Thermal Characteristics of Lignin Residue from Industrial Processes

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Production of xylanase and beta-xylosidase from autohydrolysis liquor of corncob using two fungal strains

Agroindustrial residues are materials often rich in cellulose and hemicellulose. The use of these substrates for the microbial production of enzymes of industrial interest is mainly due to their high availability associated with their low cost. In this work, corncob (CCs) particles decomposed to soluble compounds (liquor) were incorporated in the microbial growth medium through autohydrolysis, as a strategy to increase and undervalue xylanase and beta-xylosidase production by Aspergillus terricola and Aspergillus ochraceus. The CCs autohydrolysis liquor produced at 200 A degrees C for 5, 15, 30 or 50 min was used as the sole carbon source or associated with untreated CC. The best condition for enzyme synthesis was observed with CCs submitted to 30 min of autohydrolysis. The enzymatic production with untreated CCs plus CC liquor was higher than with birchwood xylan for both microorganisms. A. terricola produced 750 total U of xylanase (144 h cultivation) and 30 total U of beta-xylosidase (96-168 h) with 0.75% untreated CCs and 6% CCs liquor, against 650 total U of xylanase and 2 total U of beta-xylosidase in xylan; A. ochraceus produced 605 total U of xylanase and 56 total U of beta-xylosidase (168 h cultivation) with 1% untreated CCs and 10% CCs liquor against 400 total U of xylanase and 38 total U of beta-xylosidase in xylan. These results indicate that the treatment of agroindustrial wastes through autohydrolysis can be a viable strategy in the production of high levels of xylanolytic enzymes.

Produzione di bioetanolo da scarti lignocellulosici della canna da zucchero: condizioni di saccarificazione e fermentazione simultanee (SSF) e aspetti ambientali del processo

