Biomass Conversion and Biorefinery

Process design and economics of an aluminium chloride catalyzed Organosolv process

(Supplementary material)

Martin Schwiderski*,1, Andrea Kruse2

1 Karlsruhe Institute of Technology, Hermann-von-Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen , Germany. Fax: +49 721 608-22244; Tel: +49 721 608-26511; E-mail:

2University of Hohenheim, Garbenstrasse 9, 70599 Stuttgart, Germany. Fax: +49 711-459 24702; Tel: +49 711-459 24700; E-mail:

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Cooking & washing

Fig. S1: Flowsheet of the designed Organosolv plant.

Methanol & lignin recovery

Fig. S1: Flowsheet of the designed Organosolv plant (continued).

Methanol & lignin recovery (continued)

Fig. S1: Flowsheet of the designed Organosolv plant (continued).

Furfural recovery

Fig. S1: Flowsheet of the designed Organosolv plant (continued).

Enzymatic Hydrolysis

Boiler & turbine

Fig. S1: Flowsheet of the designed Organosolv plant (continued).

1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12
Mass flow solids [t/h] / C6-carbohydrates / 32.24 / 27.74 / 27.74 / 27.74
C5-carbohydrates / 15.49 / 0.43 / 0.43 / 0.43
Lignin / 18.57 / 8.96 / 8.96 / 8.96
Others / 17.00 / 5.55 / 5.55 / 5.55
Cellulase
Mass flow liquids [t/h] / AlCl3 / 0.99 / 0.47 / 0.52 / 0.01 / 0.47 / 0.01 / 0.47
C6-carbohydrates / 0.38 / 0.39 / 0.38 / 0.38
C5-carbohydrates / 0.22 / 0.23 / 0.22 / 0.22
Lignin / 4.59 / 4.97 / 4.59 / 4.59
Furfural / 0.07 / 0.07 / 2.16 / 2.35 / 0.18 / 2.16 / 0.18 / 2.16
MeOH / 0.84 / 29.59 / 121.17 / 121.17 / 72.80 / 78.80 / 75.18 / 72.80 / 75.18 / 72.80
Water / 83.30 / 81.59 / 3.36 / 16.35 / 16.35 / 88.60 / 96.00 / 157.65 / 88.60 / 157.65 / 66.44 / 88.60
Mass flow natural gas [t/h]
T [°C] / 20 / 20 / 105 / 67 / 69 / 180 / 180 / 36 / 90 / 82 / 20 / 74
p [bar] / 1 / 1 / 3.8 / 1 / 1 / 20 / 20 / 1 / 20 / 1 / 1 / 20
Vapor fraction / 0 / 0 / 0 / 0 / 0.5 / 0 / 0 / 0 / 0 / 0.1 / 0 / 0

Tab. S1: Mass balances of the designed Organosolv plant.

13 / 14 / 15 / 16 / 17 / 18 / 19 / 20 / 21 / 22 / 23 / 24
Mass flow solids [t/h] / C6-carbohydrates / 27.74 / 27.74 / 27.74
C5-carbohydrates / 0.43 / 0.43 / 0.43
Lignin / 8.96 / 8.96 / 9.02
Others / 5.55 / 5.55 / 5.55
Cellulase
Mass flow liquids [t/h] / AlCl3 / 0.47 / 0.01 / 0.46
C6-carbohydrates / 0.38 / 0.38
C5-carbohydrates / 0.22 / 0.22
Lignin / 4.59 / 0.06 / 4.53
Furfural / 2.16 / 0.03 / 0.17 / 0.04 / 0.24 / 0.19 / 2.22
MeOH / 72.80 / 4.01 / 37.94 / 74.88 / 0.50 / 117.33 / 75.70 / 114.43 / 0.52
Water / 66.44 / 88.60 / 84.49 / 0.54 / 2.09 / 59.62 / 0.19 / 146.93 / 94.77 / 140.77 / 295.39 / 232.51
Mass flow natural gas [t/h]
T [°C] / 60 / 74 / 20 / 67 / 30 / 51 / 72 / 41 / 41 / 62 / 20 / 20
p [bar] / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1
Vapor fraction / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0

Tab. S1: Mass balances of the designed Organosolv plant (continued).

