET model; Scale benefits will allow a further improvement of the bioethanol environmental profile.

Baseline Process Scheme 2G Bioethanol Plant Biomass THOSE INTERMEDIATES REPRESENT A STARTING POINT FOR A NEW GREEN CHEMISTRY BASED ON RENEWBLES PRO.E.SA™ PRO.E.SA™ M&G Lignocellulosic sugar technology C6 Sugars C5 Sugars By-product Lignin TECHNOLOGY IS READY! 2G BIOETHANOL

How to exploit PRO.E.SA TM Technology …? ETHANOLOGEN ENZYMES PRO.E.SA™ PRO.E.SA™ M&G Lignocellulosic sugar technology We can adapt the composition of the sugar stream to various fermentations: With / without lignin; Higher / lower sugar concentration; Free from inhibitory compounds.

How to exploit PRO.E.SA TM Technology BUTANOL GREEN DIESEL JET FUEL ETHANOL 1,4 BDO FATTY ALCOHOLS ADIPIC ACID ACETIC ACID PE EG PX THE BIOMASS SUGAR PLATFORM