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DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS www.waste2go.eu Work Package 5: Process development for cellulose degradation Malcolm Lock (CPI) Brussels14 - 15 September 2015
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Page 1: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL

FEEDSTOCKS

www.waste2go.eu

Work Package 5: Process development for cellulose degradation

Malcolm Lock (CPI)Brussels14 - 15 September 2015

Page 2: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Introduction• WP5 Objectives

• Process challenges

• Developing mixing strategies: Biomixer MR2

• The Biomixer in action

• Solid-liquid separation technologies

• Downstream processing using the Hydropress

• Production of materials for WP6

• WP5 Conclusions

Page 3: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

WP5 Objectives

• Utilizing waste feedstocks from WP2 – data for feedstock development

• Application of specific enzyme combinations from WP3

• Process optimization for mixing cellulosic feedstock with enzymes

• Solid-liquid DSP to provide feedstocks for WP6 process developments

Page 4: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Process challenges for WP5• Require 15 – 20% (dw/w) loadings for acceptable yields

• Dry weight

– Cellulosic wastes have a high water content

• Substrate composition

– Cellulose low percentage of total weight

– Cellulose content varies between waste streams and batches

– Inhibitory components (e.g. metals from inks)

– pH altering factors (CaCO3 as paper whitener)

• Accessibility of cellulose for degradation

– Proportion trapped as crystalline cellulose

– Pre treatment designed to increase accessibility

• Batched at start or batch fed process (building up to target dw after liquefaction)?

• Enzyme combination

Page 5: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

• Even at 6% dry weight solids loadings cellulosic suspensions have a high viscosity

• Rusden impellors are not satisfactory for mixing dense / viscous materials

– Impellor shape does not aid mixing

– Compaction in column fermentor increases viscosity

• Alternative mixing strategies needed to be employed:

Ribbon blender (bread and cheese

manufacturing)

Rotary augar (waste processing)

Process challenges: Mixing

Page 6: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

• Horizontal mixing more efficient

• ‘Lift and drop’ action maximises substrate coating with enzyme

• Thermal jacket to control reaction temperature, data logging for multiple probe options

• Consideration of loading and unloading operations

Stainless Steel Horizontal Drum Reactor/Mixer

T

PH Addition

Three-Blade-Mixing-Insert

Motor (variable speed control)

PH Indicator

Thermocouple and Trip

Lute to remove any gas build-up

Sample take-off

Heated Jacket

Viewing Port/Filling Hatch

Heated Jacket

A-Frame Support and

tilt mechanism

to aid emptying of

vessel

Control Box.Process Temperature

Measurement, Temperature Control &

Trip.PH Monitoring.

Motor RPM Control.Data Logging.

E-STOP BUTTON

Process Media Temperature

Thermocouple

T

Motor Support and Shaft Seal

Mixer Blade Shaft Bearing Support

One end of Vessel to have a sealed hinged door opening and viewing port to assess liquefaction

Tilt-Wheel/Pivot Point to allow 30 degrees tilt either side from horizontal

Blade/Mixer Insert to have minimal clearance to inside of Mixer side wall

Process challenges: Designing a mixing vessel

Page 7: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Biomixer MR2 Features – Mixing

• Replaceable tri bladed impellor

• Designed to “lift and drop” high viscosity materials, coating with enzyme solution

• Drilled holes create vortex mixing once liquefaction has occurred

Page 8: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Biomixer MR2 – Data logging

• Data collected through back plate mounted sensors: pH and temperature

• Data logged through Eurotherm Chessel

• Impellor driven by inline motor, 0.37kW, with 40:1 step down gearbox

• Water jacket provides reaction temperature (Hüber recirculating water bath)

Page 9: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Biomixer MR2 – Loading and unloading

• Top port modifiable (e.g. solids loading chute), currently acting as lute

• Rotation for ease filling and unloading

• 50L working volume just fills vessel to below half

• Sealed hatch to enable easy loading or unloading

Page 10: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Biomixer MR2 in action

A. Starting material B. 23 hours C. 30 hours D. 48 hours

E. 59 hours F. 95 hours G. 99 hours decanted material

• Biomixer run 8 (20th to 23rd March 2015),

• MaCel45a digest (11.75 g.kg (dw)-1 in terms of total protein)