25 / 26 / 27 / 28 / 29 / 30 / 31 / 32 / 33 / 34 / 35 / 36
Mass flow solids [t/h] / C6-carbohydrates / 27.74
C5-carbohydrates / 0.43
Lignin / 9.50 / 9.02 / 9.50 / 9.50 / 9.50
Others / 5.55
Cellulase
Mass flow liquids [t/h] / AlCl3 / 0.01 / 0.01 / 0.51 / 0.97 / 0.97 / 0.97 / 0.01 / 0.96
C6-carbohydrates / 0.39 / 0.77 / 0.77 / 0.77 / 0.77
C5-carbohydrates / 0.23 / 0.45 / 0.45 / 0.45 / 0.45
Lignin / 4.97
Furfural / 0.21 / 0.21 / 0.07 / 0.07 / 2.14 / 4.29 / 4.29 / 4.29 / 0.03 / 4.26
MeOH / 29.63 / 29.59 / 0.04 / 125.19 / 125.19 / 49.17 / 38.41 / 0.52 / 38.41 / 38.41 / 0.29 / 38.12
Water / 11.65 / 3.36 / 8.29 / 16.89 / 16.89 / 84.35 / 208.23 / 232.51 / 208.23 / 208.23 / 1.56 / 206.67
Mass flow natural gas [t/h]
T [°C] / 120 / 108 / 140 / 72 / 67 / 120 / 88 / 49 / 63 / 60 / 60 / 60
p [bar] / 3.9 / 3.8 / 3.8 / 1 / 1 / 3.9 / 1 / 1 / 1 / 1 / 1 / 1
Vapor fraction / 1 / 1 / 0 / 1 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0
37 / 38 / 39 / 40 / 41 / 42 / 43 / 44 / 45 / 46 / 47 / 48
Mass flow solids [t/h] / C6-carbohydrates
C5-carbohydrates
Lignin / 9.50 / 9.50
Others
Cellulase
Mass flow liquids [t/h] / AlCl3 / 0.01 / 0.98 / 0.98 / 0.98 / 0.01 / 0.01
C6-carbohydrates / 0.77 / 0.77 / 0.77
C5-carbohydrates / 0.45 / 0.45 / 0.45
Lignin
Furfural / 0.03 / 4.50 / 0.03 / 4.47 / 4.47 / 0.02 / 0.02 / 0.16 / 0.16
MeOH / 0.27 / 0.02 / 38.44 / 37.94 / 0.50 / 0.50 / 33.23 / 33.23 / 41.94 / 41.94
Water / 63.99 / 4.01 / 0.08 / 278.94 / 2.09 / 276.85 / 276.85 / 14.32 / 14.32 / 143.32 / 143.32
Mass flow natural gas [t/h] / 0.98
T [°C] / 60 / 60 / 20 / 60 / 62 / 30 / 60 / 60 / 82 / 71 / 85 / 85
p [bar] / 1 / 1 / 1 / 1 / 0.2 / 0.2 / 0.2 / 1 / 1 / 1 / 1 / 0.2
Vapor fraction / 0 / 0 / 1 / 0 / 1 / 0 / 0 / 0 / 1 / 0 / 0 / 0

Tab. S1: Mass balances of the designed Organosolv plant (continued).

