Chemicals from Biomass - Integrating Bioprocesses into Chemical Production Complexes for Sustainable Development

481 Pages·2012·32.37 MB·English

by  Debalina Sengupta

GREEN CHEMISTRY AND CHEMICAL ENGINEERING
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CHEMICALS FROM BIOMASS
Integrating Bioprocesses into
Chemical Production Complexes
for Sustainable Development
GREEN CHEMISTRY AND CHEMICAL ENGINEERING
Series Editor: Sunggyu Lee
Ohio University, Athens, Ohio, USA
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Process Integration for Resource Conservation
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Chemicals from Biomass: Integrating Bioprocesses into Chemical Production Complexes
for Sustainable Development
Debalina Sengupta and Ralph W. Pike
GREEN CHEMISTRY AND CHEMICAL ENGINEERING
CHEMICALS FROM BIOMASS
Integrating Bioprocesses into
Chemical Production Complexes
for Sustainable Development
DEBALINA SENGUPTA
RALPH W. PIKE
CRC Press
Taylor & Francis Group
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Version Date: 20120530
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Contents
Series Preface..........................................................................................................xi
Preface...................................................................................................................xiii
Authors................................................................................................................xvii
1. Introduction.....................................................................................................1
1.1 Introduction...........................................................................................1
1.2 Research Vision.....................................................................................3
1.3 New Frontiers........................................................................................4
1.4 Chemical Industry in the Lower Mississippi River Corridor.........5
1.5 Criteria for the Optimal Configuration of Plants.............................9
1.6 Optimization of Chemical Complex................................................10
1.7 Contributions of This Methodology.................................................13
1.8 Organization of Chapters..................................................................14
1.9 Summary..............................................................................................18
2. BiomassasFeedstock...................................................................................21
2.1 Introduction.........................................................................................21
2.2 Biomass Formation.............................................................................25
2.2.1 Calvin–Benson Cycle.............................................................26
2.2.2 C4 Cycle...................................................................................26
2.2.3 CAM Cycle..............................................................................26
2.3 Biomass Classification and Composition........................................27
2.3.1 Saccharides and Polysaccharides........................................27
2.3.2 Starch.......................................................................................28
2.3.3 Lignocellulosic Biomass........................................................29
2.3.4 Lipids, Fats, and Oils.............................................................31
2.3.5 Proteins....................................................................................31
2.4 Biomass Conversion Technologies....................................................32
2.4.1 Biomass Pretreatment...........................................................33
2.4.2 Fermentation...........................................................................35
2.4.3 Anaerobic Digestion..............................................................36
2.4.4 Transesterification..................................................................39
2.4.5 Gasification/Pyrolysis...........................................................44
2.5 Biomass Feedstock Availability........................................................46
2.5.1 Forest Resources.....................................................................48
2.5.1.1 Forestland Base.......................................................48
2.5.1.2 Types of Forest Resource.......................................48
2.5.1.3 Limiting Factors for Forest Resource
Utilization................................................................51
2.5.1.4 Summary for Forest Resources............................51
v
vi Contents
2.5.2 Agricultural Resources.........................................................52
2.5.2.1 Agricultural Land Base.........................................52
2.5.2.2 Types of Agricultural Resource...........................53
2.5.2.3 Limiting Factors for Agricultural Resource
Utilization................................................................56
2.5.2.4 Summary for Agricultural Resources.................58
2.5.3 Aquatic Resources..................................................................58
2.5.3.1 Recent Trends in Algae Research.........................60
2.5.3.2 Algae Species..........................................................63
2.6 Summary..............................................................................................65
3. ChemicalsfromBiomass.............................................................................67
3.1 Introduction.........................................................................................67
3.2 Chemicals from Nonrenewable Resources.....................................68
3.3 Chemicals from Biomass as Feedstock............................................70
3.4 Biomass Conversion Products (Chemicals).....................................73
3.4.1 Single-Carbon Compounds..................................................73
3.4.1.1 Methane...................................................................73
3.4.1.2 Methanol..................................................................74
3.4.2 Two-Carbon Compounds.....................................................76
3.4.2.1 Ethanol.....................................................................76
3.4.2.2 Acetic Acid..............................................................87
3.4.2.3 Ethylene...................................................................88
3.4.3 Three-Carbon Compounds..................................................91
3.4.3.1 Glycerol....................................................................91
3.4.3.2 Lactic Acid...............................................................93
3.4.3.3 Propylene Glycol.....................................................93
3.4.3.4 1,3-Propanediol.......................................................94
3.4.3.5 Acetone....................................................................95
3.4.4 Four-Carbon Compounds....................................................95
3.4.4.1 Butanol.....................................................................95
