1. Ethanol Production from Wastepaper Ben DaltonMarie Labrie Cassia DavisAlex Saputa John OzbekSteve Wild Murat Ozkaya4/15/09

2. Outline Project Purpose Project Purpose Assumptions Assumptions Process Flow Process Flow Pre-Treatment Pre-Treatment Saccharification & Fermentation Saccharification & Fermentation Distillation/Purification Distillation/Purification CO 2 /H 2 O Footprint CO 2 /H 2 O Footprint Economics Economics Summary Summary

3. Project Purpose Design a facility that converts wastepaper into ethanol.

4. Assumptions 100 Tons of Waste Paper per Day 100 Tons of Waste Paper per Day Waste Paper Contains 50% Cellulose Waste Paper Contains 50% Cellulose Target Purity: 99.5wt% Ethanol Target Purity: 99.5wt% Ethanol

5. PAPER PRE-TREATMENT WATER YEAST & ENZYME PRODUCTION SACCHARIFICATION & FERMENTATION PURIFICATION Ethanol

6. Pulp Preparation

7. Enzymes-What are they? Proteins that catalyze reactions (increase the rate of) Proteins that catalyze reactions (increase the rate of) Like catalysts, enzymes work by lowering the activation energy for a reaction. This dramatically increases the rate of the reaction. Like catalysts, enzymes work by lowering the activation energy for a reaction. This dramatically increases the rate of the reaction.

8. Breaking up Cellulase (Saccharification) Breaking up cellulose requires three enzymes collectively called cellulases Breaking up cellulose requires three enzymes collectively called cellulases

9. How Do You Produce Enzymes? Trichoderma reesei (yeast) Trichoderma reesei (yeast) Secretes cellulases Secretes cellulases One of the most powerful secretors of cellulases known to date One of the most powerful secretors of cellulases known to date

10. + Producing Enzymes Yeast Pre-Culture 190 gal 30 °C Yeast Enzyme Production Culture 4,800 gal 30 °C Yeast Water Nutrients Water Nutrients 2,400 gal/day Enzyme 160 gal/day Mixture

11. Non-Isothermal Continuous Saccharification and Fermentation (NCSF) CO 2 Yeast Enzyme EthanolSlurry Enzymatic Hydrolysis Fermentation

12. NCSF Material Balance 20 Tons CO 2 Yeast Enzyme 400 Tons H 2 O 50 Tons Cellulose 50 Tons Lignin 40ºC45ºC50ºC35ºC30ºC 400 Tons H 2 O 21 Tons Cellulose 50 Tons Lignin

13. NCSF Energy Balance 40ºC45ºC50ºC35ºC30ºC 24.3 MBtu/Day 13.1 MBtu/Day Cooling H 2 O HPS 13.5 MBtu/Day 13.9 MBtu/Day 14.3 MBtu/Day

14. NCSF Reactor System Design 81 % Conversion to Ethanol in 25 Hours Tank Volume = 8,000 gal

15. Distillation & Purification

16. Distillation: Material Balance FEED F= 420 tons/day X F = 0.050 wt% EtOH f= -0.102 DISTILLATE D= 23 tons/day X D = 0.906 wt% EtOH BOTTOMS B= 400 tons/day X B = 3x10 -4 wt% EtOH

17. Distillation: Condenser Duty CONDENSER Q C = 110 MBTU/day A HT = 2080 ft 2 Agent HT = Cooling Water QCQC VL

18. Distillation: Reboiler Duty VL QRQR REBOILER Q R = 195 MBTU/day A HT = 2860 ft 2 Agent HT = HPS

19. Distillation: McCabe Thiele Method

20. Distillation: Column Specifications 11 ft Sieve tray 2 ft1 stage 40 ft 20 stages

21. Column Height = 60 ft Packing Diameter = 3.0 ft Packing Height = 50 ft Sieve Dimensions

22. 23 Total Tons / Day 21 Tons EtOH + 2 Tons H 2 O ~21 Tons EtOH Adsorption Phase 11 Tons Synthetic Zeolite

23. Regeneration Phase 7.1 MBtu/Day 6 Tons CO 2 / Day ~ 6 Tons Hot CO 2 + 2 Tons H 2 O Vapor Per Day 11 Tons Synthetic Zeolite

24. Waste Utilization Steam Boiler Lignin 720 MBtu/Day High-Pressure Steam 520 MBtu/Day ***120 tons of CO 2 released per day

25. CO 2 Footprint CO 2 emissions require an operating permit…… CO 2 emissions require an operating permit…… Papernol Papernol Produces 55,000 tons CO 2 /year

26. H 2 O Footprint In the near future fresh water use will be as regulated as CO 2 emissions…….. In the near future fresh water use will be as regulated as CO 2 emissions…….. Grey Water Papernol Plant Uses 7,000 tons/year Papernol

27. Economic Analysis Capital Costs Equipment Cost = $4.4M Plant Heuristic x (2.4) Total Capital Cost = $10.5M

28. Annualized Capital Cost

29. Annual Operating Costs Wastepaper Water Enzyme & Yeast Nutrients Electricity Cooling Total Operating Cost $300K $200K $33K $1.3M $1.4M $21K $3.8M

30. Production Costs Annualized Capital Cost Annual Operating Cost Annual Production Production Cost $2.4M $3.8M 2.3M Gal $2.70/Gal

31. Energy Papernol Plant 1,300 MBtu/Day 500 MBtu/Day

32. Summary Project Purpose Project Purpose Assumptions Assumptions Process Flow Process Flow Pre-Treatment Pre-Treatment Saccharification & Fermentation Saccharification & Fermentation Distillation/Purification Distillation/Purification CO 2 /H 2 O Footprint CO 2 /H 2 O Footprint Economics Economics

33. Conclusion This design project is not economically feasible due to current market conditions. This design project is not economically feasible due to current market conditions. Future technology advances may lower production costs. Future technology advances may lower production costs.