Excelergy Biofuels Corporation Chapter 5

Catacutan, Fusi, Laygo, Sabido Process Description

CHAPTER V
PROCESS DESCRIPTION

This chapter presents the detailed discussion of the product specifications, the
raw materials and the processes involved in the production of bioethanol.

PRODUCT SPECIFICATION

Bioethanol will be the main product of Excelergy Biofuels Corporation. This will
serve as an essential alternative transportation fuel resulting to significantly low levels of
toxins in the environment. Listed in Table 5.1 are the properties of anhydrous ethanol.

Table 5.1
Physical and Chemical Properties of Anhydrous Ethanol
Properties Nominal Value
Molecular Formula C2H5OH
Molecular weight 46.069 g/mol
Density (at 20°C) 0.789 g/cc
Viscosity (at 20°C) 1.17
Boiling Point 78.15 °C
Melting Point -114.1 °C
Heat of Combustion 5625 kcal/L
Heat of Vaporization 9.225 kcal/mol
Auto Ignition Temperature 793.0 °C
Octane Rating 106-108
Stoichiometric Air/Fuel Ratio 9/1
Source: www.astm.org

The above parameters are based on the bioethanol standards, ASTM-D4806,

which must first met before a pure bioethanol will be used for blending. The plant will be
producing 16, 535.5690 kg/day. The bioethanol to be produced by the plant will be
based on the properties on Table 5.1

RAW MATERIALS SPECIFICATION

Microalgae have recently considered as a third-generation feedstock for biofuel

production. Since some microalgae species have high carbohydrate content, in terms of
starch and cellulose, they are also excellent substrates for bioethanol production. Using
carbohydrate-rich microalgal biomass for bioethanol production is advantageous since

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microalgae grow faster and fix CO2 at a higher rate than terrestrial plants. In addition,
microalgae-based carbohydrates are mainly in the form of starch and cellulose (with the
absence of lignin), are thus much easier to convert to monosaccharides compared with
lignocellulosic materials. In this study, Chlorella vulgaris will be utilized and cultivated for
the production of bioethanol. Table 5.2 shows the composition of the said microalgae in
percent by weight.

Table 5.2
Microalgae (C. vulgaris) Composition
Components % Weight
Carbohydrate 50.83
Protein 23.31
Lipid 13.14
Ash 8.13
Moisture 4.59
Source: Shih-Hsin Ho, et. al, 2012

MANUFACTURING PROCESS

Excelergy Biofuels Corporation will utilize the separate hydrolysis and

fermentation process to produce bioethanol. It involves several unit operations that are
essential in obtaining quality products matching the international standards.

Cultivation

Microalgal C. vulgaris FSP-E will be cultivated in 1.08 kg BBM (Bold Basal

medium). The medium will be used for both pre-culture and culture of this strain. Under
the pre-culture condition, the microalgal strain was grown with continuous CO 2 feeding
and under illumination with a TL5 tungsten lamp at a light intensity. The photobioreactor
(PBR) is used to grow the microalga strain. The microalgal strains were pre-cultured and
inoculated into the photobioreactor with an inoculum density of 1.4 kg/L. Initial cell mass
in inoculum is assumed as 0.5 kg/L with 90% nutrient consumption.

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Water &
Nutrient
Water & Water &
Water & CO2
Nutrient Nutrient
Nutrient
CO2
CO2
CO2

CULTIVATION
Feed Broth Broth
Broth TANK Broth

Cell Mass Cell Mass Cell Mass Cell Mass

Accumulation Accumulation Accumulation Accumulation
Nutrient Nutrient Nutrient Nutrient
Consumed Consumed Consumed Consumed

Figure 5.1 Cultivation of Microalgae

Pretreatment

Approximately 217102.1721 kg of broth will be obtained from the

photobioreactor. It will undergo centrifugation process to obtain the 35% dry weigh basis
(DWB) of the algae which will also remove the cultivation medium and the excess water
from the biomass. About 132835.2603 kg of algae and water solution will be produced
after centrifugation.

Hydrolysis

The concept of conversion of carbohydrate fraction into fermentable sugars

involves the pretreatment of the raw material followed by acid hydrolysis. Dilute sulfuric
acid can be used and is an ideal approach for degrading the carbohydrates into
fermentable sugars which operates at high temperature (121°C) and pressure. Separate
Hydrolysis and Fermentation (SHF) will be utilized since the major advantage of this
method will be the possibility to carry out the hydrolysis and fermentation at their own
optimum conditions. A ratio of algae solution and H 2SO4 solution (50:1) will be used for
acid hydrolysis and 1739.7 kg of H 2SO4 will be added which produces 380314.223 kg of
acidic hydrolysate during the process. The resulting hydrolysate will then be subjected
to centrifugation which will separate 134574.9922 kg of hydrolysate from the unreacted
algae, acid, and water. The hydrolysate coming from centrifugation will undergo to

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sterilizer (110ºC) and 43025.2752 kg of sterilized hydrolysate will be used in the

fementation process

Figure 5.2 Pretreatment and Hydrolysis Process

Fermentation

Fermentation will be carried out for the production of ethanol. Separate tanks for
the yeast and ammonia will be provided and 43025.28 kg of sterilized hydrolysate enters
the fermentation tank to convert 41297.08 kg of glucose to ethanol. Under this process,
about 980.69 kg of ammonia and 3706.9 kg of yeast (Saccharomyces Cerevisiae) which
readily utilizes glucose will be added. Fermentation will operate and be held at 30˚C and
1 atmospheric pressure. The fermentation process will produce 31343.5149 kg of
fermented broth and 16375.49 kg of carbon dioxide which will be stored and
compressed in a storage tank. The resulting fermented broth then enters a centrifugation
unit and thus producing 20545 kg ethanol solution and 10798.1519 kg solid residues.