49 / 50 / 51 / 52 / 53 / 54 / 55 / 56 / 57 / 58 / 59 / 60
Mass flow solids [t/h] / C6-carbohydrates
C5-carbohydrates
Lignin
Others
Cellulase
Mass flow liquids [t/h] / AlCl3 / 0.01 / 0.01 / 0.98
C6-carbohydrates / 0.77
C5-carbohydrates / 0.45
Lignin
Furfural / 0.16 / 0.01 / 0.15 / 0.15 / 0.15 / 9.29 / 9.29 / 9.29 / 4.97 / 4.98 / 4.32 / 0.05
MeOH / 41.94 / 0.29 / 41.65 / 41.65 / 0.01 / 0.73 / 0.73 / 0.73 / 0.69 / 0.23 / 0.04 / 0.03
Water / 143.32 / 98.02 / 45.30 / 45.30 / 276.61 / 35.30 / 35.30 / 35.30 / 35.19 / 35.06 / 0.11 / 0.91
Mass flow natural gas [t/h]
T [°C] / 52 / 60 / 40 / 40 / 100 / 98 / 96 / 40 / 40 / 97 / 40 / 87
p [bar] / 0.2 / 0.2 / 0.2 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1
Vapor fraction / 0.2 / 0 / 0 / 0 / 0 / 1 / 0 / 0 / 0 / 0 / 0 / 0
61 / 62 / 63 / 64 / 65 / 66 / 67 / 68 / 69 / 70 / 71 / 72
Mass flow solids [t/h] / C6-carbohydrates / 27.74 / 2.77 / 2.77 / 2.77
C5-carbohydrates / 0.43 / 0.43 / 0.43 / 0.43
Lignin / 9.02 / 9.02 / 9.02 / 9.02
Others / 5.55 / 5.55 / 5.55 / 5.55
Cellulase / 0.55 / 0.55 / 0.55 / 0.55 / 0.55
Mass flow liquids [t/h] / AlCl3
C6-carbohydrates / 27.74 / 25.84 / 1.90 / 0.01 / 1.89 / 27.73
C5-carbohydrates
Lignin
Furfural / 4.27
MeOH / 0.52 / 0.52 / 0.48 / 0.04 / 0.04 / 0.52
Water / 0.02 / 9.23 / 241.74 / 238.97 / 222.59 / 16.38 / 50.00 / 27.47 / 38.91 / 261.50 / 9.30 / 246.10
Mass flow natural gas [t/h]
T [°C] / 151 / 20 / 48 / 48 / 48 / 48 / 20 / 20 / 32 / 46 / 20 / 178
p [bar] / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 1 / 9.5
Vapor fraction / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0

Tab. S1: Mass balances of the designed Organosolv plant (continued).

73 / 74 / 75 / 76 / 77 / 78
Mass flow solids [t/h] / C6-carbohydrates
C5-carbohydrates
Lignin
Others
Cellulase
Mass flow liquids [t/h] / AlCl3
C6-carbohydrates
C5-carbohydrates
Lignin
Furfural
MeOH
Water / 54.50 / 9.30 / 300.60 / 246.10 / 54.50
Mass flow natural gas [t/h] / 1.05
T [°C] / 192 / 279 / 454 / 240 / 273 / 20
p [bar] / 13 / 62 / 60 / 9.5 / 13 / 1
Vapor fraction / 0 / 1 / 1 / 1 / 1 / 1

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Tab. S2: Electricity consumption of the Organosolv plant. It is scaled based on a similar Organosolv process.[21]

Electricity consumption [MW] / Scaling based on
Debarrking & chipping / 2.5 / Total mass flow
Cooking & washing
Digester / 2.1 / Total mass flow
Washer / 1.2 / Total mass flow
Total / 3.3
MeOH & lignin recovery
Pumps / 0.1 / Not scaled, assumed similar to [21]
Agitators / 0.3 / Not scaled, assumed similar to [21]
Filtration equipment / 0.6 / Not scaled, assumed similar to [21]
Total / 1.0
Enzymatic hydrolysis
Pumps / 0.5 / Not scaled, assumed similar to [21]
Agitators / 1.2 / Not scaled, assumed similar to [21]
Insolubles equipment / 0.9 / Insolubles mass flow
Total / 2.6
Boiler & turbine / 1.6 / Heat load
Utilities
Cooling tower system / 2.0 / Total cooling duty
Chilled water package / 1.4 / Total cooling duty
Plant/Instrument air / 0.2 / Not scaled, assumed similar to [21]
Process water system / 0.1 / Not scaled, assumed similar to [21]
Sterile water & CIP/CS system / 0.3 / Not scaled, assumed similar to [21]
Total / 4.0
Total electricity consumption / 15.0

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Tab. S3: Overview of the capital investment (SE = scaling exponent; CB = costing basis; IC = Installed equipment cost) and the electricity consumption.