• Acetic acid washed office white paper at 20.1% (w/v) dry weight

• 12.95 kg batched at start with 12.95 kg added after 4.5 h

Page 11: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Biomixer MR2 in action

• Run 9: After batch addition solids • 17.5 % dw/v loading• Balling and lift-drop action• Full slurry never formed

• Run 3: Early trial with commercial enzyme

• 24.7% dw/v loading• Rapid development of thick slurry

Page 12: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

• Viscosity

• Particle size of solids

• Percentage solids content

• Throughput requirements

• Reaction of slurry to pressure

• Target dry weight of produced solids

Centrifuge Filter press Gaffe bag

X X X

Solid-liquid separation technologies

Page 13: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Downstream processing using the Hydropress

• Lancman VSPX-98

• 98L capacity: 40L minimum working

volume

• Scalable technology (beer production)

• Pressure range 0.1 – 2.9 bar

• Process time dependent dewatering

• Filter media available

• Polypropylene monofilament lining bag

(average 106 µm pore size)

Page 14: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Samples for fractionation trials• Direction from WP3: LPMO + MtCDH and MaCel45a yielded highest DP fragmentation

• Dry Mixed Recycling and White Paper as substrates

• Liquefaction observed in flask trials with both substrates and both LPMOs

• Enzymes loaded with 1:1:1 ratio based on volume (concentrations comparable)

• Batched at start with one solids addition after 24 h

• Recoveries restricted by retention of sticky solids on Biomixer frame and CO2 release

• Hydropress produced solids with low water content

Run # Enzymes used Run time Waste typePercentage

loading (dw)Solids weight

(kg)Liquid weight

(kg)[Glucose] (g/L)

[Lactic acid] (g/L)

Recovery (%)Post

hydropress dry weight %

4 LPMO 3328, MtCDH, MaCel45a

99h15 Dry Mix Recycling 16.8 15.751 22.468 0.00 5.55 89.17 44.5

5 LPMO 3328, MtCDH, MaCel45a

101h15White paper & Dry

Mix Recyc14.7 11.28 32.84 0.02 1.05 85.63 43.4

6 LPMO 2916, MtCDH, MaCel45a

98h40 Dry Mix Recycling 16.8 16.16 31.45 0.34 0.10 94.80 43.6

8 MaCel45a 97h10Acid washed white

paper20.1 11.56 15.87 0.12 0.04 91.77 41.9

9 LPMO 3328 & MtCDH 28h15Acid washed white

paper17.5 NR NR 0.11 0.05 NR NR

Page 15: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Samples for fractionation trials

• Run 5 logged data showing stable pH and temperature control, motor current draw and stable rotation of the impellor

Page 16: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

Samples for fractionation trials

Run 5 soluble sugar release with LPMO 3328 Run 6 soluble sugar release with LPMO 2916

Assuming entire added mass is cellulosic:

• 10.3% conversion to soluble sugars

• 3.62% yield soluble sugars

Assuming entire added mass is cellulosic:

• 26.1% conversion to soluble sugars

• 5.72% yield soluble sugars

0 1 2 3 4

24

48

72

96

Product

Concentration (g/L)

Tim

e (H

ours

) Cellotetraose (g/L)

Cellotriose (g/L)

Cellobiose (g/L)

Lactic acid (g/L)

Glucose (g/L)

Page 17: DEVELOPMENT AND VERIFICATION OF AN INNOVATIVE FULL LIFE SUSTAINABLE APPROACH TO THE VALORISATION OF MUNICIPAL SOLID WASTE INTO INDUSTRIAL FEEDSTOCKS .

WP5 Conclusions• Demonstration of high dry weight cellulose slurry mixing by Biomixer MR2

• Sterility (no lactic acid production) can be maintained within Biomixer setup at elevated temp

• DSP technologies for solid-liquid separation investigated

• Hydropress sufficient for W2G separation requirements

• Adequate mixing enabled production of soluble polysaccharides

• Analytical capability at CPI cannot analyse insoluble polysaccharide breakdown

• Scale up of process optimization factors exceedingly challenging

• Range of soluble and insoluble polysaccharides from different enzyme digestions of varying

waste cellulose feedstocks provided to WP6


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