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Final Report: 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: Hazardous Waste/Remediation , Targeted Research

Description:

Objective:

The objective of this research is to construct a pilot plant that converts waste biomass into ketones. The pilot plant has facilities for pretreating biomass with lime to make it more digestible. The lime-treated biomass is then fermented to carboxylic acids using a mixed culture of acid-forming microorganisms. The acids are neutralized with calcium carbonate and converted to carboxylate salts. The carboxylate salts are concentrated to dryness. The dry salts are thermally converted to ketones, such as acetone and methyl ethyl ketone.

Summary/Accomplishments (Outputs/Outcomes):

The following has been accomplished:

  1. concrete pad poured to locate pilot. Plant
  2. fence constructed to secure the site
  3. utilities have been installed, including steam, cooling water, electricity (110-V, 220-V,220-V three-phase), and lighting
  4. service building installed
  5. steam jacketed pretreatment vessels installed
  6. pretreatment vessel insert baskets constructed
  7. fermentation system installed including temperature control systems, circulating systems, solids transport systems
  8. fermentation system has been started and is producing carboxylate salts
  9. scrubber system installed to reduce odors
  10. water treatment system installed to remove chlorine from tap water
  11. amine dewatering system partially constructed
  12. vapor compression system partially constructed
  13. thermal conversion unit partially constructed Midway through the construction of the amine dewatering system, we invented a novel vapor compression system for concentrating the carboxylate salts to dryness. This new system promises to require less capital and energy.

Further, it can remove so much water, the salts will precipitate. (This was not possible with amine dewatering.)This new dewatering system also is a promising method for desalinating seawater.

The pilot plant is nearly completed... we are still working on it. A major oil company likes our technology and is helping us build a small demonstration plant. Eventually, we believe the process will be commercialized on a large scale and will produce fuels and chemicals from biomass. This has the following benefits:

The following patents have issued related to the project. Many more are pending.

M.T. Holtzapple, R.R. Davison. T. Luettich, Recovery of Fermentation Salts from Dilute Aqueous Solutions, U.S. Patent 6,478,965 (November 12, 2002).

M.T. Holtzapple, R.R. Davison, Process for Recovering Low-Boiling Acids, U.S. Patent 6,395,926 (May 28, 2002).

M.T. Holtzapple, R.R. Davison, "Thermal Conversion of Fatty Acid Salts to Ketones," U.S. Patent 6,262,313 (July 17, 2001).

M.T. Holtzapple, R.R. Davison, "Method for Conversion of Biomass to Chemicals and Fuels," U.S. Patent 6,043,392 (March 28, 2000).

M.T. Holtzapple, R.R. Davison, T. Luettisch, "Recovery of Fermentation Salts from Dilute Aqueous Solutions," U.S. Patent 5,986,133 (November 16, 1999).

M.T. Holtzapple, R.R. Davison, "Thermal Conversion of Volatile Fatty Acid Salts to Ketones," U.S. Patent 5,969,189 (October 19, 1999).

M.T. Holtzapple, R.R. Davison, M.K. Ross, M. Loescher, "Apparatus for Producing Organic Acids," U.S. Patent 5,962,307 (October 5, 1999).

M.T. Holtzapple, R.R. Davison, M.K. Ross, M. Loescher, "Method and Apparatus for Producing Organic Acids" U.S. Patent 5,874,263 (February 23, 1999).

M.T. Holtzapple, R.R. Davison, M. Nagwani, "Methods of Biomass Pretreatment," U.S. Patent 5,865,898 (February 2, 1999).

Supplemental Keywords:

None. , 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
Relevant Websites:

None.

Progress and Final Reports:
Original Abstract

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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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