SE / CB / IC [M$] / Scaling based on
Debarking & chipping / [21] / 41.7 / Not scaled, assumed similar to [21]
Cooking & washing
Digester & washer / 0.7 / [21] / 65.8 / Total mass flow
HX I - HXV / [19] / 1.4
Total / 67.2
MeOH & lignin recovery
Flash tank / [19] / 0.2
RC I - RC V / [19] / 9.8
Pump I - Pump V / [19] / 0.4
HX IV - HX VI / [19] / 0.2
Lignin filter / 0.8 / [32] / 2.5
Lignin filtration equipment / [21] / 1.3 / Not scaled, assumed similar to [21]
Lignin spray dryer / [19] / 1.7
Total / 16.1
Furfural recovery
RC VI - RC VIII / [19] / 2.8
Decanter / [19] / 0.2
HX VIII / [19] / 0.1
Total / 3.1
Enzymatic hydrolysis
Mixer / 0.5 / [32] / 0.2 / Total hydrolysate flow
Hydrolysis reactor / 0.7 / [32] / 6.1 / Total hydrolysate flow
Insolubles equipment / 0.8 / [32] / 6.8 / Total hydrolysate flow
Total / 13.1
Storages / [32] / 5.0 / Not scaled, assumed similar to [32]
Utilities
Cooling tower system / 0.6 / [32] / 3.2 / Total cooling duty
Chilled water package / 0.6 / [32] / 1.6 / Total cooling duty
Plant/Instrument air / [32] / 0.1 / Not scaled, assumed similar to [32]
Process water system / [32] / 0.6 / Not scaled, assumed similar to [32]
Sterile water & CIP/CS system / [32] / 1.4 / Not scaled, assumed similar to [32]
Total / 6.9
Boiler & turbine / 0.6 / [32] / 83.3 / Heat load
Total installed equipment cost / 236.4

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Calculation of the MSSP

The MSSP is that price that makes the net present value after the operation time (in this work 20 years) equal to zero. The net present value is calculated using following equations:

Net present value (year) = Present value (year) + Net present value (year -1)

Present value (year) = Annual cash flow (year) * (1 + Discount rate)^(-year)

Annual cash flow = Total revenues - Total operating costs - Equity financing - Land -

Working capital - Loan payment - Loan interest payment - Income tax

Income tax = Taxable income * Tax rate; for Taxable income ≥ 0

Income tax = 0; for Taxable income < 0

Taxable income = Net revenue + Losses forward

Losses forward (year) = Losses forward (year - 1) + Net revenue (year -1)

Net revenue = Total revenues - Total operating costs - Loan interest payment

- General plant depreciation - Steam plant depreciation

The Depreciation values, Loan payment and Loan interest payment are calculated according to the manual presented by Short et al..[23]

For the cash flow analysis it is considered that the plant is built within 3 years. The time table and the cash flows of the plant are shown in Tab. S4a.

Tab. S4a: Time table and cash flows of the Organosolv plant.

Time [months] / Cash flow
Planning and engineering / 0 - 12 / 8 % of FCI & Land costs
Construction / 13 - 24
25 - 36 / 60 % of FCI
32 % of FCI & Working capital
Start up / 37 - 39 / 50 % of production
75 % of variable costs
100 % of fixed costs
Full production / from 39 till the end

The discounted cash flow analysis to determine the MSSP is shown in Tab. S4b.

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Tab. S4b: Discounted cash flow analysis for the determination of the MSSP.

