Presentation of Carlos Eduardo Vaz Rossell for the Workshop on Hydrolysis Route for Cellulosic Ethanol from Sugarcane. Apresentação de Carlos Eduardo Vaz Rossell realizada no "Workshop on Hydrolysis Route for Cellulosic Ethanol from Sugarcane" Date / Data : February 10 - 11th 2009/ 10 e 11 de fevereiro de 2009 Place / Local: Unicamp, Campinas, Brazil Event Website / Website do evento: http://www.bioetanol.org.br/workshop1

1. PILOT PLANT FOR
PROCESS DEVELOPMENT – PPDP
Centro de Ciência e Tecnologia do Bioetanol – CTBE
Carlos Eduardo Vaz Rossell
crossell@bioetanol.org.br
Workshop on Hydrolysis Route
for Cellulosic Ethanol from Sugarcane
February 10-11 th 2009-Campinas, Brazil

2. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
• Bagasse conversion to Bio-Ethanol;
• PPDP, site location, project;
• Main scope: Enzymatic hydrolysis
conversion of Bagasse to Ethanol;
• Justification for the project
• Scope of the Pilot Plant,
• Conceptual Project;
• CTBE support to Research Groups.

3. Sugar cane Bagasse and straw
conversion to Bio-Ethanol
• Bio-Ethanol (1st Generation technology) Fuel from Sugar
Cane Agro-Industrial Sector is very important to Brazilian
Economy, it is sustainable, green, captures CO2, has a
net positive energy balance, does not compete with food
crops and generate employment and welfare.
• A better use of energy available in sugar cane can be
attained if Ethanol Distilleries are revamped and
optimized, straw remaining after cane harvesting be
recovered, as well as the most of remaining bagasse is
obtained after cane processing.
• This lignin-cellulose biomass recovered if converted to
ethanol by Hydrolysis and fermentation can increase
ethanol productivity in at least 40% for the same planted
area.
• Assessment of a feasible, economic and sustainable
technology it is strategic for Brazil continues his
leadership in Bio-fuels production.

4. PPDP location at the Campus of
LNLS

5. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
Lay-out
A
1 2 3 4 5 6 7 8 9 10 11 12 13
C
CIRCULAÇÃO
B
FERMENTADOR
DE 40L
SEMI-ANALITICAS
PREPARO DE MATERIAL
BALANÇAS
FREEZER
AUTOCLAVE
ESPECTOFOTÔMETRO CENTRIFUGA
LABORATÓRIO 1 NB-2 AUTOCLAVE
FERMENTADOR
GELADEIRAS
DE 10L
MICRO
BALANÇA GELADEIRA
CENTRIFUGA
ANALITICA PREPARO
BANCADA PARA
ELETROFORESE DE MEIO DE
ESPECTOFOTOMETRO CULTURA
FILTRAÇAO
ACOMPANHAMENTO
FERMENTADOR
MICRO
DE 10L BALANÇA
PREPARAÇAO
DE MATERIAL BALANÇA ANALÍTICA
MICROCENT.
GELADEIRA
BALANÇA SEMI ANALÍTICA
PCR ESTUFA
CAPELA DE CAPELA DE
4.60
CAPELA DE PHMETRO
FLUXO LAMINAR FLUXO LAMINAR FLUXO LAMINAR
SHAKER PCR
SHAKER PLACA AGITADORA
C
A

6. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
Front view of PPDP
A B C

7. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
Layout of PPDP6 – Unit for ethanol
Fermentation
11
10

8. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
Enzymatic hydrolysis conversion of
Bagasse to Ethanol, the main purpose
of the PPDP

9. Critical steps for hydrolysis technology
Physical Chemistry pretreatment of sugar
cane bagasse (and straw);
Development of enzymes tailored for
conversion of sugar cane cellulosic raw
materials into fermentable sugars;
Development of enzymatic hydrolysis
processes of sugar cane bagasse
conversion ;
Development of microorganisms for
fermentation of pentoses to ethanol.

