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A Pilot Plant for Producing Mixed Ketones from Waste Biomass

EPA Grant Number: R828598C705
Title: A Pilot Plant for Producing Mixed Ketones from Waste Biomass
Investigators: Holtzapple, Mark
Institution: Texas A & M University
EPA Project Officer: Krishnan, Bala S.
Project Period: September 1, 1998 through August 31, 2001
Project Amount: $43,042
RFA: Gulf Coast Hazardous Substance Research Center (Lamar University) (1996)
Research Category: Targeted Research , Hazardous Waste/Remediation

Description:

For the last eight years, our research group has performed laboratory studies to develop processes to convert waste biomass into animal feed, chemicals (e.g., ketones, carboxylic acids) and fuels (e.g., alcohols). In 1996, we were awarded the Presidential Green Chemistry Challenge Award initiated by President Clinton and Vice President Gore to recognize technologies that are both environmental and economical.

Among the various products that can be made using our technology, ketone production requires the fewest steps. Our laboratory studies indicate that ketones can be made economically, so we will increase the scale and construct a pilot plant. The laboratory studies have processed about 15 g1d of biomass; the pilot plant will process about 50 lb/d.

Our preliminary economic evaluations indicate that ketones can be made economically from biomass, particularly if the biomass is a waste that requires a tipping fee for its disposal. Currently, industrial biosludge has a tipping fee of $200 to 750/tonne. By lowering the tipping fee to $100/tonne, which will save Gulf Coast industry a substantial amount of money, we can sell mixed ketones for $0.38/gal while making a 60% return on investment. The mixed ketones are useful solvents for degreasing operations. If desired, for a modest cost (about $0.10/gal) the mixed ketones can be distilled into their individual components and sold as pure chemicals.

The problem being addressed by this research program is to find a cost-effective, environmentally friendly method for disposing of industrial biosludge from Gulf Coast chemical industries and paper fines from Gulf Coast paper mills.

Objective:

The objective of our research program is to operate a pilot plant that has the following steps: 1) lime pretreatment to enhance digestibility of industrial biosludge, 2) anaerobic mixed-culture fermentation to produce calcium carboxylates (e.g., calcium acetate, propionate, and butyrate), 3) dewatering system to concentrate fermentation broth, and 4) thermal conversion process for producing ketones from calcium carboxylates. The goal is to operate the pilot plant such that a large fraction of the industrial biosludge and paper fines are digested. Further, it is desired to obtain a high yield of ketones.

Approach:

Mass balances will be performed on the pilot plant to determine the flow rates of gas, undigested residue, calcium carboxylate, and ketones at each step in the process. Based upon model simulations, process conditions (e.g., solid loading rate in fermentor, liquid residence time in fermentor) will be adjusted in order to obtain high degrees of digestion and high product yields. The gas flow rates will be measured with wet-test meters, solid flow rates by scales, and liquid flow rates by volume. The composition of the liquid and gas will be determined by gas chromatography. The composition of the solids will be determined by ashing the samples to measure the volatile solids.

Supplemental Keywords:

INTERNATIONAL COOPERATION, Sustainable Industry/Business, Scientific Discipline, RFA, Technology for Sustainable Environment, Sustainable Environment, Chemicals Management, cleaner production/pollution prevention, Environmental Chemistry, biomass, green chemistry, biosludge, environmentally conscious manufacturing, alternative materials, environmentally friendly green products, alternative fuel, environmentally conscious design, ketone production, pollution prevention

Progress and Final Reports:
Final Report

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The perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.

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