Year / 0 0 / 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12
Fixed capital investment / 33,4 / 250,7 / 133,7
Equity financing / 13,36 / 100,3 / 53,5
Loan / 20 / 150,4 / 80,2
Loan principal / 20 / 170,5 / 250,7 / 233,4 / 214,7 / 194,5 / 172,7 / 149,2 / 123,7 / 96,3 / 66,6 / 34,6 / 0
Loan interest payment / 1,6 / 13,6 / 20,1 / 20,1 / 18,7 / 17,2 / 15,6 / 13,8 / 11,9 / 9,9 / 7,7 / 5,3 / 2,8
Loan payment / 37,36 / 37,36 / 37,36 / 37,36 / 37,36 / 37,36 / 37,36 / 37,36 / 37,36 / 37,36
Land / 3
Working capital / 21,8
Total sales / 162,7 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5
Fixed costs / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3
Variable costs / 100,8 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2
Baghouse bags / 0,7 / 0,7
Total operating costs / 113,5 / 119,5 / 119,5 / 119,5 / 119,5 / 120,2 / 119,5 / 119,5 / 119,5 / 119,5
General plant depreciation / 95,6 / 68,3 / 48,8 / 34,8 / 29 / 29 / 29
Steam plant depreciation / 12,5 / 10,6 / 9 / 7,7 / 7,2 / 7,2 / 7,2 / 7,2 / 7,2 / 7,2
Net revenue / -78,8 / -32,4 / -9,8 / 7,1 / 15 / 16,2 / 19 / 50,2 / 52,6 / 55,1
Losses forward / 0 / -78,8 / -111,2 / -121,1 / -114 / -99 / -82,8 / -63,8 / -13,6
Taxable income / -78,8 / -111,2 / -121,1 / -114 / -99 / -82,8 / -63,8 / -13,6 / 38,9 / 55,1
Income Tax / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 13,6 / 19,3
Annual cash flow / -18 / -113,9 / -95,3 / 12 / 27,8 / 27,8 / 27,8 / 27,8 / 27,1 / 27,8 / 27,8 / 14,1 / 8,5
Present value / -18 / -103,6 / -78,8 / 9 / 19 / 17,2 / 15,7 / 14,2 / 12,6 / 11,8 / 10,7 / 5 / 2,7
Net present value / -18 / -121,5 / -200,3 / -191,3 / -172,4 / -155,1 / -139,5 / -125,2 / -112,6 / -100,8 / -90,1 / -85,1 / -82,4

Tab. S4b: Discounted cash flow analysis for the determination of the MSSP (continued).

Year / 13 / 14 / 15 / 16 / 17 / 18 / 19 / 20 / 21 / 22 / 23
Fixed capital investment
Equity financing
Loan
Loan principal
Loan interest payment
Loan payment
Land
Working capital
Total sales / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5 / 184,5
Fixed costs / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3 / 12,3
Variable costs / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2 / 107,2
Baghouse bags / 0,7 / 0,7 / 0,7
Total operating costs / 120,2 / 119,5 / 119,5 / 119,5 / 119,5 / 120,2 / 119,5 / 119,5 / 119,5 / 120,2 / 119,5
General plant depreciation
Steam plant depreciation
Net revenue / 64,4 / 65,1 / 65,1 / 65,1 / 64,4 / 65,1 / 65,1 / 65,1 / 65,1 / 64,4 / 65,1
Losses forward
Taxable income / 64,4 / 65,1 / 65,1 / 65,1 / 64,4 / 65,1 / 65,1 / 65,1 / 65,1 / 64,4 / 65,1
Income Tax / 22,5 / 22,8 / 22,8 / 22,8 / 22,5 / 22,8 / 22,8 / 22,8 / 22,8 / 22,5 / 22,8
Annual cash flow / 41,9 / 42,3 / 42,3 / 42,3 / 41,9 / 42,3 / 42,3 / 42,3 / 42,3 / 41,9 / 42,3
Present value / 12,1 / 11,1 / 10,1 / 9,2 / 8,3 / 7,6 / 6,9 / 6,3 / 5,7 / 5,1 / 4,7
Net present value / -70,3 / -59,2 / -49 / -39,8 / -31,5 / -23,9 / -17 / -10,7 / -5 / 0,2 / 4,9

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