10. Enzymatic Hydrolysis for bagasse/ethanol conversion
BAGASSE
ETHANOL
CLEANING DISTILLATION/DEHYDRATION
SAND,
SOIL
METALS 4
PENTOSE FERMENTATION
FRACTIONATION TO ETHANOL
FINES WINE
YEAST PRODUCTION
AND
RIND
PREHYDROLYSIS PENTOSE LIQUOR HEXOSE FERMENTATION
TO ETHANOL
SPECIAL YEAST
1 HEXOSE LIQUOR
LIGNIN
LIQUOR PURIFIYNG
DESLIGNIFIYNG
CELULASE
TREATED FIBER
PRODUCTION
2
ENZYMATIC HEXOSE LIQUOR
HYDROLYSIS
2
CELULASE RECOVER
CELULASES 10
back next

11. PPDP- Justification for the project
• Processes involved in Hydrolysis are extreme
complex and we must advance in the domain of
them;
• Bio-fuels are strategic for Brazil and it must be
assured the maintenance of leadership;
• Brazilian research projects are been executed (most
of them) in laboratory scale which does not assure
their reproduction at industrial scale;
• Facilities for experimentation at near industrial
conditions are required.

12. PPDP- Justification for the project
• Most of the processes and unit operations involve a two
phases solid-fluid heterogeneous system, which
increases complexity and makes scaling-up difficult;
• Main technical barriers to the advance of Hydrolysis
require the confirmation of laboratory results in a scale
more representative;
• Consumption of utilities: steam, water, electrical power
and products: enzymatic complex, chemicals, etc.,
require a more precise estimate which can only be
obtained in a pilot unit;
• Investments in fixed capital only could be forecasted with
a certain precision level after pilot plant trials.

13. PPDP- Scope of the Pilot Plant
• Development of the route(s) for sugar cane bagasse and straw
conversion in Bio-Ethanol;
• To scale-up Physical, Chemical and Biological processes
related to Hydrolysis;
• To validate laboratory experiments;
• Assessment of reliable mass and energy balances and
kinetics data of processes involved in Hydrolysis technology;
• Optimization of the operational ranges of the processes being
studied;
• Assessment of data for selection of building materials
(resistant to corrosion, abrasion, high temperature and
pressure);
• Obtaining of data for the conceptual design of processing
equipment.

14. PPDP- Conceptual Project
• Basis of the Project:
 A multipurpose unit;
 The highest level of flexibility;
 Size (compatible with installation and operation in a Research
Center. Minimum size (batch size or production rate) able to
reproduce industrial operation;
 Divided in independent units that do not operate
simultaneously and are able to combine different arrangements
of Physical, Chemical and Biological processes.
 Units must be able to incorporate new processes and to
reformulate and up-grade existing processing lines; The
highest level of Instrumentation, Automation and Data
Acquisition and Transfer,

15. PPDP- Conceptual Project
Operational model between Research Groups
and CTBE facilities: LDP, PPDP, Scientists
and Engineers team and the Virtual Bio-
Refinery project.

16. Research, Development and Innovation
Research Groups
(including CTBE group)
PDU
Process
LDP PPDP Demonstration
Process Pilot Plant Unit
Development For Process
Laboratory Development STEPS NOT CONSIDERED
IN THIS PROJECT
COMMERCIAL UNIT
CTBE

17. Research, Development and Innovation
Research,
Development
and Innovation
Basic and Process Start-up and
Engineering Operation of PDU
Conceptual
Engineering
Detailed Design and Building
Engineering of an Industrial Unit
Areas in which PDU Building Industrial Units
CTBE is directly
involved
Areas in which CTBE
could be indirectly
involved through
technical support

18. Interaction between PPDP and the
Virtual Bio-refinery Project
Hydrolysis process
Technical, Economical
development involving
and Sustainable
Research Groups, LDP
evaluation of the
and the PPDP
technology.
Technological
route for Hydrolysis Virtual
Bio-Refinery
PDU
Assessment of technology for
Hydrolysis

19. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
Organization
• PPDP1– Unit for physical treatment of sugarcane
bagasse;
• PPDP2 – Unit for physical chemical pretreatment
of Lignin-cellulose material;
• PPDP3 – Unit for Fungi, Yeasts and Bacteria
Production;

20. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
Organization
• PPDP4 – Unit for biomass enzymatic
Hydrolysis;
• PPDP5 – Unit for Separation and Purification;
• PPDP6 – Unit for ethanol Fermentation.

