ENK6-2002-30029 Development of a Biotechnological High Yield Process for Ethanol Production Based on a Continuous Fermentation Reactor - FERMATEC

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Biological Conversion : EESD (Energy, Environment and Sustainable Development) : Liquid Biofuels and Biogas

Proposal No:	ENK6-2002-30029
Date Prepared:	February 2004
Source:	European Bio-Energy Projects (EUR 20808)

Introduction

In the EU, as elsewhere, an increase in energy output is projected over the next 20 years: from 12 million barrels per day (600 million toe) in 2000 to 13.2 million barrels per day (660 million toe) in 2020.

In the EU the dependence on oil imports is already high (currently 75%) and it is likely to increase even further and exceed 85% by the year 2020. The rising fossil fuel consumption implies the augmentation of greenhouse gas emissions, in particular of CO₂. In the EU about 60% of CO emissions come from transport, accounting for 25% of total energy-related CO₂. emissions, of which 80% comes from road transport. The use of alternative fuels like alcohol, biodiesel, biogas, electricity etc. can help: they can reduce petroleum dependence and, in the case of alcohol, it can also reduce gaseous emissions.

The EC's contribution to lowering CO₂. emissions can be achieved by several measures, but the largest is the possibility of using up to 25% anhydrous ethanol blended with gasoline. (Brazil is using up to 22-23%.)

The EC has taken certain decisions which will impact on the community's ethanol industry, both directly and indirectly: The most recent directive (May 2003) provides for indicative targets of a 5.75% biofuel content in all fuels by 31 December 2010, starting at 2% by 31 December 2005.

As a consequence, ethanol use could reach 11 billion litres a year by 2010 if all 15 member states were to comply fully with the legislation, which is a great step compared with an estimated 390 million litres in 2003.

Activities

In the FERMATEC project a Fluidised-Bed Biorreactor - Three Phase (FBR 3P) will be dimensioned and used for the field tests to ensure performance in real conditions.

The work is to be carried out first at laboratory scale, which includes the use and selection of the best micro-organisms and the testing of some variations in the solid matrix for cell immobilisation and several raw materials. Afterwards, the long term operation of a laboratorial FBR-3P new fermenter will be implemented.

The second part of the work will be concentrated on a scaled-up and long term operation of the prototype FBR-3P including optimising operating conditions such as pH, temperature, dissolved oxygen, substrate flow rate and also maximising the yield. This work is especially focused on the building and operation of an industrial prototype in an end user installation.

The process conception, which includes the selection of micro-organisms and the immobilisation, process modelling, solid support selection, establishment of process control and monitoring, must be performed mostly by the RTD partners due to their large knowledge in these fields.

It is expected that strong partnerships between the researchers and members of industry will develop as they work in co-operation to solve technical problems and meet changing, concerning demands.

Progress

The project started in January 2003 and the work scheduled for the 1st semester has been concluded. The main tasks developed are related to process modelling, laboratorial tests and a survey on the raw materials and requirements, which will be verified in the final bio-reactor. It has developed the model of the first Fluidised Bed Reactor - 3 Phases laboratorial prototype.

From this model it was possible to establish the configuration of the fermenter, develop the necessary technical drawings, specifications and material selection that has led to the construction of the first laboratorial prototype. This will be running continuously at INETI installations, as predicted in the initial workplan.

Also resulting from the work developed in the first semester, it is possible to now have a selection of the micro-biological species and solid supports that will be used when the reactor is continuously running during in the second semester of 2003.

Impact and exploitation

Recent figures reveal that the world ethanol production in 2003 can achieve the highest annual growth rate by more than 10% to almost 38 billion litres against a revised 2002 total of 34.3 billion. Ethanol output in the European Union (EU) is increasing by under 7%. It is a goal of this project to obtain a final prototype that gives the best per formance possible thus giving to industries, both in and out of the consortium, good perspectives to invest in the modernisation of their industrial facilities and stimulate new investments in bioethanol industry.

The product of FERMATEC will be available on the market in approximately one year, and the technology could be used without further tests and research. This is a consequence of the size of the final tested prototype. Commercial conditions, like real raw materials, will be used and industrial tests will also be conducted.