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The Research Association of Innovative Bioethanol Technology The University of Tokyo An Integrated System of Ethanol Production from the Cellulosic Energy Crop Napier Grass Pacific Rim Summit on Industrial Biotechnology and Bioenergy December 9, 2013@ San Diego M. Samejima, S. Morita Graduate School of Agricultural and Life Sciences The University of Tokyo, JAPAN E. Morita, S. Mihashi Research Association of Innovative Bioethanol Technology, JAPAN 1
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Page 1: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

An Integrated System of

Ethanol Production from the Cellulosic

Energy Crop Napier Grass

Pacific Rim Summit on Industrial Biotechnology and Bioenergy December 9, 2013@ San Diego

M. Samejima, S. Morita Graduate School of Agricultural and Life Sciences

The University of Tokyo, JAPAN

E. Morita, S. Mihashi Research Association of Innovative Bioethanol Technology, JAPAN

1

Page 2: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Political background on biofuel in Japan

"Sophisticated Methods of Energy Supply Structures" law in

Japan mandates to introduce 850,000 kL/yr of ethanol

equivalent to 500,000 kL/yr of crude oil in the trasnportation

sector by 2017.

The criteria of assessing biofuel is requested to be more than

50% reduction of greenhouse effect gases (GHG) versus the

same action by gasoline.

Introduction

2

Page 3: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Final target on bioethanol technology project

To proceed biofuel project, establishment of technology to

produce ethanol from cellulosic energy crops should be

addressed as following conditions.

Production cost of ethanol : 40 JPY/L (ca. 0.4 US$/L)

Production scale of ethanol: 200,000kL/y

Balance ratio by fossil energy used: over 2.0

Reduction of CO2 emission: over 50%.

Introduction

3

Page 4: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

NEDO Technology Development Organization

Contract

Research Association of Innovative Bioethanol Technology (RAIB) Head Quarter/ Common laboratory (at Entrepreneur Plaza in UT)

Member Companies: JX-Nippon Oil and Energy, Mitsubishi Heavy Industries,

Toyota Motors, Kajima Corp., Sapporo Engineering, Toray Industries

Framework of research group

The University of Tokyo (UT), Graduate School of Agricultural & Life Sciences

In 2009, to proceed this project, Research Association of

Innovative Bioethanol Technology (RAIB) was established by six

leading companies in Japan and our university cooperates with

their activities.

Introduction

4

Page 5: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Process flow of our project

Cellulose

Hemicellulose

Cultivation Harvest, Storage

Transport Pre-treatment Saccharification Fermentation

Concentration, Dehydration Process

Non-arable land Energy crops Lignin

Glucose

Xylose

Dehydrated ethanol

Ethanol

Toyota Kajima JX Energy Toray Sapporo

Mitsubishi, RAIB

University of Tokyo

Fundamental Idea and technologies

The aim of our project is to establish an integrated system of ethanol production

from the cellulosic energy crop Napier grass with a size of bench-scale production

(75 L of ethanol from 300 kg of feedstock for each run).

Introduction

5

Page 6: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Biomass Supply

shredding

NH3 treatment

Enzymatic

Saccharifi-

cation

Fermentation

Ammonia

Nitrogen Gas

Sulfuric Acid

Fertilizer(NPK)

Biomass Energy

Supply Center

Steam

Process Water

Ethanol

Ethanol Distillation

Ethanol Dehydration

Drying

Post treatment

Enzyme

Cooling Energy

Compressed Air

Electricity

Fertilizer(Urea)

Enegy Supply from

Saccharification

Residue

Life cycle assessment of system

LCA analysis

with GaBi6 software

Diesel Oil

Steam

Steam

Analysis

6

Page 7: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Cultivation sites

Sapporo

Nasu

Tokyo

Ishigaki Island

Tropical & subtropical climate

Indonesia Australia

Cool-temperate climate

Temperate climate

Kumamoto

Cultivation and productivity of biomass Feedstock

0

1 0

2 0

3 0

4 0

5 0

6 0

Bio

ma

ss p

rod

uctivity (

t/h

a)

Example of biomass yield

under tropical climate

Eria

nth

us

Na

pie

r

Gra

ss

Se

taria

Su

ga

r C

an

e

Sw

icth

Gra

ss

Corn

Gu

ine

a G

rass

Cro

tala

ria

Ram

ie

So

rgh

um

Sugar Cane Napier Grass

Erianthus

Test Field of University of Tokyo (Tokyo)

Test Field of Toyota Mortors (Indonesia)

7

Page 8: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Field A

Field B

Field C

Field D

Field E

Field F

Annual Supply

Case study of Nepier Grass in Indonesia (50 dried ton/year)

Rainy season Dry season

50t/ha・year

Cultivation for adjustment of supply

Cultivation for adjustment of supply

20t/ha 20t/ha 20t/ha

20t/ha 20t/ha 20t/ha

20t/ha 20t/ha

20t/ha

20t/ha

20t/ha 20t/ha

Year-round supply system of feedstock biomass Feedstock

8

Page 9: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Highlights on biomass conversion technologies

Pretreatment Saccharification Fermentation

Technical Highlights:

Use of ammonia without

addition of water.

Technical Merits:

All pretreated materials

remain in solid without loss.

No waste water is produced.

Technical Targets:

Reduction of ammonia used.

