Butanol production using ethanol

8/11/2019 Butanol production using ethanol

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Butanol production using ethanolas feedstock in a sugarcane biorefinery

ISAF

20thInternational Symposium on Alcohol Fuels

Antonio BonomiCentro Nacional de Pesquisa em Energia e Materiais CNPEM

Laboratrio Nacional de Cincia e Tecnologia do Bioetanol CTBE

Spier Estate, South Africa, March 2013


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VSB Virtual Sugarcane Biorefinery


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Butanol production from sugarcane

Sugarcane

Bagasse

Sucrose Ethanol

ButanolABE

Butanolcatalysis

2G Ethanol

Sucrochemistry X Alcoholchemistry routes

2G ButanolABE

Butanolcatalysis


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ABE Acetone Butanol Ethanol fermentation process

Mostly studied process

Conventional microorganism strains:

Low productivity

Low butanol concentration in the reactor

Product inhibition

Engineered strains

Hyper-butanol producers

Use of integrated reaction-separation process

Vacuum extractive fermentation significantly reduces energyconsumption


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Use of catalysts hydroxyapatite, hydrotalcites, etc forethanol conversion into hydrocarbons

Other important products: 2-ethyl-butanol, hexanol,butenol, 2-ethyl-hexanol, octanol, acetaldehyde, 1,3-butadiene

Co-product: mixed alcohols (mixture of hydrocarbonsheavier than butanol), may be used as fuel or asfeedstock

Alcoholchemistry production of butanol from ethanol


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Simulation of a sugarcane biorefinery for production of

ethanol, sugar, electricity and butanol

Annexed 50/50 distillery500 t sugarcane/h


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Hydroxyapatite catalyst for butanol production

vapor-phase catalysis

20% ethanol conversion69.8% butanol selectivity

Reaction conditions:298 C1.78 s1 bar

Tsuchida et al., Journal of Catalysis 2008, 259, 183-189


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Ni/Al2O3catalyst for butanol production liquid-

phase catalysis

25% ethanol conversion80% butanol selectivity

Reaction conditions:250 C

72 h70 bar

Riittonen et al., Catalysts2012, 2, 68-84


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Hexanol

Products

Reactor 1

Reactor 2

Reactor 3

Reactor 4

Reactor 5

Reactor 6

Ethanol

Ethanol

Ethanol

Ethanol

Ethanol

Ethanol

Ethanol

ButanolMixed alcohols

Purification

Reactors scheme

Liquid phase catalysis

Vapor-phase catalysis

Series-parallelReactorEthanol

Ethanol

ButanolPurification

Vapor-phase catalysis

Single reactor

Mixed alcohols

ReactorEthanol

Ethanol

ButanolPurification


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Technical results

Steam consumption: 7.5 22.4 12.0(Butanol Plant:kg steam/L butanol)


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Equipment: Packed bed reactor

Distillation columns

Absorption columns Heat exchangers

Investment estimate butanol plant


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Product Price Unity

Anhydrous ethanol1 0.66 US$/LHydrated ethanol1 0.59 US$/LVVHP Sugar1 0.48 US$/kg

Electricity2 60.98 US$/MWhSugarcane3 27.26 US$/tSugarcane trash 18.29 US$/tButanol (fuel) 1.03 US$/kgButanol (chemical)4 1.65 US$/kgMixed alcohols 0.91 US$/L

Hexanol5 3.29 US$/kg1Six-years moving average prices (jan2002-dec2011) (CEPEA,2012)2 Weighted average of auction based on energy from sugarcanebagasse between 2005 and 2011 (2011 value)3 Six-years moving average prices (jan2002-dec2011) (UDOP,2012)

4 Mariano et al., 20125 ICIS, 2012

PricesInvestment estimate

Annexed distillery

Total investment US$ 180 million

(US$ 85/TC - UNICA)

Item InvestmentFraction

(%)

Equipment 60

Electromechanical set-up 7

Civil works 13

Electrical installations 8

Instrumentation 2

Engineering, services, etc 10


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Results economic analysis


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Results economic analysis

Sensitivity

butanol price

Chemical price: 2011 sale price of butanol in Brazil.

Fuel price: proportional to anhydrous ethanol fuel price in 2011 in Brazil (LHV basis).


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Results life cycle analysisComparison with petrochemical butanol

ADP: abiotic depletion; AP: acidification; EP: eutrophication; GWP: global warming; ODP: ozonelayer depletion; HTP: human toxicity; FAWET: fresh water aquatic toxicity; MAET: marine aquaticecotoxicity; TET: terrestrial ecotoxicity; POP: photochemical oxidation.


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Results life cycle analysisImpacts scores per kilometer for dedicated and flex vehicles: butanol(vapor-phase catalysis), ethanol 1G and gasoline

Efficiency of engines (fleet average):flex (2.74 MJ/km)gasoline (3.46 MJ/km)ethanol (3.09 MJ/km)

Energy content of fuels:hydrated ethanol (26.38 MJ/kg)gasoline C (43.54 MJ/kg)

butanol (34.32 MJ/kg)

Transport: 300 km

Emissions for each type of fuel: CO2, CH4, CO, NOx,

RCHO, NMVOC, MP

Offshore

Imported

Onshore

Refinery Biorefinery

Crude oil

Imported

Gasoline Storage Storage

Sugarcane

Distribution

Use

Transport


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Results life cycle analysisImpacts scores per kilometer for dedicated and flex vehicles: butanol(vapor-phase catalysis), ethanol 1G and gasoline

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Butanol

Flex

Butanol

dedicated

Ethanol

Flex

Ethanol

dedicated

Gasoline

dedicated

Gasoline

Flex

Global Warming Eutrophication


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Final remarks

IRR of the process with vapor-phase catalysis in series ofreactors is similar to the annexed distillery, consideringbutanol sale in the current chemical market

For butanol fuel, investment in the butanol plant must bedecreased for the process to be competitive Increase in butanol price due to its renewable origin will

significantly improve IRR Most of the impacts of butanol production are related with

the agricultural stage of sugarcane cultivation Further studies, regarding the use of catalysts in industrial

scale, are required


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Thank you

[email protected]

Marina O.S. DiasLucas G. Pereira

Tassia L. JunqueiraLucas G. Pavanello

Mateus F. ChagasOtvio Cavalett

Rubens Maciel Filho

Antonio Bonomi

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Butanol production using ethanol

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