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Anaerobic Fermentation of Glycerol to Ethanol

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Anaerobic Fermentation of Glycerol to Ethanol University of Pennsylvania ScholarlyCommons Department of Chemical & Biomolecular Senior Design Reports (CBE) Engineering 4-14-2009 Anaerobic Fermentation of Glycerol to Ethanol Chloe LeGendre University of Pennsylvania Eric Logan University of Pennsylvania Jordan Mendel University of Pennsylvania Tamara Seedial University of Pennsylvania Follow this and additional works at: https://repository.upenn.edu/cbe_sdr Part of the Chemical Engineering Commons LeGendre, Chloe; Logan, Eric; Mendel, Jordan; and Seedial, Tamara, "Anaerobic Fermentation of Glycerol to Ethanol" (2009). Senior Design Reports (CBE). 5. https://repository.upenn.edu/cbe_sdr/5 This paper is posted at ScholarlyCommons. https://repository.upenn.edu/cbe_sdr/5 For more information, please contact [email protected]. Anaerobic Fermentation of Glycerol to Ethanol Abstract The purpose of this design project is to examine the plant-scale economic viability of the anaerobic fermentation of crude glycerol to ethanol by a hypothetical wild strain of Escherichia coli. The manufactured ethanol, before being denatured with gasoline, has a purity requirement of 99.5% by weight. The capacity of the ethanol plant, as suggested by the problem statement, is 50 MM gallons per year. The process uses crude glycerol (a waste byproduct from the biodiesel industry) as a primary feedstock, so the manufactured ethanol can be considered a “green” or renewable fuel source. The process energy requirements must meet the current energy benchmark of 35,000 BTU/gallon of ethanol, typical for a modern corn-to-ethanol process of this scale according to the design problem statement. This goal is more than met, with an energy usage of 8,000 BTU/gallon of ethanol. The process design consists of three main sections: upstream preparation of the glycerol feed for the E. coli, anaerobic fermentation of this glycerol feed to ethanol and succinic acid (a valuable specialty chemical and a side-product of fermentation), and downstream separation to recover the ethanol and succinic acid. When performing the economic analysis, the plant was assumed to be a grass roots plant located in the Gulf Coast region of the United States. The total capital investment is $108 million, including a working capital of $23.6 million. In the base case scenario, with crude glycerol priced at $0.05/lb, ethanol priced at $2.50/gallon, gasoline priced at $3.15/gallon, and succinic acid priced at $2.00/lb, the net present value (NPV) of the project is $95 MM based on an interest rate of 15%, and the investor’s rate of return (IRR) is 32.24%. The process profitability improves with increasing crude oil prices and decreasing crude glycerol prices, which we believe are highly likely scenarios based on our market research. Disciplines Chemical Engineering This article is available at ScholarlyCommons: https://repository.upenn.edu/cbe_sdr/5 LeGendre, Logan, Mendel, Seedial Anaerobic Fermentation of Glycerol to Ethanol Senior Design Project Chloe LeGendre Eric Logan Jordan Mendel Tamara Seedial Submitted to: Professor Leonard Fabiano Professor Warren Seider April 6, 2009 Chemical and Biomolecular Engineering CBE 459 Chemical and Biomolecular Engineering Department University of Pennsylvania 1 LeGendre, Logan, Mendel, Seedial Professor Leonard Fabiano Professor Warren Seider Chemical and Biomolecular Engineering Department University of Pennsylvania Philadelphia, PA 19104 April 6, 2009 Dear Professor Fabiano and Professor Seider, Contained within this report is the design of a process to convert crude glycerol to ethanol for fuel consumption via the anaerobic fermentation of the feedstock by a wild strain of the microorganism Escherichia coli. As suggested by industrial consultant Mr. Bruce Vrana (DuPont), we have designed a plant to produce 50 MM gallons of denatured fuel ethanol annually using a combination of batch fermentation and continuous processing. The plant design that we suggest is comprised of a continuous feed preparation section, a batch fermentation section, and a subsequent continuous separation section for the recovery of ethanol and succinic acid (a valuable fermentation side-product). In the feed preparation section, crude glycerol, a byproduct from the biodiesel industry, is treated to remove salts and other impurities and then mixed with a nutrient supplement, diluted, and sterilized. In the batch fermentation section, this sterile glycerol feed is anaerobically metabolized by the E. coli, resulting in the formation of ethanol and succinic acid. The broth and vapor from the fermentation section are then sent to the separation section of the plant for product recovery. Although the design uses a hypothetical strain of Escherichia coli as per the problem statement, researchers Dharmadi, Murarka, and Gonzalez of Rice University present a case for the same fermentation process in existing Escherichia coli. As such, the design presented here is physically feasible. The design has a good economic outlook, assuming that crude oil prices continue to rise and that political support for renewable fuels continues. The process is projected to have an approximate investor’s rate of return (IRR) of 32.24% on a total capital investment of about $108 MM. The net present value was estimated to be $95 MM based on an interest rate of 15%. Additionally, the energy consumption of the process was determined to be 8,000 BTU/gallon of ethanol, well below the 35,000 BTU/gallon energy benchmark provided in the problem statement. If you have any questions, comments, or concerns regarding the report, please do not hesitate to contact us. We want to thank you very much for your support throughout the duration of the project and your present consideration. Sincerely, Chloe LeGendre Eric Logan Jordan Mendel Tamara Seedial 2 LeGendre, Logan, Mendel, Seedial Table of Contents Abstract ................................................................................................................................................... 7 A. Process Overview .......................................................................................................................... 10 B. Importance for the Study .............................................................................................................. 11 C. Initial Project Charter .................................................................................................................... 16 Market and Competitive Analysis........................................................................................................... 17 Process Flowsheets and Material Balances............................................................................................ 24 Process Description ............................................................................................................................... 42 Fermentation Feed Preparation Section ............................................................................................. 43 Laboratory Section ............................................................................................................................. 46 Plant Seed Fermentation Section ....................................................................................................... 48 Main Fermentation Section................................................................................................................ 50 Separation Section ............................................................................................................................. 53 Energy Balance and Benchmark ............................................................................................................. 56 Unit Descriptions ................................................................................................................................... 61 Feed Preparation Section ................................................................................................................... 62 Storage Tanks: ............................................................................................................................... 62 Heat Exchangers: ........................................................................................................................... 65 Pumps:........................................................................................................................................... 66 Miscellaneous: ............................................................................................................................... 69 Seed Fermentation Train (Plant and Lab) ........................................................................................... 70 Fermenters: ................................................................................................................................... 70 Pumps:........................................................................................................................................... 73 Main Fermentation Section................................................................................................................ 77 Fermenters: ................................................................................................................................... 77 Storage Tanks: ............................................................................................................................... 79 Heat Exchangers: ..........................................................................................................................
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