Lignocellulosic ethanol production plant by Biochemtex in Italy Lignocellulosic Ethanol Process and Demonstration A Handbook Part I Authors: Rita Mergner (Part I), Rainer Janssen (Part I), Dominik Rutz (Part I), Isabella de Bari (Part I - Chapter 4), Fabio Sissot (Part I - Chapter 3), David Chiaramonti (Part II), Arianna Giovannini (Part II), Stefania Pescarolo (Part II), Renato Nistri (Part II) Editors: David Chiaramonti, Arianna Giovannini, Rainer Janssen, Rita Mergner ISBN: 3-936338-32-9 Published: © 2013 by WIP Renewable Energies, Munich, Germany Contact: WIP Renewable Energies, Sylvensteinstr. 2, 81369 Munich, Germany [email protected], Tel.: +49 89 720 12 731 www.wip-munich.de Website: www.biolyfe.eu Copyright: All rights reserved. No part of this book may be reproduced in any form or by any means, in order to be used for commercial purposes, without permission in writing from the publisher. The authors do not guarantee the correctness and/or the completeness of the information and the data included or described in this handbook. Acknowledgement: This handbook was elaborated in the framework of the BioLYFE project (Grant agreement No. TREN/FP7EN/239204), supported by the European Commission under the FP7 framework programme. The authors would like to thank the European Commission for the support of the BioLYFE project as well as the reviewers and BioLYFE partners for their contribution to the handbook. 2 Content The BIOLYFE project........................................................................................................... 6 Preface ................................................................................................................................. 7 Part I Overview on the lignocellulosic ethanol production .............................................. 8 1 Introduction .................................................................................................................. 8 RITA MERGNER, RAINER JANSSEN 1.1 (Bio)ethanol as fuel and chemical............................................................................ 8 1.2 World ethanol markets ...........................................................................................14 1.3 Sustainability ..........................................................................................................16 1.4 Indirect land use change (ILUC) .............................................................................19 1.5 Biomass potential ...................................................................................................20 1.6 Overview on second generation production process ..............................................25 1.7 Support policies ......................................................................................................27 2 Components of lignocellulosic feedstock .................................................................31 RITA MERGNER, RAINER JANSSEN 3 Feedstock provision ...................................................................................................35 FABIO SISSOT 3.1 Introduction ............................................................................................................35 3.2 Biomass sources ....................................................................................................35 3.3 Cultivation, supply chain and logistic ......................................................................39 4 Pretreatment technologies .........................................................................................45 ISABELLA DE BARI 4.1 Introduction ............................................................................................................45 4.2 Biological pretreatment ...........................................................................................46 4.3 Physical pretreatment .............................................................................................48 4.3.1 Mechanical comminution .................................................................................48 4.3.2 Irradiation ........................................................................................................49 4.3.3 Extrusion .........................................................................................................49 4.4 Chemical pretreatment ...........................................................................................49 4.4.1 Ozonolysis ......................................................................................................49 4.4.2 Acid pretreatment ............................................................................................50 4.4.3 Alkali pretreatment ..........................................................................................52 4.4.4 Oxidative delignification ...................................................................................53 4.4.5 Organosolv ......................................................................................................55 4.4.6 Ionic Liquids (ILs) ............................................................................................56 3 4.5 Physicochemical pretreatment ...............................................................................58 4.5.1 Ammonia Fiber Explosion (AFEX) ...................................................................58 4.5.2 Steam explosion ..............................................................................................60 4.5.3 Liquid hot water pretreatment (LHW) ...............................................................64 4.5.4 Supercritical Fluid Pretreatment (SCF) ............................................................65 4.6 Comparison of pretreatment methods ....................................................................66 5 Hydrolysis processes .................................................................................................71 RITA MERGNER, RAINER JANSSEN 5.1 Introduction ............................................................................................................71 5.2 Acid hydrolysis .......................................................................................................71 5.2.1 Diluted acid hydrolysis .....................................................................................71 5.2.2 Concentrated acid hydrolysis ..........................................................................74 5.3 Enzymatic hydrolysis ..............................................................................................75 5.3.1 Production of cellulolytic enzymes ...................................................................77 5.3.2 Enzyme recycling ............................................................................................78 5.3.3 Factors affecting hydrolysis .............................................................................79 6 Fermentation and process configurations ................................................................81 RITA MERGNER, RAINER JANSSEN 6.1 Introduction ............................................................................................................81 6.2 Mixed sugar fermentation .......................................................................................83 6.3 Overview on integrated fermentation technologies .................................................86 6.4 Separate Hydrolysis and Fermentation (SHF) ........................................................87 6.5 Simultaneous Saccharification and Fermentation (SSF) .........................................88 6.6 Simultaneous Saccharification and Co-Fermentation (SSCF) ................................91 6.7 Separate Hydrolysis and Co-Fermentation (SHCF) ................................................93 6.8 Consolidated Bioprocessing (CBP) ........................................................................93 7 Downstream processing (DSP) ..................................................................................96 RITA MERGNER, RAINER JANSSEN 7.1 Ethanol recovery ....................................................................................................96 7.2 Residual solids and wastewater treatment .............................................................99 8 Demonstration projects ............................................................................................ 100 RITA MERGNER, RAINER JANSSEN 8.1 Introduction .......................................................................................................... 100 8.2 Mossi&Ghisolfi/Biochemtex demo plant, Crescentino, Italy .................................. 101 8.3 Biocombustibles de Castilla y León (BCyL) plant, Spain ...................................... 101 8.4 Demonstration plant in Lacq, France .................................................................... 103 8.5 BioGasol plant, Denmark ..................................................................................... 104 4 8.6 Kalundborg plant, Denmark .................................................................................. 105 8.7 Iogen demonstration plant, Canada ...................................................................... 106 8.8 Demonstration plant in Straubing, Germany ......................................................... 107 8.9 Jennings demonstration plant, USA ..................................................................... 109 8.10 INEOS Bio pilot plant, USA .................................................................................