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BC Bugwood Envirochem Services Inc. 4.5 Lignocellulosic Ethanol 4.5.1 The Lignol Process There is currently no commercial technology to extract ethanol from softwood, although attempts are being made to gasify wood to produce ethanol or methanol (see chapter on methanol). MEMS USA is planning to build a gasification plant in Ontario by 2010, using low- cost forest residues.6 However, Lignol Innovations, a Vancouver, BC company, is working on the commercialization of the Organosolv process that allows using softwood as a feedstock for ethanol production while avoiding the energy-intensive gasification step. The company has recently attracted new investors and installed new management. They have advised that some of the older public information available on their process may not reflect the current state of the technology but they are not prepared to publicly release new information. Much of the data described below is therefore based on older information. Figure 4.5.1 shows the Lignol process, which uses enzymatic hydrolysis and results in a large number of products, including lignin, ethanol. xylose, and furfural. The first demonstration plant is planned to be completed by 2007, and successful testing could result in commercialization of the process in the coming decade, when the bugwood resource is at its peak. Incoming bugwood would have to be de-barked and chipped. The existing (laboratory-scale) pilot plant processes 6 kg quantities of lignocellulosic fibre treated with a 50:50 blend of ethanol and water at approximately 200°C and 27 bar (400 psi) pressure. The generated black liquor is then sequentially processed to recover a series of chemical byproducts. The remaining cellulose fibre is sufficiently delignified to be more readily converted to ethanol. While the extraction process is a batch process in the pilot plant, solvent and byproducts recovery is operated continuously. Lignin is recovered by “flashing” the high pressure black liquor to atmospheric pressure, followed by rapid dilution with water. Subsequently, lignin precipitates readily and is dried to a fine powder. The remaining solution contains numerous valuable materials such as ethanol, furfural, extractives and dissolved sugars. This liquid stream is fed to a distillation tower for ethanol recovery while the resulting ethanol-free stream, or stillage, is processed in various systems to isolate and purify several high value products described below. The process produces several by-products, some of which may have significant market value: Organosolv lignin major current market applications include antioxidants (greases, lubricating oils), resin replacements for waferboard or OSB production, animal feed supplements, additives (brake linings, rubber products, concrete) and advanced light weight materials. Acetic acid is sold commercially in several grades, depending on its purity. It is the basis for manufacturing acetic anhydride used in the production of cellulose acetate fibres and membranes. It is also used in the production of vinyl acetate, a basic raw material used to manufacture latex paint and paper coatings. Xylose is a five-carbon sugar widely present in fruit and root vegetables. It is readily converted into a specialty polyol (xylitol) that has about 60% of the sweetness of sucrose and is suitable for diabetics to consume without the need for insulin. However, no xylose can be extracted from softwood feedstocks. Furfural can be used to produce polytetramethylene ether glycol for the production of Lycra® and spandex. It is also used to produce lubricants, coatings, adhesives, plastics and foundry resins for cores and moulds to cast metal components. 6 See http://www.northernontariobusiness.com/regionalReports/ThunderBay/01-05-Hearst.asp Page 54PDF Image | IDENTIFYING ENVIRONMENTALLY PREFERABLE USES FOR BIOMASS
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