Projects
Current
Funded by FAPESP (23/01072-7)
This research aims to propose the concept of a Symbiotic Energy-Cane Biorefinery (SYMBioref) in which energy cane, a sugarcane type rich in fibers, is co-processed with waste materials from other industries, especially refuse-derived fuel (RDF) from municipal solid-waste processing plants, to expand the production of ethanol to a portfolio of fuels and chemicals. This project will investigate techno-economic-environmental aspects of conceptual design alternatives of the SYMBioref that integrate fermentation processes with gasification technology. In the SYMBioref, energy-cane juice is fermented year-round to produce ethanol, and part of the cane biomass is pretreated and enzymatically hydrolyzed to produce glucose and then ethanol. The bagasse hemicellulose hydrolysate (containing xylose) is fed to a multi-product fermentation by two non-genetically modified Clostridium species to produce acetone, butanol, ethanol, and 1,3-propanediol. Part of the energy-cane biomass and lignin are co-processed with other wastes (RDF, eucalyptus biochar, and biodiesel-derived glycerol) by gasification, and the resulting synthesis gas is converted into H2, natural gas, and electricity. Interestingly, the CO2 produced by fermentation will be used as a gasification agent, and part of the H2 will be used to produce jet fuel from the hemicellulose hydrolysate-derived butanol via alcohol-to-jet technology. This proposed design of the SYMBioref will be assessed against design alternatives without the biochemical processing of bagasse, and another that substitutes gasification by a conventional boiler-based cogeneration system. The project is organized into four tasks: (1) techno-economic and life cycle analyses of the proposed design configurations of the SYMBioref; (2) characterization of the wastes considered for gasification; (3) simulation of gasification for the co-processing of wastes, and simulation of the conversion of synthesis gas into hydrogen, natural gas, and electricity; and (4) development of a fermentation strategy that enables the conversion of non-detoxified energy-cane hemicellulose hydrolysate into butanol and other chemicals. The overarching goal of this research is to encourage the continuing growth of the agribusiness sector in the markets of gas and liquid fuels and bioelectricity supported by a solution to face the threat of landfill saturation in densely populated areas. (AU)
Past
Funded by FAPESP (18/23983-3)
Changes in the petrochemical industry have resulted in decreasing production of four-carbon olefins and, consequently, it has affected the supply of 1,3-butadiene to the rubber tires industry. For this reason, chemical companies have been searching for renewable sources of butadiene precursors, thereby creating a potential market for sugarcane companies. However, it is not obvious which technological route can give sugarcane and chemical companies the best win-win solution. The route based on the conversion of first-generation ethanol (1G) to butadiene can accelerate the penetration of sugarcane in the tires value chain because this option does not require investments from sugarcane companies. On the other hand, for sugarcane companies planning to produce second-generation ethanol (2G) from sugarcane bagasse, the conversion of hemicelluloses from the bagasse into n-butanol or 2,3-butanediol (other possible routes) may be more interesting. These bagasse-based routes can boost the economic feasibility of 2G ethanol biofuel while offering chemical companies better buying price and yields. Nevertheless, fermentative conversion of the hemicellulose hydrolysate faces technical challenges. The hydrolysate is dilute (~20 g/L xylose) and biomass pretreatment-derived microbial inhibitors prevent the efficient conversion of xylose. The present work plan aims at increasing the conversion efficiency of sugarcane hemicellulose hydrolysate (non-detoxified) into n-butanol and 2,3-butanediol. To achieve this aim, we will develop a fermentation strategy that features three aspects: mixing with molasses, fed-batch operation, and cell immobilization using the sugarcane bagasse as cell carrier. Moreover, we will assess the techno-economic and environmental (carbon footprint) potential of producing 1,3-butadiene from butanol, butanediol, and 1G ethanol. Therefore, with the proposed research we expect to find technological solutions that accelerate the penetration of sugarcane in the tires value chain in a way that is economic and environmentally attractive for sugarcane and chemical companies. (AU)
Funded by FAPESP (15/07097-5)
Following the current global evolution of the pulp industry, Brazilian eucalyptus pulp producers are interested in expanding their product portfolio and penetrate emerging markets of the bio-economy. Among an array of products, there is a special interest in biofuels and chemicals such butanol. Although modern pulp mills are energy exporters, high steam consumption and excessive stillage (vinasse) production can considerably decrease the attractiveness of projects with bioprocesses such as fermentation. The major issues are the investment needed to meet the new energy demands and limitation of the new process to a non-competitive production scale. Besides, attention must also be given to process flexibility and its key importance to business robustness in face of intrinsic market oscillations. In this manner, process integration, energy efficiency, and process flexibility are the issues to be tackled in this project.In this context, the aim of this project is the development of a bioprocess with high energy efficiency for the flexible production of butanol/ethanol integrated to a Kraft pulp mill. The main scientific challenge consists in developing a fermentation technology which is at the same time intensified and flexible (production of ethanol and of butanol). Not least important is the determination/assessment of integration strategies between the new process and a Kraft pulp mill so that both businesses benefit economically and environmentally from each other.Thus, based on a multidisciplinary approach, process systems engineering tools (computer simulation and techno-economic analysis) in association with laboratory-scale activities will serve the development of (i) a flexible bioprocess and (ii) the advanced fermentation technology - dubbed here as "flexible flash fermentation"- with integrated product recovery suitable for both ethanol and butanol fermentation.
Participation in the following projects
FAPESP 18/25682-0 – SPEC - São Paulo Excellence Chairs – PI: Lee Lynd (Dartmouth College)
FAPESP 17/11523-5 – Thematic Project – PI: Antonio Bonomi (LNBR/CNPEM)
FAPESP 15/20630-4 – Thematic Project – PI: Rubens Maciel Filho (FEQ/UNICAMP)
