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    Griffin LanzaTech - 20 July 2011 MAS

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    Nitin Thakur
    Griffin LanzaTech - 20 July 2011 MAS

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    Griffin LanzaTech - 20 July 2011 MAS

    Uploaded by

    Nitin Thakur
    45 views17 pages
    Griffin LanzaTech - 20 July 2011 MAS

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    Griffin LanzaTech - 20 July 2011 MAS

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    45 views17 pages

    Griffin LanzaTech - 20 July 2011 MAS

    Uploaded by

    Nitin Thakur
    Griffin LanzaTech - 20 July 2011 MAS

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 17

    Bio-Processing Case Study:

    Sampling, Monitoring, & Control for


    Gas Fermentation to Fuel & Chemicals

    Derek Griffin

    CPAC Summer Institute


    20 July, 2011
    University of Washington

    © 2011 LanzaTech Inc. All rights reserved.


    The LanzaTech Process

    Novel gas fermentation


    technology captures CO-rich
    gases and converts the carbon
    to fuels and chemicals

    Gas feed stream

    Gas reception Compression Fermentation Recovery Product


    tank

    • Gases are sole source of energy


    • Production of fuels and chemicals
    • Potential to make material impact on the future energy pool (>100s of billions of gallons
    per year)
    • Completely outside of the food value chain
    • Biofuel and carbon capture technology solution

    2
    Making H2 On Demand

     LanzaTech can use a Hydrogen free-gas for the


    production of ethanol

     The ethanol molecule contains 6 Hydrogens:

    CO + H2O CO2 + H2

    [H2]

    • Microbe can make H2 from CO and


    water as required
    Reduces Need for • Any CO:H2 ratio can be used
    Thermochemical WGS,
    Improving Overall C Balance
    3
    Feedstock Flexible
    Gas
    Composition
    Industrial Fuels & Chemicals
    Flue Gas
    e.g. from Steel Mill Gas-to-liquid Conversion
    CO
    Syngas
    Coal
    Municipal Solid
    Waste (MSW)

    Reformed Methane
    e.g. Biogas
    H2

    Biomass

    A broad range of CO:H2 ratios can


    be used by the LanzaTech process

     Fuel production has been demonstrated with


    a wide range of available waste gas resources
    4
    LanzaTech Gas to Liquid Platform
    Resources CO H2 H2 CO2 CO2
    CO
    Industrial Syngas: Biomass, Coal, Methane COG, Chemical Power

    Native
    Customized Engineering
    Control
    Catalysts
    Synthetic Chemistry

    C2 C3 C4 C5 Other
    • Ethanol • i-propanol • BDO • Isoprene • PHB
    Product Suite • Acetic acid • n-Butanol • …….
    • i-Butanol
    • Succinic acid
    Thermochemical Approaches
    Hydrocarbon Fuels
    Product Suite (diesel, jet, Chemical Chemicals
    gasoline) Intermediates Olefins

    5
    Process Overview

     3 Main Sections to LanzaTech Process


    – Gas Conditioning
    – Anaerobic Gas Fermentation
    – Product Recovery

    6
    Gas Conditioning & Clean-up

     Key Measurements:
    – Inlet gas composition – On-line Gas Chromatography (GC)
    • Measure CO, CO2, N2, H2, CH4, O2, & H2S
    – Gas temperature and pressure
    – Gas flowrate

     Bioreactor system operates at 8-10 bar


    – Low pressure gases require up to 4 compression trains
    – Compression sizing and design based on inlet gas flowrate, pressure, and overall
    composition
    – Need to account for pressure drop through deoxygentation and gas-cleanup

    7
    Deoxygenation

     Anaerobic fermentation requires reduced


    oxygen content O2 levels < 100
    ppm
    – Deoxygenation vessel size, temperature, and
    residence time based on gas flowrate, inlet O2
    level, and catalyst activity
     Continuous gas streams require accurate O2
    measurement in and out of deoxygenation bed
    – Simple feed-forward and feed-back control can
    be used for changes in inlet and outlet gas
    respectively

     Some gas streams are intermittent (steel mill BOF gas)


    requiring gas holder(s)
    – Improved process robustness with multiple gas holders that
    can be tested for O2 & contaminant levels before using gas
    as fermentation feed
    8
    Gas Clean-up