Conversion

Biomass Ethanol

Technical Highlights:

Efficient production of enzymes.

Optimization of enzyme cocktail.

Recovery and reuse of enzymes.

Technical Targets:

Reduction of enzyme cost(less than

10 JPY/L of ethanol production) to

obtain 500 g of sugar from 1 kg of

biomass within 24 hrs incubation.

Adaptation for Scale-up.

Technical Highlights: Tandem C6/C5

fermentation.

Use of Non-GM for

C5 fermentation.

Technical Targets: High performance and yield.

9

Page 10: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Effects of ammonia pretreatment

The reactivity of enzymes for biomass is dramatically improved by

following effects of ammonia pretreatment.

1) Breaking of ester linkages on xylan or between xylan and lignin

2) Swelling of cellulose structure

Cellulose

Lignin

Lignin-hemicellulose bond

Hemicellulose

Ammonia pretreatment

Swelling of cellulose structure Cleavage of chemical bond

Conversion

10

Page 11: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Reduction of energy for pretreatment

Dried Biomass

High Pressure

Ammonia

Treatment

3.7 MPa, 80 C

Recovery

of

Ammonia

One-step process

under higher pressure

Dried Biomass

Low Pressure

Ammonia

Treatment

Liquid Phase

Ammonia

Treatment

Recovery

of

Ammonia

Reduction of

88 % of

Energy

Two-steps process

under lower pressure

Conversion

11

Page 12: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Enzymatic saccharification of pretreated biomass

0

100

200

300

400

500

600

未処理処理後 未処理処理後 未処理処理後 未処理処理後

糖収量(g/kg乾燥バイオマス)

キシロース

グルコース

Erianthus

Napier grass

Switchgrass Salix

Xylose

Glucose

Before/After NH3-treat.

Before/After NH3-treat.

Before/After NH3-treat.

Before/After NH3-treat.

Su

ga

r yie

ld (

g/k

g-d

ry b

iom

ass)

-Most of sugar compounds retains in pretreated biomass as solid-state.

-Dramatic improvement of sugar yield from biomass by enzymatic

saccharification.

Sugar yield from biomass

Conversion

12

Page 13: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Strategy on reduction of enzyme cost

(3) Enzyme

Recovery & Reuse

Enzyme cost

10 JPY/L

(2) Highly-efficient

Saccharification (1) Production of

Enzyme

Improvement of enzyme-producing fungi

Optimization of culture condition

Minimum enzyme components production

→ Less than 1,000 JPY/kg of enzyme

Optimization of enzyme

components for ammonia-

pretreated biomass

→ Less than 1/100 (Enzyme/Biomass)

Optimization of enzyme recovery

Optimization of enzyme components for reuse.

→ More than 75 %

Conversion

13

Page 14: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Analysis of Base Enzymes Preparation

Improvement of Enzyme Cocktail

Analysis and improvement of enzyme cocktail

Feedstock: Ammonia treated Napier grass Enzyme/Biomass (1/100)

Conversion

14

Page 15: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Tandem system for ethanol fermentation

1st Step: Glucose

fermentation

2nd Step: Xylose

fermentation

Ethanol

separation

Ethanol

Yield: 93 %

Yield: 90 %

Conversion

15

Page 16: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Outline of bench-scale plant (1)

Pre-treatment process

Saccharification process

Cru

she

r &

Dry

er

Re

acto

r

Sacc

har

ific

atio

n v

ess

el

Solid

-liq

uid

se

par

ato

r

Enzy

me

se

par

atio

n m

em

bra

ne

Suga

r co

nce

ntr

atin

g m

em

bra

ne

Fermentation process

C6

Fe

rme

nta

tio

n v

ess

el

Yeas

t se

par

atio

n f

acili

ty

Eth

ano

l se

par

ato

r

Sto

rage

B

iom

ass

Pre

-tre

ate

d b

iom

ass

Ammonia

Ammonia/ Effluent treatment

Enzyme solution Enzyme /Recycle

Residue Discharged water

Yeast /Recycle

Ethanol solution

Yeast

Ce

llulo

sic

Su

gar

De

hyd

rate

d e

than

ol

Discharged water

Dis

tille

r

De

hyd

rato

r

Sto

rage

C5

Fe

rme

nta

tio

n v

ess

el

Bench Plant

16

JX Energy Toray Industries Sapporo Engineering

Page 17: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Biomass feedstock

(Napier grass)

Ethanol

Ammonia pretreatment (JX energy)

Enzymatic saccharification (Toray)

Ethanol fermentation &

purification (Sapporo)

Outline of bench-scale plant (2) Bench Plant

17

Page 18: An Integrated System of Ethanol Production from the ... Samejima... · Ethanol Production from the Cellulosic Energy Crop ... is to establish an integrated system of ethanol production

The Research Association of Innovative Bioethanol Technology The University of Tokyo

Summary of our achievement

Production of feedstock (Napier grass): over 50 dried ton/ha

Production cost of feedstock : less than 3 JPY/kg (ca 0.03 US$/kg)

Enzyme cost : 10 JPY/L of ethanol production (ca 0.1 US$/L)

Production cost of ethanol : less than 80 JPY/L (ca. 0.8 US$/L)

Balance ratio by fossil energy used: over 2.0

Reduction of CO2 emission: over 50%.

18


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