Lentikats Biotechnology in distilleries
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Transcript of Lentikats Biotechnology in distilleries
Content1. PRINCIPLES
• Principles of Lentikats Biotechnology
• Benefits of Lentikats Biotechnology
• Lentikats Biotechnology in distilleries
2. CASE STUDIES
• Case study – molasses distillery
• Case study – distillery processing sugar solutions
• Case study – corn distillery
3. WHAT CAN WE OFFER?
• References and experiences, our partners
• Contacts
What is a Lentikats Biocatalyst?Unique shape of the matrix and the original principle of immobilisation enable the encapsulation of free enzymes or microorganisms (bacteria, yeasts, fungi) in a stable porous PVA (polyvinylalcohol) carrier. The carrier‘s advantages are:
• Excellent physio-mechanical characteristics that provide forlong-term mechanical stability
• Low biodegradability• Zero toxicity
Lentikats Biocatalyst enables easy separation of enzymes and microorganisms from the surrounding media and therefore it can be reused multiple times.
Biotechnologies are changing
the world…
Lentikats Biocatalyst
Advantages of using PVA as a matrix for encapsulation:
• inexpensive, non-toxic
• polymerization under optimal conditions, cell conservation
• enables creation of hydrogels with excellent mechanical properties
• no side effects in processes
• large capacity for cell building
• easily supervised processes
• stable processes
• easy separation from bulk media
Lentikats Lentikats Biocatalyst &
Biotechnology (our product) (application process)
Lentikats Biocatalyst Production Lentikats Biocatalyst
Application
How does Lentikats Biocatalyst function?
Due to its maximum surface and at the same time minimum volume of the Lentikats Biocatalyst, the diffusion limitations associated with the transport of the substrate into the lens and the product out of the lens are significantly reduced.
What are the advantages of Lentikats Biotechnology over
traditional technologies?
Higher biomass concentration
Reacti
on
rate
Biomass concentration
Reduced volume of reactors
Investment costs saving
Operational costs saving (electricity, heat, etc.)Higher yields
1)
100 €100 €100 €100 €
11
What are the advantages of Lentikats Biotechnology over
traditional technologies?Easy separation from bulk media
Repeatable use of Biocatalyst
Operational costs saving
Lower production of waste and by-
products
100 €100 €100 €100 €
Applicability under extreme or stress
conditions
2)
3) Robustness towards environmental
shocks
profound change of pH level higher concentration of toxic compounds
Technological process set-up
Legend:
1.Sugars media inlet2.Fermented media3.Inlet for Lentikats Biocatalyst filling4.Outlet for Lentikats Biocatalyst emptying5.Sieve separator (angle slop 15-20°, aperture 0.8-1 mm)6.Liquid fermentation broth with Lentikats Biocatalyst7.Liquid fermentation broth without Lentikats Biocatalyst8.Gear with speed change box9.Stirrer10.pH probe well11.Temperature probe well12.Antifoam agent inlet13.Liquid level measurement (stainless steel pressure probe)
Which substrates can be used for Lentikats Biotechnology?
Lentikats Biocatalysts provide a solution for the production of bioethanol from the following substrates:
1. Molasses, beet juice and sugar cane2. Starch-containing (cereal) materials (corn,
wheat, etc.)3. Ligno-cellulose containing materials (straw,
pollard…)
Our products• Lentikats Biocatalyst for the fermentation of sucrose,
glucose and lactose solutions (immobilized bacteria Zymomonas mobilis, yeast Saccharomyces cerevisiae, Kluyveromyces sp.)
• Lentikats Biocatalyst for the 2nd step of hydrolyses of liquefied starch solution (immobilized enzyme glukoamylase)
• Lentikats Biocatalyst for the production of inverted sugar from molasses (immobilized enzyme invertase)
Energy is all around us… …the key is to obtain it effectively…
…and protect the environment at the same time…
bacteria Zymomonas mobilis, yeast Saccharomyces cerevisiae
Starch containing material (corn, wheat)
Milling
MashingLiquification
Saccharification
Fermentation
Distillation
Molasses, sugar beet Lignocellulosicmaterial (straw, pollard)
Hydrolysis (acidpressure, enzymatic)
Cellulose hydrolysis
pre-treatment
enzyme glucoamylase enzyme ?-glucosidase
bacteria Zymomonas mobilis, yeast Saccharomyces cerevisiae
Starch containing material (corn, wheat)
Milling
MashingLiquification
Saccharification
Fermentation
Distillation
Molasses, sugar beet Lignocellulosicmaterial (straw, pollard)
Hydrolysis (acidpressure, enzymatic)
Cellulose hydrolysis
pre-treatment
enzyme glucoamylase enzyme ?-glucosidaseβ
Molasses distillery (125,000 L A.A. per day, continuous mode)
dil
luti
on
2x fermentation tank
equalisation tank
distillation
Eth
an
ol
molasses
reserve tank
(TFS* 48 %)
404 tons/day
* Total Fermentable Sugars
130 g/L TFS
45 tons of Lentikats Biocatalyst
41 6
67 m
3/y
ear
a.a
.
Fermentation conditions
• Saccharomyces cerevisiae
• continuous mode
• 180 g sucrose . hour-1 . kg-1
• ethanol yield 95 %
• 8.4 vol. % ethanol
Biotechnologies are changing the world…..
Economic comparison of traditional Economic comparison of traditional technology and Lentikats technology and Lentikats
Biotechnology Biotechnology for for molasses distillerymolasses distillery
Biotechnologies are changing the world…..