21. PROCESS DEVELOPMENT -
PPDP
Organization
• PPDPns: area reserved (600 m²) for new experimental
units to be developed and installed once new
developments be introduced;
• Utilities: Saturated Steam at 10 Bar and 35 Bar, Thermal
Utilities
fluid (35-280ºC), cooling water (25-29ºC), cold water (6-
12ºC), compressed air at 10 Bar (dry, oil and particle
free);
• Support Units: Control Laboratory, Workshop,
Instrumentation and Control Office, Visitant Researchers
Offices

22. PPDP1 – Unit for physical treatment of
sugarcane bagasse
• Development of flexible new technologies for sugarcane bagasse
and trash physical treatment, adaptable to downstream processes
• Study sugarcane raw bagasse depithing process and the
applicability of its fractions in the enzymatic route for ethanol
production
• Development of a methodology for the characterization of the
fractions obtained from sugarcane bagasse and trash
• Establishment of operational and project parameters to validate
developed technologies, provide knowledge to scale-up and for
technical, economical and sustainability evaluation.
• Production of sugarcane bagasse and trash samples for studies at
CTBE and at the Research Groups involved with Hydrolysis

23. PPDP3 – Unit for Fungi, Yeasts and
Bacteria Production
Process Flow sheet-2008.23.100.04.001.000-SUBMERGED
FERMENTATION FOR THE PRODUCTION OF YEASTS,
BACTERIA, FUNGI AND HYDROLASES
SAS
H2O
SAS
H2OC H2OR
H 2O
H2OG
H
SA
MT-01
CON H2OR SAS
H2O SA
FE- FE-03 H2OR
SA CON
H 2O
SAS PT-01 CON
H2OR H2OC
H 2O H2OR
PC-01
H2OC
H2OC
CO
SA
CON SAS
H2
H2 H2OR CA
H2OC
CAR FIM
XT-01
SA FIM P-05
P-03 CE-01
CAR
P-02 MF-
DE-01
P-04
LEV

24. PPDP3 – Unit for Fungi, Yeasts and
Bacteria Production
PPDP3: Unidade de produção de fungos, leveduras e bactérias (produção de leveduras
para fermentação, produção de hidrolases)
N° Identif. Qt Cap Un. Descrição Especificação
1 TM-01 1 250 litros Tanque de Tanque em aço inox 304, atmosférico, com camisa para Equipamento a ser projetado
preparo de aquecimento com vapor eserpentina para resfriamento
com água, borbotor para injeção de vapor direto
construção sanitária, com agitador tipo turbina com
passo (1/2 HP), rotação variável ( 0-300 rpm)
N° Identif. Qt Cap Un. Descrição Especificação
2 TC-01 1 1000 tros/horaEsterilizador Conjunto para esterilização com seção de aquecimento Equipamento a ser especificado
Preliminary continuo com aquecedor de placas, seção de retenção tubular e
resfriamento com trocador de placas temperatura de
operação até 140 ºC, com módulo de controle
incorporado
em parceria com o fornecedor
Equipment N°
3
Identif.
FE-02
Qt
1
Cap
75
Un.
litros
Descrição
Fermentador
Especificação
Fermentador em aço inox 316 L, com controles Equipamento a ser especificado
automáticos de temperatura, pH, O2 dissolvido, aeração, em parceria com o fornecedor
ciclo de esterilização, rotação variável (0-500 rpm),
Data Sheet
condensador de saída, com sonda de capacitância, 04
entradas padrão para adição de sondas suplementares
(NIR, potencial redox, etc), composição de gas de saída
N° Identif. Qt Cap Un. Descrição Especificação
4 FE-03 1 250 litros Fermentador Fermentador em aço inox 316 L, com controles Equipamento a ser especificado
automáticos de temperatura, pH, O2 dissolvido, aeração, em parceria com o fornecedor
ciclo de esterilização, rotação variável (0-500 rpm),
condensador de saída, com sonda de capacitância, 04
entradas padrão para adição de sondas suplementares
(NIR, potencial redox, etc), composição de gas de saída
N° Identif. Qt Cap Un. Descrição Especificação
5 CE-01 1 1000 tros/horaCentrífuga de Centrífuga contínua com descarga automática de Equipamento a especificar
separação sólidos, esterilizável "in situ", com rotação variável
de
microorganis
N° Identif. Qt Cap Un. Descrição Especificação
6 MF-01 1 1000 tros/hora Microfiltro Conjunto de microfiltração de feixe de tubos capilares, Equipamento a ser especificado
para esterilizavel in situ , com bomaba de recirculação, em parceria com o fornecedor
concentração sistema de contralavagem,tanques auxiliares, modulo de
de leite de controle, casco, válvulas, tubulaçoes e acccessórios em
levedura aço inox 316, construção sanitária
N° Identif. Qt Cap Un. Descrição Especificação
7 DE-01 1 250 litros Decantador Tanque em aço inox 304, atmosférico, com fundo cónico, Equipamento a ser projetado
para construção sanitária, com agitador tipo áncora (1/2 HP),
concentração rotação variável ( 0-50 rpm)
de biomassa
d
N° Identif. Qt Cap Un. Descrição Especificação
8 B-01 1 2500 tros/hora Bomba Bomba em aço inox 316, construção sanitária com selo Equipamento a especificar
centrífuga de mecânico
alimentação
de mosto ao
fermentador
N° Identif. Qt Cap Un. Descrição Especificação
9 B-02 1 50 tros/hora Bomba de Bomba em aço inox 316, construção sanitária com selo Equipamento a especificar
mecânico
dosagem de
mosto ao
fermentador
N° Identif. Qt Cap Un. Descrição Especificação
10 B-03 1 1500 tros/hora Bomba Bomba em aço inox 316, construção sanitária com selo Equipamento a especificar