Il presente studio ha avuto l’obiettivo di indagare la produzione di bioetanolo di seconda generazione a partire dagli scarti lignocellulosici della canna da zucchero (bagassa), facendo riscorso al processo enzimatico. L’attività di ricerca è stata svolta presso il Dipartimento di Ingegneria Chimica dell’Università di Lund (Svezia) all’interno di rapporti scambio con l’Università di Bologna. Il principale scopo è consistito nel valutare la produzione di etanolo in funzione delle condizioni operative con cui è stata condotta la saccarificazione e fermentazione enzimatica (SSF) della bagassa, materia prima che è stata sottoposta al pretrattamento di Steam Explosion (STEX) con aggiunta di SO2 come catalizzatore acido. Successivamente, i dati ottenuti in laboratorio dalla SSF sono stati utilizzati per implementare, in ambiente AspenPlus®, il flowsheet di un impianto che simula tutti gli aspetti della produzione di etanolo, al fine di studiarne il rendimento energetico dell’intero processo. La produzione di combustibili alternativi alle fonti fossili oggigiorno riveste primaria importanza sia nella limitazione dell’effetto serra sia nel minimizzare gli effetti di shock geopolitici sulle forniture strategiche di un Paese. Il settore dei trasporti in continua crescita, consuma nei paesi industrializzati circa un terzo del fabbisogno di fonti fossili. In questo contesto la produzione di bioetanolo può portare benefici per sia per l’ambiente che per l’economia qualora valutazioni del ciclo di vita del combustibile ne certifichino l’efficacia energetica e il potenziale di mitigazione dell’effetto serra. Numerosi studi mettono in risalto i pregi ambientali del bioetanolo, tuttavia è opportuno fare distinzioni sul processo di produzione e sul materiale di partenza utilizzato per comprendere appieno le reali potenzialità del sistema well-to-wheel del biocombustibile. Il bioetanolo di prima generazione ottenuto dalla trasformazione dell’amido (mais) e delle melasse (barbabietola e canna da zucchero) ha mostrato diversi svantaggi: primo, per via della competizione tra l’industria alimentare e dei biocarburanti, in secondo luogo poiché le sole piantagioni non hanno la potenzialità di soddisfare domande crescenti di bioetanolo. In aggiunta sono state mostrate forti perplessità in merito alla efficienza energetica e del ciclo di vita del bioetanolo da mais, da cui si ottiene quasi la metà della produzione di mondiale di etanolo (27 G litri/anno). L’utilizzo di materiali lignocellulosici come scarti agricolturali e dell’industria forestale, rifiuti urbani, softwood e hardwood, al contrario delle precedenti colture, non presentano gli svantaggi sopra menzionati e per tale motivo il bioetanolo prodotto dalla lignocellulosa viene denominato di seconda generazione. Tuttavia i metodi per produrlo risultano più complessi rispetto ai precedenti per via della difficoltà di rendere biodisponibili gli zuccheri contenuti nella lignocellulosa; per tale motivo è richiesto sia un pretrattamento che l’idrolisi enzimatica. La bagassa è un substrato ottimale per la produzione di bioetanolo di seconda generazione in quanto è disponibile in grandi quantità e ha già mostrato buone rese in etanolo se sottoposta a SSF. La bagassa tal quale è stata inizialmente essiccata all’aria e il contenuto d’acqua corretto al 60%; successivamente è stata posta a contatto per 30 minuti col catalizzatore acido SO2 (2%), al termine dei quali è stata pretrattata nel reattore STEX (10L, 200°C e 5 minuti) in 6 lotti da 1.638kg su peso umido. Lo slurry ottenuto è stato sottoposto a SSF batch (35°C e pH 5) utilizzando enzimi cellulolitici per l’idrolisi e lievito di birra ordinario (Saccharomyces cerevisiae) come consorzio microbico per la fermentazione. Un obiettivo della indagine è stato studiare il rendimento della SSF variando il medium di nutrienti, la concentrazione dei solidi (WIS 5%, 7.5%, 10%) e il carico di zuccheri. Dai risultati è emersa sia una buona attività enzimatica di depolimerizzazione della cellulosa che un elevato rendimento di fermentazione, anche per via della bassa concentrazione di inibitori prodotti nello stadio di pretrattamento come acido acetico, furfuraldeide e HMF. Tuttavia la concentrazione di etanolo raggiunta non è stata valutata sufficientemente alta per condurre a scala pilota un eventuale distillazione con bassi costi energetici. Pertanto, sono stati condotti ulteriori esperimenti SSF batch con addizione di melassa da barbabietola (Beta vulgaris), studiandone preventivamente i rendimenti attraverso fermentazioni alle stesse condizioni della SSF. I risultati ottenuti hanno suggerito che con ulteriori accorgimenti si potranno raggiungere gli obiettivi preposti. E’ stato inoltre indagato il rendimento energetico del processo di produzione di bioetanolo mediante SSF di bagassa con aggiunta di melassa in funzione delle variabili più significative. Per la modellazione si è fatto ricorso al software AspenPlus®, conducendo l’analisi di sensitività del mix energetico in uscita dall’impianto al variare del rendimento di SSF e dell’addizione di saccarosio. Dalle simulazioni è emerso che, al netto del fabbisogno entalpico di autosostentamento, l’efficienza energetica del processo varia tra 0.20 e 0.53 a seconda delle condizioni; inoltre, è stata costruita la curva dei costi energetici di distillazione per litro di etanolo prodotto in funzione delle concentrazioni di etanolo in uscita dalla fermentazione. Infine sono già stati individuati fattori su cui è possibile agire per ottenere ulteriori miglioramenti sia in laboratorio che nella modellazione di processo e, di conseguenza, produrre con alta efficienza energetica bioetanolo ad elevato potenziale di mitigazione dell’effetto serra.

