Solid-liquid Separations in Biomass Processing

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1 Solid-liquid Separations in Biomass Processing Brian Cooper HAZEN RESEARCH, INC 4601 INDIANA ST. GOLDEN, CO 80403

2 Basic Process Flow Diagram Mill Feedstock Bio-Processing Hydrolysis Filter Purification Shipping and Profit

3 Solid-Liquid Separations Commit your blunders on a small scale; make your profits on a large scale. L.H. Baekeland (inventor of Bakelite, the first synthetic plastic)

4 Solid Liquid Separations as a Process PRE-TREATMENT Chemical Flocculation Coagulation ph adjustment SOLIDS CONCENTRATION Physical Crystal Growth Addition of filter aids Freezing Ageing Clarification Gravity sedimentation Thickening Gravity sedimentation Centrifugal sedimenters Hydrocyclones Delayed cake filters Crossflow filters Assisted separations Magnetic Electric/Dielectric Acoustic Vibration Flotation SOLIDS SEPARATION Cake filters Pressure Vacuum Centrifugal Gravity Depth filters Granular beds Cartridges Precoat Crossflow POST-TREATMENT Filtrate Polishing Decolourisation Cake Consolidation Washing Deliquoring Thermal Drying Wakeman, R. and Tarleton, S., Solid Liquid Separation: Principles of Industrial Filtration, Elsevier Advanced Technology, 2005, p. 2.

5 Solid-Liquid Separations as a Process Solids Concentration is where significant improvements can often be made. Simple equipment capable of handling large quantities of slurry. Well understood, established technology and often less capital intensive.

6 Filtration Q= K(AΔp/μL) Q = flow through a bed of solids K = permeability of bed A = surface area Δp = driving pressure μ = fluid viscosity L = thickness of bed

7 Case Study: Filtration Use of a vacuum belt filter to separate hydrolysate fractions

8 Case Study: Filtration Use of a vacuum belt filter to separate hydrolysate fractions hydrolysate solids 1 gallon EtOH requires 20 gallons hydrolysate at 80 g/l Commercial belt filter can accept 2 gal/min liquid out to polishing filter Motors required: belt drive, vacuum pump, feed pump, product pump, wash pump

9 Case Study: Filtration Use of a vacuum belt filter to separate hydrolysate fractions 10 minutes for separation = 1.23 kwh Cost for power = $0.05/gal EtOH equivalent

10 Case Study: Filtration liquid and fines direct to polishing filter hydrolysate solids liquid out to polishing filter liquid and coarse solids to HVBF 1 gallon EtOH requires 20 gallons hydrolysate at 80 g/l Utilize hydrocylone to send fines and liquid directly to polishing filter Commercial belt filter can accept 5 gal/min 4 minutes for separation = 0.49 kwh Cost for power = $0.02/gal EtOH equivalent

11 Solid-Liquid Separations Feedstock Hydrolysis Steam PI PI Controlled vent Safety Vent TI Screen ½ Autoclave PI TI Condenser Blow Down Tank Overheads Collection Pan

12 Gravity Separation/Flotation as Pretreatment Sedimentation u t = x 2 (ρ s -ρ)g/18μ x = particle size ρ = density g = acceleration due to gravity/force μ = fluid viscosity

13 Gravity Separation/Flotation Kynch Testing Figure from Cheremisinoff, Nicholas, Pocket Handbook for Solid-Liquid Separations: Calculations and Guidelines for Process Engineering, Gulf Publishing Company, 1984, p. 89.

14 Gravity Separation/Flotation Kynch Testing

15 Gravity Separation/Flotation Kynch Testing Feedstock Initial slurry %solids Terminal pulp % solids Ponderosa 1st Stage Lodgepole 1st Stage Lodgepole 2nd Stage

16 Thickeners/Clarifiers Feed Liquid out (overflow) Solids out (underflow)

17 Continuous Countercurrent Decantation (CCD) Bulk liquids movement overflow Feed Liquid out underflow Solids out Bulk solids movement

18 Gravity Separation/Flotation as Pretreatment Flotation u t = x 2 (ρ l -ρ g )g/18μ x 2 = diameter of gas-solid agglomerate ρ l = density of liquid ρ g = density of gas g = acceleration due to gravity/force µ = viscosity

19 Flotation Cells Figure from Evans, Geoffrey M., Atkinson, Bruce W. and Jameson, Graeme J., The Jameson Cell, Flotation Science and Engineering, Marcel Dekker, Inc., 1995, p. 334.

20 Flotation Air inlet Froth Froth collected Slurry (Tails at Completion) Mixer Concentrate Air dispersed in Liquid

21 Flotation

22 Flotation

23 Particles in Untreated Hydrolysate

24 Particles in Flotation concentrate

25 Slurry Photographs Concentrate Tails

26 Particle Size distributions

27 Particle Size distributions

28 Conclusions Solid liquid separations in commercial operations are very capital intensive and can represent a significant fraction of overall capital and operating costs. As such, they represent a large risk factor when scaling processes It is preferable to begin examining technologies as soon as the process chemistry is determined Treat solid liquid separations as multi-step processes Collect representative slurries, preferably at the pilot stage before the final commercial equipment selection

29 Suggested Reading/References Cheremisinoff, Nicholas, Pocket Handbook for Solid-Liquid Separations: Calculations and guidelines for process engineering, Gulf Publishing Company, 1984 Evans, Geoffrey M., Atkinson, Bruce W. and Jameson, Graeme J., The Jameson Cell, Flotation Science and Engineering, Marcel Dekker, Inc., 1995 Gochin, R.J. Flotation, Solid-liquid separation, 2nd ed., edited by Svarovsky, Butterworths and Co., 1981 Matis, K.A. and Zouboulis, A.I., Flotation Science and Engineering, Marcel Dekker, Inc., 1995 Perry, Robert H., and Green, Don W. ed, Perry s Chemical Engineer s Handbook, 7th edition, Sections 18 and 19. Peters, Max S., Timmerhaus, Klaus D. and West, Ronald E., Plant Design and Economics for Chemical Engineers, 5th ed. McGraw-Hill, 2003 Pierson, H.G.W., The Selection of Solid-Liquid Separation Equipment, Solid-Liquid Separation, L. Svarovski, 2nd ed., Seidel, D. C. Laboratory Procedures for Hydrometallurgical-Processing and Waste-Management Programs, United States Department of the Interior Bureau of Mines Information Circular 9431, 1995 Svarovsky, L., Hydrocyclones, Hold, Rinehart and Winston Ltd., 1984 Wakeman, R. and Tarleton, S., Solid Liquid Separation: Principles of Industrial Filtration, Elsevier Advanced Technology, Wakeman, R. and Tarleton, S., Solid Liquid Separation: Scale-up of Industrial Equipment, Elsevier Advanced Technology, Contact: Brian Cooper, Hazen Research, Inc. cooperb@hazenresearch.com

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