25. Preliminary forecast of costs involved in
the project of LDP and PPDP
• Buildings; R$ 9.800.000,00
• LDP Equipment; R$ 4.900.000,00
• PPDP Equipment: R$ 2.600.000,00
• Utilities: R$ 1.300.000,00
• Instrumentation and control: R$ 2.875.000,00
• Costs related to LDP and PPDP
equipment installation: R$10.060.000,00
• Total: R$ 31.535.000,00

26. PPDP - Project Schedule
• Conceptual Project (submitted to evaluation);
• Scientist and Engineers hiring (to be finished until
6/2009);
• Basic Project (to be finished until 3/2009);
• Detailed Project ( to be finished until 4/2009);
• Civil works and Buildings construction:
 LDP (started and to be completed until 9/2008);
 PPDP (forecasted to 10/2009);
• Equipment Acquisition (from 3/2009 until 7/2009);
• Equipment installation (until the end of 2009)
• Testing of equipment and start-up (forecasted to the
beginning of 2010).

27. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
CTBE support to Research Groups:
• A skilled team of postgraduates (Biologists,
Physics, Chemists and Engineers) for:
 Give support to researchers in processes and
equipment operation, training, planning and
execution of experimental work;
 Management of PPDP and LDP (maintenance,
calibration, installing, configuration and set-up of
process lines and up-grade of equipments).
 To support in the acquisition and storage of
experimental data.

28. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
CTBE support to Research Groups:
• A set of Units (PPDP1 to PPDP6) that involve
various alternatives of Physical, Chemical and
Biological processes that could be combined
in arrangements, in order to reproduce
specific routes for bagasse conversion to
ethanol;
• A Process Development Laboratory (LDP) with
the aim of providing the required infra-
structure for analytical procedures and the
Physical, Chemical and Biological
characterization of the process streams to be
studied.

29. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
CTBE support to Research Groups:
• Supply of standardized streams to
Researchers:
 Raw materials (as an example: raw and
pretreated bagasse and straw);
 Process Streams;
 Intermediary products( Hydrolysis liquors,
strains of microorganisms, etc.)
 Final products (Bio-Ethanol, formulated
hidrolases with various levels of purity , etc.).

30. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
Main users of the PPDP facilities:
• Research team of CTBE
• Research Groups and Institutions
involved in Research and Development
of the conversion of sugarcane
bagasse and trash to Bio-ethanol.

31. PILOT PLANT FOR
PROCESS DEVELOPMENT - PPDP
Potential users of the PPDP facilities:
• Engineering and contracting Companies;
• Equipment Suppliers Companies;
• Sugar cane to Ethanol Distilleries;
• Public and Private Companies of the
Energy sector;
• The Chemical, Petrochemical and Food
Industries (Bio-Refineries).

32. PPDP - Interaction Between CTBE
and third parties
Research groups:
• Research will be oriented to generate
and make public knowledge, and
innovative research and technology
transfer in order to assure the
Brazilian leadership in the Bio-Ethanol
production chain;
• Confidentiality related to research will
be assured for attaining the
requirements for publications and
thesis;
• Rights, Patent filing, technology
transfer will follow the existing
regulations of LNLS.

33. PPDP - Interaction Between CTBE and
third parties
Project approval:
• The LNLS has well established procedures
for the approval of projects and the use of it
Laboratories by third parties. This
procedures will be extended to the projects
to be submitted to CTBE by Research
groups and Institutions
• Research Projects from third parties in
course at LDP and PPDP could be
submitted to evaluation by the Virtual Bio-
Refinery model.

34. PPDP- Project Group
• Carlos E. V. Rossell - Coordinator
• José Geraldo Pradella- Senior Researcher
• Edgardo O. Gomes- Engineer
• Fabio Squina- Researcher

35. Workshop on Hydrolysis Route
for Cellulosic Ethanol from Sugarcane
Thanks very much for your attention