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Figure 5.3 Fermentation Process

Purification

The product leaving the preceding process is called the beer which contains
water and ethanol. The distillation process removes the majority of the remaining water
in which 17341.33 kg of hydrous ethanol is produced which is concentrated to 95%
ethanol and 5% water

Ethanol and water form an azeotrope, or constant boiling solution, of about 95%
alcohol and 5% water. The 5% water cannot be separated by conventional distillation.
The production of pure, water-free ethanol will require another process which is the
dehydration step. This produces an end product of 16535.57 kg of anhydrous ethanol.

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Catacutan, Fusi, Laygo, Sabido Process Description

Distillate DISTILLATION
Ethanol Solution
DEHYDRATION

ANHYDROUS
ETHANOL

Bottom

WTP WTP

Figure 5.4 Purification Process

BY-PRODUCTS PROCESSING

Biomethane and Carbon Dioxide

Biomethane is a naturally occurring gas which is produced by the so-called

anaerobic digestion of organic matter. It is one of the by-products to be produced by the
plant. Table 5.3 shows the physical and chemical properties of biomethane produced.

Table 5.3
Physical and Chemical Properties of Biomethane
Properties Nominal Value
Molecular Formula CH4
Molecular weight 16.04 g/mol
Density (at 20°C) 0.668 kg/m3
Viscosity (at 20°C) 1.10 Pa.s
Boiling Point -161.11 °C
Melting Point -182.5 °C
Heat of Combustion 2290 kJkg
Latent Heat of Fusion 32.6 kJ/kg
Latent Heat of Evaporation 510 kJ/kg
Thermal Conductivity .035 W/m°C
Specific Heat 2260 J/kg.K
Source: www.engineeringtoolbox.com

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For the production of biomethane, residues from hydrolysis and fermentation

process will be utilized. About 89285 kg saccharification residue and 10798 kg
fermentation residue will be used to produce methane using anaerobic digester. About
6645.5215 kg of biogas will be produced and 3893.2441 kg of digester sludge will be
centrifuged to separate the solids which will be used as organic fertilizer and water.
Figure 5.6 shows the process of anaerobic digestion.

Figure 5.5 Production of Biogas

In order to separate the components of biogas, a gas absorption process will be

used. The biogas will undergo absorption with the addition of iron (III) oxide to produce
6579.4 kg with less H2S content and 169.2972 kg of Fe2S3 and water mixture. The
biogas with less amount of H2S will then undergo pressure swing absorber to further
separate the components which will produce 4372.4928 kg of CH4 and 2202.9353 kg of
CO2. Carbon dioxide and methane produced will be compressed and stored in a storage
tank. Figure 5.7 shows the process of producing methane and carbon dioxide.

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Figure 5.6 Production of Biomethane and Carbon Dioxide

Organic Fertilizer

The plant will also be producing an organic fertilizer to fully utilize the solids and
residues left in the anaerobic digester. Shown in the table below is the Philippine
Standard for organic fertilizers.

Table 5.4
Chemical Composition of Organic Fertilizer
Properties Nominal Value
Total NPK 5% - 7%
C:N 12:1 – 20:1
Organic Matter >20%
Actual Moisture Content 30% - 35%
Color Brown to Black
Consistency Friable
Odor No foul odor
Source: Philippine National Standard, 2013

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Solid Sulfur

Ferric Sulfide and water coming from the gas absorption will be further processed
to separate its components. An amount of 169.2972 kg of the mixture will undergo to
oxidizer in which 147.69 kg of air will be added to produce 116.6744 kg of spent air and
stream of mixture of 200.32 kg of iron (III) oxide, sulfur, and water. Iron (III) oxide mixture
will be further processed to produce 68.91 kg of solid sulfur. Figure 5.8 shows the
process of producing solid sulfur.

Figure 5.7 Production of Solid Sulfur

Wastewater Treatment

Wastewater has always been one of the major concerns in every industrial and
manufacturing plant. That is why treatment is taken into consideration. Proper disposal
of waste will be executed to conform to existing Philippine rules and regulations on
waste.

Figure 5.8 represents the designed wastewater treatment facility of Excelergy

Biofuels Corp.

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Figure 5.8 Wastewater Treatment

Solid Wastes

Waste disposal of the suspended solids acquired from sedimentation tank and
disinfection tank, will make use of Philippine wetland, Las Piñas-Parañaque Critical
Habitat and Ecotourism Area (LPPCHEA) located in Manila.

Solid wastes that are generated by facilities such as administrative offices,

canteen, comfort rooms, and other departments will be disposed according to the rules
and regulations regarding waste disposals. These will be collected and transferred to the
solid waste management facility of the plant.

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