     LanzaTech process can tolerate high levels


    of impurities so extensive gas cleanup may
    not be necessary
    – Microbes tolerant to H2S up to 2%
    • Can be measured by GC
    – Currently testing BTEX up to 500 ppm in
    laboratory
    – Contaminant testing currently performed
    off-line to measure levels of BTEX, HCN,
    NH3, etc..
     Microbes require low level of sulfur in
    fermentation broth
    – Inlet gas may provide sulfur in form of H2S
    eliminating requirement for sulur
    component in media preparation

    9
    Contaminants

    The addition of multiple potentially toxic, Gases, Metal Ions


    and organic contaminants have been tested off-line:

     H2S: 2% in gas feed  Chromium: (II) 2mMol/L


     SO2: 500ppm (III) 100mMol/L
     NOX: 50ppm
     Benzene: 0.12 mol% in gas  Vanadium: 10µMol/L
     Toluene: 0.008 mol % in gas  Bromide: 100µMol/L
     Copper: 100µMol/L  Iodide: 50µMol/L

     Arsenic: 12μmol/L  CO2: >50% in gas

     Methane: >50% in gas  N2 : >50% in gas

     HCl: Buffered in media

     Goal: Certain gases will contain different impurities; need various


    on-line low level impurity measurement for different gas feeds 10
    Fermentation System – Bioreactor

     Air-lift bioreactors are commonly


    used for fermentation over
    stirred tank reactors
    – Gas well mixed
    – Homogeneous 3-phase
    mixture
    – No agitator or stirrer,
    minimal cell shear & lower
    power consumption
    – Pressure difference between
    riser and downcomer aids in
    fluid circulation
    – Fewer internal moving parts
    = better sterilization
    Internal Loop Reactors External Loop Reactors

    11
    Mass Transfer Estimation

     CL – conc. of gas in liquid


     C* - gas solubility in liquid
     kL – overall mass transfer
    coefficient
     aL – specific interfacial area

    dC L
     Measure of reactor inlet, Cin, & outlet CO composition determines
    dt
     Gas solubility, C*, depends on headspace pressure & reactor
    temperature which are monitored and controlled
     Other variables that contribute to G/L mass transfer
    – Gas/liquid holdup
    – Bubble size/number distribution effects aL
    – Gas velocity (mean residence time) effects boundary layer and kL
    – Mixing times & Turbulent/Laminar Flow also effects kL 12
    Potential Control Structures
     Multiple inputs/outputs & complicated process model
    combining 3-phase bioreactor hydrodynamics and microbial
    reaction system
    – Numerous unique bioreactor ‘scenarios’ and overall system
    non-linearity eliminate use of simple feedback control
     Model predictive control requires extensive data-base covering
    all possible ‘scenarios’
     Fuzzy Logic – apply a ‘truth value’ to
    variables in different scenarios
     Neural Net - more complex, adaptive,
    computational model. Can be taught or
    trained on various scenarios

     Goal: singular structure that can be


    programmed to handle batch start-up, Artificial neural network
    transition to continuous mode, and dynamic
    transition to steady-state 13
    Product Recovery & Waste Water Treatment

    Product recovery &


    waste water systems
    mature technologies
    with well developed
    control structures

    1. Broth concentration measured entering recovery section


    2. Metabolites leaving product recovery measured entering water treatment
    3. Nutrients and metabolites measured in water recycle to media preparation
    – Need to be able to accurately measure low levels of salts & minerals

     Anhydrous ethanol product, waste water purge, & biomass purge also
    monitored to ensure within target specifications 14
    Media Preparation

     Continuous media preparation requires inputs from gas stream


    composition and nutrient concentration in water recycle
     Water treatment & gas flow is continuous while media is prepared
    in batches
     Currently Investigating dissolved O2 measurement in media
    – Requires costly in-situ monitor that can measure ppb levels
    15
    Summary

     LanzaTech’s gas fermentation technology differs from


    conventional biological fermentation processes due to gasesous
    feedstock and G/L mass transfer issue of nearly insoluble gases

     Conventional sampling, monitoring, and control can be achieved


    for gas conditioning and product recovery sections
     Biggest challenge surrounds bioreactor
    – In-situ measurements of G/L ratio, dissolved CO, metabolite &
    nutrient concentrations are current challenges
    – Numerous inputs & outputs based on biological system requires
    detailed process model & complicated control structure
    – Bioreactor & microbial behavior can drastically change depending
    on microbe, gas feed, and/or metabolites produced requiring unique
    process models and control schemes

    16
     Questions & Comments:
    [email protected]

    17

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