3.4.4.2 Succinic Acid...........................................................96
3.4.4.3 Aspartic Acid..........................................................98
3.4.5 Five-Carbon Compounds.....................................................98
3.4.5.1 Levulinic Acid........................................................98
3.4.5.2 Xylitol/Arabinitol..................................................100
3.4.5.3 Itaconic Acid..........................................................100
3.4.6 Six-Carbon Compounds......................................................102
3.4.6.1 Sorbitol...................................................................102
3.4.6.2 2,5-Furandicarboxylic Acid.................................102
3.5 Biopolymers and Biomaterials........................................................103
3.6 Natural-Oil-Based Polymers and Chemicals................................105
3.7 Summary............................................................................................108
Contents vii
4. SimulationforBioprocesses.....................................................................111
4.1 Introduction.......................................................................................111
4.2 Ethanol Production from Corn Stover Fermentation...................115
4.2.1 Process Description for Ethanol Production
from Corn Stover Fermentation.........................................116
4.2.1.1 Pretreatment Section............................................119
4.2.1.2 Fermentation Section...........................................121
4.2.1.3 Purification Section..............................................122
4.2.2 Process Cost Estimation for Ethanol Production
from Corn Stover Fermentation.........................................125
4.2.3 Summary of Ethanol Production from Corn Stover
Fermentation.........................................................................128
4.3 Ethylene Production from Dehydration of Ethanol.....................128
4.3.1 Process Description for Ethylene Production
from Dehydration of Ethanol.............................................129
4.3.2 Process Cost Estimation for Ethylene Production
from Dehydration of Ethanol.............................................131
4.3.3 Summary of Ethylene Production from Dehydration
of Ethanol..............................................................................133
4.4 Fatty Acid Methyl Ester and Glycerol
from Transesterification of Soybean Oil........................................134
4.4.1 Process Description for Fatty Acid Methyl Ester
andGlycerolfromTransesterificationofSoybeanOil....137
4.4.1.1 Transesterification Section..................................140
4.4.1.2 Methyl Ester Purification Section......................141
4.4.1.3 Glycerol Recovery and Purification...................141
4.4.2 ProcessCostEstimationforFattyAcidMethylEster
andGlycerolfromTransesterificationofSoybeanOil.....144
4.4.3 Summary of Fatty Acid Methyl Ester and Glycerol
from Transesterification of Soybean Oil...........................146
4.5 PropyleneGlycolProductionfromHydrogenolysisofGlycerol....147
4.5.1 Process Description for Propylene Glycol Production
from Hydrogenolysis of Glycerol......................................147
4.5.2 Process Cost Estimation for Propylene
Glycol Production from Hydrogenolysis of Glycerol.....150
4.5.3 Summary of Propylene Glycol Production from
Hydrogenolysis of Glycerol................................................152
4.6 AceticAcidProductionfromCornStoverAnaerobicDigestion....152
4.6.1 Process Description for Acetic Acid Production
from Corn Stover Anaerobic Digestion............................154
4.6.1.1 Pretreatment Section............................................154
4.6.1.2 Anaerobic Digestion Section..............................158
4.6.1.3 Purification and Recovery Section.....................160
viii Contents
4.6.2 Process Cost Estimation for Acetic Acid Production
from Corn Stover Anaerobic Digestion............................163
4.6.3 Summary of Acetic Acid Production from Corn
Stover Anaerobic Digestion................................................165
4.7 Ethanol Production from Corn Dry-Grind Fermentation...........165
4.8 Summary............................................................................................170
5. BioprocessesPlantModelFormulation.................................................171
5.1 Introduction.......................................................................................171
5.2 Ethanol Production from Corn Stover Fermentation...................174
5.2.1 Pretreatment (Corn Stover).................................................175
5.2.2 Fermentation (Corn Stover)................................................180
5.2.3 Purification Section (Corn Stover EtOH)..........................181
5.3 Ethanol Production from Corn Dry-Grind Fermentation...........196
5.3.1 Pretreatment (Corn).............................................................197
5.3.2 Fermentation (Corn)............................................................201
5.3.3 Purification (Corn EtOH)....................................................201
5.4 Ethylene Production from Dehydration of Ethanol.....................209
5.5 AceticAcidProductionfromCornStover
AnaerobicDigestion.........................................................................212
5.5.1 Pretreatment (Corn Stover) Anaerobic Digestion............216
5.5.2 Anaerobic Digestion............................................................217
5.5.3 Purification (Acetic Acid)....................................................219
5.6 Fatty Acid Methyl Ester and Glycerol
from Transesterification of Natural Oil.........................................225
5.7 PropyleneGlycolProductionfromHydrogenolysis
ofGlycerol.........................................................................................232
5.8 Algae Oil Production........................................................................235
5.9 Gasification of Corn Stover..............................................................239
5.10 Summary of Bioprocess Model Formulation................................242
5.11 Interconnections for Bioprocesses..................................................244
5.12 Summary............................................................................................246
6. FormulationandOptimizationoftheSuperstructure.......................247
6.1 Introduction.......................................................................................247
6.2 Integrated Biochemical and Chemical Production
Complex Optimization.....................................................................247
6.3 Binary Variables and Logical Constraints for MINLP................255
6.4 Constraints for Capacity and Demand..........................................257
6.5 Optimization Economic Model—Triple Bottom Line..................259
6.6 Optimal Structure.............................................................................265
6.7 Multiobjective Optimization of the Integrated
Biochemical Production Complex..................................................274