Vanillin production from ferulic acid with Pseudomonas fluorescens BF13-1p4

Bioconversion of ferulic acid to vanillin represents an attractive opportunity for replacing synthetic vanillin with a bio-based product, that can be label “natural”, according to current food regulations. Ferulic acid is an abundant phenolic compound in cereals processing by-products, such as wheat bran, where it is linked to the cell wall constituents. In this work, the possibility of producing vanillin from ferulic acid released enzymatically from wheat bran was investigated by using resting cells of Pseudomonas fluorescens strain BF13-1p4 carrying an insertional inactivation of vdh gene and ech and fcs BF13 genes on a low copy number plasmid. Process parameters were optimized both for the biomass production phase and the bioconversion phase using food-grade ferulic acid as substrate and the approach of changing one variable while fixing the others at a certain level followed by the response surface methodology (RSM). Under optimized conditions, vanillin up to 8.46 mM (1.4 g/L) was achieved, whereas highest productivity was 0.53 mmoles vanillin L-1 h-1). Cocktails of a number of commercial enzyme (amylases, xylanases, proteases, feruloyl esterases) combined with bran pre-treatment with steam explosion and instant controlled pressure drop technology were then tested for the release of ferulic acid from wheat bran. The highest ferulic acid release was limited to 15-20 % of the ferulic acid occurring in bran, depending on the treatment conditions. Ferulic acid 1 mM in enzymatic hydrolyzates could be bioconverted into vanillin with molar yield (55.1%) and selectivity (68%) comparable to those obtained with food-grade ferulic acid after purification from reducing sugars with a non polar adsorption resin. Further improvement of ferulic acid recovery from wheat bran is however required to make more attractive the production of natural vanillin from this by-product.

1st and 2nd Generation Ethanol from Biomass Crops

In chapter 1 and 2 calcium hydroxide as impregnation agent before steam explosion of sugarcane bagasse and switchgrass, respectively, was compared with auto-hydrolysis, assessing the effects on enzymatic hydrolysis and simultaneous saccharification and fermentation (SSF) at high solid concentration of pretreated solid fraction. In addition, anaerobic digestion of pretreated liquid fraction was carried out, in order to appraise the effectiveness of calcium hydroxide before steam explosion in a more comprehensive way. In As water is an expensive input in both cultivation of biomass crops and subsequent pretreatment, Chapter 3 addressed the effects of variable soil moisture on biomass growth and composition of biomass sorghum. Moreover, the effect of water stress was related to the characteristics of stem juice for 1st generation ethanol and structural carbohydrates for 2nd generation ethanol. In the frame of chapter 1, calcium hydroxide was proven to be a suitable catalyst for sugarcane bagasse before steam explosion, in order to enhance fibre deconstruction. In chapter 2, effect of calcium hydroxide on switchgrass showed a great potential when ethanol was focused, whereas acid addition produced higher methane yield. Regarding chapter 3, during crop cycle the amount of cellulose, hemicellulose and AIL changed causing a decrease of 2G ethanol amount. Biomass physical and chemical properties involved a lower glucose yield and concentration at the end of enzymatic hydrolysis and, consequently, a lower 2G ethanol concentration at the end of simultaneous saccharification and fermentation, proving that there is strong relationship between structure, chemical composition, and fermentable sugar yield. The significantly higher concentration of ethanol at the early crop stage could be an important incentive to consider biomass sorghum as second crop in the season, to be introduced into some agricultural systems, potentially benefiting farmers and, above all, avoiding the exacerbation of the debate about fuel vs food crops.

Efeito da adição de fibras de cana-de-açúcar pré-tratadas na produção de metano advinda da biodigestão anaeróbia de gorduras do leite

