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 Energy Utilization/Usage Energy Utilization/Usage CO 2 /H 2 O Footprint CO 2 /H 2 O Footprint Economics Economics Summary Summary

3. Project Purpose Design a facility that is: State-of-the-art State-of-the-art Flexible Flexible Adaptible Adaptible Bio-chemical processing plant Bio-chemical processing plant Optimizing Ethanol production Optimizing Ethanol production

4. Project Purpose Optimizing includes: Water usage Water usage Energy usage Energy usage CO 2 CO 2 Waste Stream Utilization/Cogeneration Waste Stream Utilization/Cogeneration Return on investment Return on investment

5. 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 81% Conversion of Cellulose to Ethanol in 24 hours 81% Conversion of Cellulose to Ethanol in 24 hours Target Purity: 99.5wt% Ethanol Target Purity: 99.5wt% Ethanol

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

7. Pre-Treatment Undesirables

8. Enzymes-What are they? Enzymes are catalysts that are biological molecules Enzymes are catalysts that are biological molecules Like all catalysts, enzymes dramatically increase the rate of reaction Like all catalysts, enzymes dramatically increase the rate of reaction

9. Breaking up Cellulose (Saccharification) Breaking up cellulose requires three enzymes collectively called cellulases Breaking up cellulose requires three enzymes collectively called cellulases

10. Where Do You Get 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

11. + Producing Enzymes Yeast Pre-Culture 25 lbs Yeast Enzyme Production Culture 600 lbs Yeast Water Nutrients Water Nutrients 300 lbs/day Enzyme 20 lbs/day Mixture

12. Saccharification by Enzymatic Hydrolysis Cellulose Enzymes C 6 H 12 O 6 (Glucose)

13. Fermentation Yeast 2C 2 H 5 OH + 2CO 2

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

15. 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 Ethanol 59 Tons Undigested Paper

16. NCSF Energy Balance 40ºC45ºC50ºC35ºC30ºC 40 MMBtu/Day Cooling H 2 O HPS 55 MMBtu/Day

17. Distillation & Purification

18. Distillation: Material Balance FEED F= 420 tons/day X F = 5.0 wt% EtOH DISTILLATE D= 20 tons/day Q C = 110 MMBtu/day X D = 90.6 wt% EtOH BOTTOMS B= 400 tons/day Q R = 200 MMBtu/day

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

20. 21 Tons EtOH + 2 Tons H 2 O ~21 Tons EtOH Water Adsorption by a Molecular Sieve 11 Tons Synthetic Zeolite

21. 7.1 MMBtu/Day 6 Tons CO 2 / Day ~ 6 Tons Hot CO 2 + 2 Tons H 2 O Vapor Per Day 11 Tons Synthetic Zeolite Regeneration of the Molecular Sieve

22. Waste Stream Utilization Steam Boiler Undigested Paper 720 MMBtu/Day High-Pressure Steam 520 MMBtu/Day Flue Gases 200 MMBtu/Day

23. Energy: Ethanol from Wastepaper Papernol Plant 200 MMBtu/Day 500 MMBtu/Day Cogenerated Electricity Ethanol

24. Corn Based Ethanol Plant 500 MMBtu/Day Ethanol 450-550 MMBtu/Day Fossil Fuels Energy: Ethanol from Corn

25. CO 2 Footprint Papernol Papernol Produces 120 tons CO 2 / day Average CO 2 released by vehicles in Chattanooga = 3,300 tons per /day

26. H 2 O Footprint Grey Water Papernol Plant Uses 20 tons/day Papernol

27. Capital Costs Reactor Vessels$1.5M Steam Boiler$1.0M Enzyme Tanks$1.0M Shredder/Conveyer$500K Distillation Column$240K Prep Tank$90K Molecular Sieve$70K Total$4.4 Million

28. Economic Analysis Capital Costs Equipment Cost = $4.4M Plant Heuristic x (4.7) Total Capital Cost = $20M

29. Annual Operating Costs Wastepaper$300K Water $200K Electricity$120K Nutrients$86K Enzyme & Yeast$33K Cooling Water$21K Total$1.2 Million

30. Production Costs Annual Capital Cost 5 Year Payback Annual Operating Cost Annual Production Production Cost $4M $1.2M 2.3M Gal $2.56/Gal

31. Return On Investment $2.56/gal 5 Year ROI $1.66/gal 10 Year ROI

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

33. Conclusion Facility Produces 21 tons of Ethanol Daily Net Energy Usage is (+)700 MMBtu/day Return on Investment of 5 Years Gives a Cost = $2.56/gallon