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Escolha uma restrição e apague as outrasUso Exclusivo do(a) CTC ou Associada ou ÁreaUso Exclusivo das Associadas ao CTCDivulgação Livre
Fermentation Process Fermentation Process IntensificationIntensification
Daniel Ibraim Pires Atala
CTC – Centro de Tecnologia Canavieira (Sugarcane Technology Center)
Process IntensificationProcess Intensification
– Colin Ramshawis widely acknowledged as a pioneer in the field of Process Intensification
– Its objective was the development of chemical plants much smaller (intensification) and therefore cheaper than the existing
– Ramshawignored the existing equipment and started from beginning.
Process IntensificationProcess Intensification– In Bioprocesses:
• Reduces energy consumption; • Increases the bioconversion rates; • Decreases the production of waste; • Improves the step of purification; • Decreases the size of equipment;
Increases the Company Sustainability
– The study about processes intensification requires a wide and meticulous knowledge of all phenomena involved.
Fermentation Process Intensification Fermentation Process Intensification in BioEthanol Productionin BioEthanol Production
TimelineTimeline
• The evolution of Brazilian Ethanol Production
Melle-Boinot
First Continuous
Fermentation Process
Continuous Reactor
connected in series ?
1975 1980 1990 Future
Continuous Vacuum Extractive Process
– The ethanol is removed while it is produced;
– The ethanol concentration remains at low levels in the Fermentor;
– It reduces significantly the inhibition by ethanol concentration;
– The yeast becomes more productive due to low ethanol concentration in the medium.
PrinciplePrinciple
• Liquid -Vapor Equilibrium Data (LVE) at 33°C
20
30
40
50
60
70
80
90
100
0 0.2 0.4 0.6 0.8 1
x,y
P [
mm
Hg
]
PrinciplePrinciple
• Liquid -Vapor Equilibrium Data (LVE) at 33°C
0
25
50
75
100
125
150
175
200
225
0 100 200 300 400 500 600 700 800
Conc [g/L]
P [
mm
Hg
]
20°C
33°C
50°C
The kinetics of fermentationThe kinetics of fermentation
• From kinetic models with inhibition
00,1
0,20,3
0,40,50,6
0,70,8
0,91
0 20 40 60 80 100 120 140
Ethanol [g/L]
Inh
ibit
ion
Fac
tor
)exp(11 SKiXm
X
Pm
P
SKs
Smn
O⋅−⋅
−⋅
−⋅
+⋅= µµ
n
Pm
PIF
−= 1
Pm=140 g/L
n=2.0 (red)
n=1.0 (dark)
Vacuum Flash TankVacuum Flash Tank
• Principle of Operation
FL , xI
TL , PL , HL
FV , yI
TV , PV , HV
FE , zI
TE , PE , HE
Válvula
Líquido
Vapor
Prototype DevelopedPrototype Developed
Prototype DevelopedPrototype Developed
Laboratory Scale
Unicamp
Experimental TrialsExperimental Trials
• Sucrose, glucose, fructose, TSR, RT
0
20
40
60
80
100
120
140
160
0 50 100 150 200 250 300 350 400
Time (h)
Con
cent
ratio
n (g
/L)
0
2
4
6
8
10
12
Res
iden
ce T
ime
(h)
Sucrose
Glucose
Fructose
TSR
RT
Experimental TrialsExperimental Trials
• Ethanol
0
20
40
60
80
100
120
140
160
0 50 100 150 200 250 300 350 400
Time (h)
Con
cent
ratio
n (g
/L)
300
350
400
450
500
Eto
l-Con
d (°G
L)
TSR
Ethanol-Ferm
Ethanol-Cond
Experimental TrialsExperimental Trials
• General Overview
0
20
40
60
80
100
120
140
160
0 50 100 150 200 250 300 350 400
Time (h)
Eth
anol
, TS
R, P
rodu
ctiv
ity
0
2
4
6
8
10
12
14
Bio
mas
s, G
lyce
rol
Etol-Ferm (g/L)
Prod (g/L/h)
Etol-Cond (°GL)
ART
Glycerol (g/L)
Biomass (%v/v)
Experimental TrialsExperimental Trials
• Conversion, Yield and Residence Time
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
0 50 100 150 200 250 300 350 400
Time (h)
Yps
, Con
vers
ion
0
5
10
15
20
25
30
35
40
45
50
Pro
duct
ivity
, Res
iden
ce T
ime
Yps
Conversion
Product. (g/L/h)
RT (h)
Positive AspectsPositive Aspects• The juice can be feed in the Fermentor at least 3 times more
concentrated;
• More productive process: at least 3 times;
• Reduction of vinasse (waste) production ;
• More compact and economical Plants;
• Reduction or Elimination of heat exchangers;
• Alcohol Production of 50°GL from vapor phase condensation implies in eliminating one distillation column.
• Equivalent to a traditional process with an alcohol content of 20° GL
Pilot Plant Pilot Plant –– PedraPedraMillMill
Process IntensificationProcess Intensification
Process IntensificationProcess IntensificationASPEN simulation
Process IntensificationProcess Intensification
Integrated with distillation unit
Process IntensificationProcess Intensification
AQUECVINHO
VINHO-AQ
A1
TOPO-A1
FUNDO-A1
TOPO-A
VINHACA
A
TOPO-D
COND-D
D
FLEGMA-L
TOPOD-FR
RECICLO
ALCOOL2
ALCOOL2A
GASES
SPLIT
FLASH
VAP2
FLEGMACAFUNDO-B
AEHC
FLASH2
REF-B
B-B1
VAP
VINHACA-
B2
H2O
P
Conventional distillation unit
Process IntensificationProcess IntensificationEnergy Balance
Vacuum Extractive fermentation Conventional process
Equipment Energy (MJ/h) Equipment Energy (MJ/h)
Heater2 10.0 Heater2 128.1
Column A reboiler 22.7 Column A reboiler 236.2
Column B reboiler 120.4 Column B Reboiler 149.0
Heater1 117.0 Evaporator 907.8
Total 270.1 Total 1421.1
Energy Savings 80%
Rethinking the process
New Challenges!
CTC Culture Collection
Biótipo - 1
Biótipo - 2
Biótipo - 3
Biótipo - 4
Over 1200 yeast strain
Over 700 bacteria strain
FAPESP – BIOEN
• The contributions of microwave energy and ultrasound in the improvement of ethanol industrial production process from sugarcane
– Prof. Dr. Antonio Marsaioli Junior (coordinator)
• GEPC/ITAL;
• CTC
FAPESP – BIOEN(PRONEX)
• An Integrated Process for Total BioethanolProduction and Zero CO2 Emission
– Prof. Dr. Rubens Maciel Filho (coordinator)
• FEQ/Unicamp;
• FEA/Unicamp;
• FURG;
• Unesp Araraquara
• CTC
An Integrated Process for Total BioethanolProduction and Zero CO2 Emission
Sugar
CaneExtraction Juice
Sugar
Production
Molasses
First
Generation
Bagasse
Second
Generation
Third
Generation
Algae
Third
Generation
Syngas
Distillation
Boiler
Straw
Thermal
Reactor
CO2
Carbohydrate
Fat acids
Protein
Vinasse
Syngas
Residue
Bioethanol
BiodigestionResidue
Methane
Nutrient
Biodiesel
Integrated Process for Total Bioethanol Production and Zero CO2 Emission
O2
Sugar