A digestão anaeróbia é uma alternativa para o tratamento de resíduos com altas concentrações de matéria orgânica. Por meio dos processos anaeróbios é possível a produção de biogás, fonte de energia renovável e ambientalmente amigável. Elevadas concentrações de lipídios, todavia, apesar de representarem elevado potencial metanogênico, interferem negativamente nos sistemas de tratamento, podendo inibir a atividade microbiana e, consequentemente, a produção de metano. O presente projeto avaliou o efeito da adição de bagaço de cana-de-açúcar no processo de biodigestão anaeróbia de elevadas concentrações de gorduras advindas de efluentes de laticínio. Para tanto foi utilizado bagaço de cana-de-açúcar in natura e pré-tratadas pelos seguintes métodos: organossolve, hidrotérmico, explosão à vapor e ácido diluído. O uso desse material lignocelulósico teve o objetivo de controlar a inibição causada pelos produtos da hidrólise dos lipídios por meio de sua adsorção e, consequentemente, diminuição das concentrações de tais compostos no meio. Outra hipótese era que o bagaço de cana-de-açúcar pudessem agir como co-substrato no processo de biodigestão anaeróbia. Inicialmente realizaram-se ensaios de biodegradabilidade anaeróbia com concentrações crescentes de gordura, que resultaram em relação entre substrato e microrganismo 0,06, 0,1, 0,2, 0,4 e 0,6 g DQO/gSTV. O ensaio com concentração em que foi verificada a inibição severa (0,4 gDQO/gSTV) do processo foi repetido com adição das fibras tratadas e não tratadas. Aos dados de produção acumulada de metano ajustou-se modelo de Gompertz, e parâmetros cinéticos foram inferidos. O bagaço de cana-de-açúcar mostrou potencial como adsorvente de gordura, pois as produções metanogênicas foram superiores à condição inibida sem adição desse material. A adição de fibras pré-tratadas por método organossolve resultou nas maiores produções de metano.

Full scale test for explosion water barriers in small cross-section galleries

Underground coal mines explosions generally arise from the inflammation of a methane/air mixture. This explosion can also generate a subsequent coal dust explosion. Traditionally such explosions have being fought eliminating one or several of the factors needed by the explosion to take place. Although several preventive measures are taken to prevent explosions, other measures should be considered to reduce the effects or even to extinguish the flame front. Unlike other protection methods that remove one or two of the explosion triangle elements, namely; the ignition source, the oxidizing agent and the fuel, explosion barriers removes all of them: reduces the quantity of coal in suspension, cools the flame front and the steam generated by vaporization removes the oxygen present in the flame. Passive water barriers are autonomous protection systems against explosions that reduce to a satisfactory safety level the effects of methane and/or flammable dust explosions. The barriers are activated by the pressure wave provoked in the explosion destroying the barrier troughs and producing a uniform dispersion of the extinguishing agent throughout the gallery section in quantity enough to extinguish the explosion flame. Full scale tests have been carried out in Polish Barbara experimental mine at GIG Central Mining Institute in order to determine the requirements and the optimal installation conditions of these devices for small sections galleries which are very frequent in the Spanish coal mines. Full scale tests results have been analyzed to understand the explosion timing and development, in order to assess on the use of water barriers in the typical small crosssection Spanish galleries. Several arrangements of water barriers have been designed and tested to verify the effectiveness of the explosion suppression in each case. The results obtained demonstrate the efficiency of the water barriers in stopping the flame front even with smaller amounts of water than those established by the European standard. According to the tests realized, water barriers activation times are between 0.52 s and 0.78 s and the flame propagation speed are between 75 m/s and 80 m/s. The maximum pressures (Pmax) obtained in the full scale tests have varied between 0.2 bar and 1.8 bar. Passive barriers protect effectively against the spread of the flame but cannot be used as a safeguard of the gallery between the ignition source and the first row of water troughs or bags, or even after them, as the pressure could remain high after them even if the flame front has been extinguished.

