PDX® reactor technology
in advanced BioFuels
production
October 2008
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Markets and Commercialisation
Food, Beverage,
Dairy and Brewing
Fire
Oil and Gas
Defence
Ethanol
Grain to
Ethanol
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In
Development
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Cellulose to
Ethanol
PDX technology
4 barG static pressure profile
4 barG temperature profile
40
0.4
35
0.2
30
0
Increases Ethanol yield by…
350
300
250
200
150
100
50
25
-0.2
20
-0.4
15
Condensation
shock-wave
-0.6
10
-0.8
5
•Instantly activating all the
starch
0
static pressure [barG]
temperature [degC]
400
0
-1
distance [mm]
Steam flow
•Activating the intracellular starch
•No hot spots = No starch
degeneration
Process flow
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Low pressure,
supersonic
vapour phase (95%
Vacuum)
Instantly activating all the starch
Analysis supported by: Campden and Chorleywood Food Research Association
and Reading Scientific Services Ltd
conventionally
cooked to 70ºC
PDX system
conventionally cooked to
85ºC held 10 minutes to 72ºC (Instantaneously)
Micrographs of 5% solution starch
cook
X
Inadequate cook
poor swelling
9
9
Good cook - full swelling/ no shear
Conclusion:
PDX gelatinises 99.9% of all starch instantly at 72 Deg C
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PDX systems
delivering value
today
4,000 Kg/Hour
(Food and Brewing)
440,000 Kg/Hour
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2x12,000 Kg/Hour
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The PDX ERT in
position at the
liquefaction tank
The PDX Ethanol Reactor Tower
arriving fully assembled
PDX systems
delivering value
today
(Biofuels)
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Oregon
Full scale PDX Ethanol Reactor Tower
install in a 40 mgal/year plant
Summary of initial third
party evaluation
• Trials conducted at respected National Corn to Ethanol
Research Center (NCERC) in Illinois, Dec 2007
• Objectives were to confirm
–
–
–
–
–
Anticipated yield improvements across full ethanol process
System design valid for production scale
Assess energy impact
Confirm expected enzyme reduction
Investigate downstream process impact
• Results excellent
• Further unanticipated savings identified
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Headline Results
- 30% Fermentation Time
+ 14% Yield uplift
- 75% Liquefaction Time
- 50% α-Amylase usage
• Performance benchmarked against a Jet Cooker Control
• Based on results from NCERC Trial December 2007
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NCERC
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PDX Reactor
verification trials at
NCERC
• Complete Ethanol production – from
slurry build & liquefaction through to
Fermentation & Distillation
• 15 x 1,500 USG batches processed
• PDX reactor system operated at a flowrate
of 60 USG / min
• This flowrate equals a plant size of 5.1 mill
USG / year of fuel ethanol
• Each test monitored and captured by 1,750
telemetry points
• Each batch processed was analysed for
performance at 50 individual sample points by
NCERC laboratory facilities and personnel
• Baseline tests performed using industry
best-in-class Jet Cooker technology
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Starch conversion to Glucose
NCERC results
100.0%
PDX
Maximum
% of starch converted to glucose
98.0%
96.0%
94.0%
92.0%
90.0%
14%
14%more
moreglucose
glucose
from
fromfeedstock
feedstock
88.0%
86.0%
Jet Cooker
84.0%
82.0%
80.0%
Jet_Cooker
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PDX
Starch conversion to Ethanol
NCERC results
116.0%
PDX
Maximum
114.0%
% Ethanol production
compared to Jet Cooker
112.0%
110.0%
108.0%
106.0%
14%
14%more
moreethanol
ethanol
from
fromfeedstock
feedstock
104.0%
102.0%
Jet Cooker
100.0%
98.0%
96.0%
Jet_Cooker
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PDX
Fermentation kinetics – NCERC results
120%
ethanol yield baselined to Jet Cooker
110%
100%
90%
80%
70%
60%
Normal industry
fermentor drop
50%
40%
PDX fermentor
sweet spot
30%
20%
Jet Cooker
PDX
10%
0%
0
5
10
15
20
25
30
time, hr
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35
40
45
50
55
60
PDX Reactor Energy Balance
•
•
•
Conventional
Liquefaction:
– Preheat to
activation temp 100
Deg C
– Maintain
liquefaction temp at
83 Deg C for 2
hours
PDX Liquefaction:
– Preheat to
activation temp 83
Deg C
– Maintain
liquefaction temp at
83 Deg C for 1/2
hours
Grinding
Liquefaction
9%
Fermentation
DDGS Drying
2%
30%
Distillation
38%
PDX has no significant
impact on plant energy
balance
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2%
Energy consumption in
First Generation
Bioethanol Processes
Source: Lurgi
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Evaporation
Separation
2%
17%
PDX Ethanol Reactor Tower
Retrofitted into existing liquefaction process
STEAM MAIN
Ethanol
Reactor
Tower
STEAM
CONDITIONING
SLURRY
TANK
LIQUEFACTION
TANK
Jet
cooker
PDX Reactor Tower
By-pass
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Link to PDX Control
Panel in Plant
Control Room
Gen 1- Full scale install
Spring 2008
Results (250908):
+ Average 7.1% Yield uplift
+ Max. 14.5% Yield uplift
- 25% α-Amylase usage
Results calculated and verified by MUSE Stancil
Muse is a global consulting firm specializing in the energy industry
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© Pursuit Dynamics 2008 CONFIDENTIAL
Oregon
Full scale PDX Ethanol Reactor Tower
install in a 40 mgal/year plant
Gen 1- Full scale install
Spring 2008
Distribution of PDX Uplift Batches
16
14
12
Number of PDX Batches
Baseline:
April/May fermentors
Excl. plant shut-down,
high lactic acid and
other abnormal
fermentors
10
8
6
4
2
0
-5%< Uplift < 0%
0%< Uplift < 5%
5% < Uplift < 10%
Batch Uplift Range
Results calculated and verified by MUSE Stancil
Muse is a global consulting firm specializing in the energy industry
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Uplift > 10%
Ethanol Reactor Tower
PDX ERT-3
Headline specification (ERT-3):
•470 gal/min (40MMgal/year ethanol production)
•Integrated CIP solution for continuous production
•Fully automized control system
•Full integration with plant operation system
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PDX in Bio-Ethanol – Third party
industry expertise
•
Co-operation established with
–
–
–
–
–
–
–
–
–
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Nottingham University – academic support
Laboratory of the Government Chemist – analysis
Eclipse Scientific Group - analysis
BRi –analysis
Novozymes – enzyme expertise
Pyxis – microscopy
SAGENTIA – External verification
NCERC- External verification
MUSEStancil-External verification
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Thank you for your attention
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