A simplified Probabilistic Safety Assesment of a Steam-Methane Reforming Hydrogen Production Plant coupled to a High-Temperature Gas Cooled Nuclear Reactor

A Probabilistic Safety Assessment (PSA) is being developed for a steam-methane reforming hydrogen production plant linked to a High-Temperature Gas Cooled Nuclear Reactor (HTGR). This work is based on the Japan Atomic Energy Research Institute’s (JAERI) High Temperature Test Reactor (HTTR) prototype in Japan. This study has two major objectives: calculate the risk to onsite and offsite individuals, and calculate the frequency of different types of damage to the complex. A simplified HAZOP study was performed to identify initiating events, based on existing studies. The initiating events presented here are methane pipe break, helium pipe break, and PPWC heat exchanger pipe break. Generic data was used for the fault tree analysis and the initiating event frequency. Saphire was used for the PSA analysis. The results show that the average frequency of an accident at this complex is 2.5E-06, which is divided into the various end states. The dominant sequences result in graphite oxidation which does not pose a health risk to the population. The dominant sequences that could affect the population are those that result in a methane explosion and occur 6.6E-8/year, while the other sequences are much less frequent. The health risk presents itself if there are people in the vicinity who could be affected by the explosion. This analysis also demonstrates that an accident in one of the plants has little effect on the other. This is true given the design base distance between the plants, the fact that the reactor is underground, as well as other safety characteristics of the HTGR. Sensitivity studies are being performed in order to determine where additional and improved data is needed.

Optimisation of environmental gas cleaning routes for solid wastes cogeneration systems - Part I - Analysis of waste incineration steam cycle

Research of advanced technologies for energy generation contemplates a series of alternatives that are introduced both in the investigation of new energy sources and in the improvement and/or development of new components and systems. Even though significant reductions are observed in the amount of emissions, the proposed alternatives require the use of exhaust gases cleaning systems. The results of environmental analyses based on two configurations proposed for urban waste incineration are presented in this paper; the annexation of integer (Boolean) variables to the environomic model makes it possible to define the best gas cleaning routes based on exergetic cost minimisation criteria. In this first part, the results for steam cogeneration system analysis associated with the incineration of municipal solid wastes (MSW) is presented. (c) 2007 Elsevier Ltd. All rights reserved.

Optimisation of environmental gas cleaning routes for solid wastes cogeneration systems. Part II - Analysis of waste incineration combined gas/steam cycle

In the first paper of this paper (Part I), conditions were presented for the gas cleaning technological route for environomic optimisation of a cogeneration system based in a thermal cycle with municipal solid waste incineration. In this second part, an environomic analysis is presented of a cogeneration system comprising a combined cycle composed of a gas cycle burning natural gas with a heat recovery steam generator with no supplementary burning and a steam cycle burning municipal solid wastes (MSW) to which will be added a pure back pressure steam turbine (another one) of pure condensation. This analysis aims to select, concerning some scenarios, the best atmospheric pollutant emission control routes (rc) according to the investment cost minimisation, operation and social damage criteria. In this study, a comparison is also performed with the results obtained in the Case Study presented in Part I. (c) 2007 Elsevier Ltd. All rights reserved.

Availability analysis of heat recovery steam generators used in thermal power plants

The combined-cycle gas and steam turbine power plant presents three main pieces of equipment: gas turbines, steam turbines and heat recovery steam generator (HRSG). In case of HRSG failure the steam cycle is shut down, reducing the power plant output. Considering that the technology for design, construction and operation of high capacity HRSGs is quite recent its availability should be carefully evaluated in order to foresee the performance of the power plant. This study presents a method for reliability and availability evaluation of HRSGs installed in combined-cycle power plant. The method`s first step consists in the elaboration of the steam generator functional tree and development of failure mode and effects analysis. The next step involves a reliability and availability analysis based on the time to failure and time to repair data recorded during the steam generator operation. The third step, aiming at availability improvement, recommends the fault-tree analysis development to identify components the failure (or combination of failures) of which can cause the HRSG shutdown. Those components maintenance policy can be improved through the use of reliability centered maintenance (RCM) concepts. The method is applied on the analysis of two HRSGs installed in a 500 MW combined-cycle power plant. (C) 2010 Elsevier Ltd. All rights reserved.

Erosion-fatigue of steam turbine blades

The premature failure of steam turbine rotor blades, manufactured in forged 12% Cr-NiMoV martensitic stainless steel, was investigated using visual inspection non-destructive testing, macro and microfractography, microstructural characterization, EDS microanalysis, chemical analysis, micro hardness and tensile testing. The blades belonged to the last stage of a thermoelectric plant steam turbine generator (140 MV A). The results indicated that the failure of the blades was promoted by foreign-particle erosion, which attacked preferentially the low-pressure side of the lower trailing edge of the blades. The resulting wear grooves acted as stress raisers and promoted the nucleation of fatigue cracks, which probably grew during the transition events of the steam turbine operation. Finally, water drop erosion was observed on the blade upper leading edge (low-pressure side). (C) 2009 Elsevier Ltd. All rights reserved.

Supercritical steam cycles and biomass integrated gasification combined cycles for sugarcane mills

Back in 1970s and 1980s, cogeneration plants in sugarcane mills were primarily designed to consume all bagasse, and produce steam and electricity to the process. The plants used medium pressure steam boilers (21 bar and 300 degrees C) and backpressure steam turbines. Some plants needed also an additional fuel, as the boilers were very inefficient. In those times, sugarcane bagasse did not have an economic value, and it was considered a problem by most mills. During the 1990s and the beginning of the 2000s, sugarcane industry faced an open market perspective, thus, there was a great necessity to reduce costs in the production processes. In addition, the economic value of by-products (bagasse, molasses, etc.) increased, and there was a possibility of selling electricity to the grid. This new scenario led to a search for more advanced cogeneration systems, based mainly on higher steam parameters (40-80 bar and 400-500 degrees C). In the future, some authors suggest that biomass integrated gasification combined cycles are the best alternative to cogeneration plants in sugarcane mills. These systems might attain 35-40% efficiency for the power conversion. However, supercritical steam cycles might also attain these efficiency values, what makes them an alternative to gasification-based systems. This paper presents a comparative thermoeconomic study of these systems for sugarcane mills. The configurations studied are based on real systems that could be adapted to biomass use. Different steam consumptions in the process are considered, in order to better integrate these configurations in the mill. (C) 2009 Elsevier Ltd. All rights reserved.

Oxidation mechanism of Si3N4-bonded SiC ceramics by CO, CO2 and steam

This paper presents a theoretical and experimental investigation into the oxidation reactions of Si3N4-bonded SiC ceramics. Such ceramics which contain a small amount of silicon offer increased oxidation and wear resistance and are widely used as lining refractories in blast furnaces. The thermodynamics of oxidation reactions were studied using the JANAF tables. The weight gain was measured using a thermogravimetric analysis technique to study the kinetics. The temperature range of oxidation measurements is from 1073 to 1573 K and the oxidation atmosphere is water vapour, pure CO and CO-CO2 gas mixtures with various CO-to-CO2 ratios. Thermodynamic simulations showed that the oxidation mechanism of Si3N4-bonded SiC ceramics is passive oxidation and all components contribute to the formation of a silica film. The activated energies of the reactions follow the sequence Si3N4>SiC>Si. The kinetic study revealed that the oxidation of Si3N4-bonded SiC ceramics occurred in a mixed regime controlled by both interface reaction and diffusion through the silica film. Under the atmosphere conditions prevailing in the blast furnace, this ceramic is predicted to be passively oxidized with the chemical reaction rate becoming more dominant as the CO concentration increases. (C) 1998 Chapman & Hall.

Reply to comments on "Oxidation mechanism of Si3N4-bonded SiC ceramics by CO, CO2 and steam," by Balat et al.

First of all, we would like to clarify that the passive to active transition was determined not by using Solgasmix [1], but by combining thermodynamic equilibrium and mass balance for the oxidation of SiC under pure CO2 and pure CO. The model used in our paper [2]was an extension ofWagner’s model [3], in a similar way as Balat et al. [4] did for the oxidation of SiC in oxygen.