Reactor volume reduction– reduced investments
Traditional technology Lentikats Biotechnology
Fermentation volume 3,450 m3 360 (2 x 180) m3
Reserve reactor - 180 m3
Pre-fermentation volume 213 m3 -
Volume for preparation of nutrients
16 m3 -
Equalisation tank before distillation
- 180 m3
Sanitation tank 48 m3 48 m3
Total 3,727 m3 768 m3
Production of ethanol 39,035,667 L/year 41,666,667 L/year
Process yield 290 L/tons 309 L/tons
Biotechnologies are changing the world…..
Lentikats Biocatalyst consumption (125,000 L a.a. per day)
* Guaranteed lifetime ** Assumed lifetime
Biocatalyst type LifetimeAnnual consumption
of Lentikats Biocatalyst
Price (€/year)
immobilised yeast Saccharomyces
cerevisiae
8*–12* months
61.5*–41** tons
790,000–526,500
Biotechnologies that are environmentally friendly …
Biotechnologies are changing the world…..
Profit of ethanol production at the capacity of 125,000 L a.a. per
dayTraditional technology
Lentikats Biotechnology
Ethanol production (m3/year a.a.) 39,036 41,667
Ethanol yield from molasses (L/ton) 290 309
Annual revenues for ethanol (€) 24,600,000 26,500,000
Gross profit without depreciation (€) 7,250,000 8,185,000
Solution for higher efficiency and stability…
Case study – distillery processing Case study – distillery processing sugar solutions sugar solutions
(sugar cane or sugar beet juice(sugar cane or sugar beet juice))
Sugar distillery (125,000 L a.a. per day, continuous mode)
dil
luti
on
2x fermentation tank
equalisation tank
distillation
Eth
an
ol
molasses
reserve tank
sugar solution
45 tons of Lentikats Biocatalyst
140 g/L
TFS *
* Total Fermentable Sugars
41 6
67 m
3/y
ear
a.a
.
Biotechnologies are changing the world…..
Biotechnologies are changing the world…..
Fermentation conditions
• Zymomonas mobilis• continuous mode• 180g saccharose. hour-1 . kg-1
• temperature: 30–35°C, pH 4.8–5• ethanol yield 95 %• 9.02 vol. % ethanol
Economic comparison of traditional Economic comparison of traditional technology and Lentikats technology and Lentikats
Biotechnology Biotechnology for distillery processing sugar for distillery processing sugar
solutionssolutions
Biotechnologies are changing the world…..
Biotechnologies are changing the world…..
* Guaranteed lifetime, ** assumed lifetime
Lentikats Biocatalyst consumption (125,000 L a.a. per day)
Biocatalyst type LifetimeAnnual consumption
of Lentikats Biocatalyst *
Price (€/year)
immobilised bacteria Zymomonas
mobilis
1.5*–2** years
27.4*–20.5** tons
351,500–263,500
Biotechnologies that areenvironmentally friendly …
Profit of ethanol production at thecapacity of 125,000 L a.a. per day
Traditional technology
Lentikats Biotechnology
Ethanol production (m3/year a.a.) 39,036 41,667
Annual revenues for ethanol (€) 24,600,000 26,500,000
Gross profit without depreciation (€) 7,240,000 8,630,000
Solution for higher efficiency and stability…
Corn distillery (15,000 L a.a. per day, continuous mode)
corn
scra
pp
ing
liqueficationtank
saccharificationtank
2x fermentationtank
equalisation tank
reserve tank
distllation
eth
ano
l(60 % of starch)
39 tons/day
1.8 tons of LB
6 tons of LB
5,0
00,0
00 m
3/y
ear
a.a
.
Hydrolysis conditions
• glucoamylase
• continuous mode
• 600 g glucose . hod-1 . kg-1
• temperature: 38–40°C, pH 4.5–5
• conversion rate 95 %
• outlet concentration 150 g/L
Biotechnologies are changing the world…..
Biotechnologies are changing the world…..
Fermentation conditions• Zymomonas mobilis
• continuous mode
• 180g glucose. hour-1 . kg-1
• temperature: 30–35°C, pH 4.8–5
• ethanol yield 95 %
• 9.21 vol. % ethanol
Economic comparison of traditional Economic comparison of traditional technology and Lentikats technology and Lentikats
Biotechnology Biotechnology for for corn corn distillerydistillery
Reactor volume reduction– reduced investments
Traditional technology Lentikats Biotechnology
Mixing tank 14 m3 14 m3
Fermentation reactor 26 m3 26 m3
Saccharification reactor 9 m3 36 m3
Fermentation volume 552 m3 72 (2 x 36) m3
Reserve reactor - 36 m3
Pre-fermentation volume 86 m3 -
Sanitation tank 9 m3 9 m3
Equalisation tank before distillation - 26 m3
Total 696 m3 219 m3
Production of ethanol 4,473,667 L/year 5,000,000 L/year
Process yield 344 L/tons 385 L/tons
Lentikats Biocatalyst consumption(125,000 L a.a. per day)
Biocatalyst type Lifetime
Annual consumption of
Lentikats Biocatalyst *
Price (€/year)
immobilised enzyme glucoamylase
1,200*–1,500** hours
11.9*–9.5** tons
150,000–120,000
immobilised yeast Saccharomyces
cerevisiae
1.5*–2** years
3.6*–2.7** tons
46,000–34,500
Biotechnologies that areenvironmentally friendly …
* guaranteed lifetime, ** assumed lifetime
Profit of ethanol production at the capacity of 15,000 L a.a. per
dayTraditional technology
Lentikats Biotechnology
Ethanol production (m3/year a.a.) 4,474 5,000
Ethanol yield (L/ton of corn) 344 385
Annual revenues for ethanol (€) 2,817,000 3,150,000
Gross profit without depreciation (€) 1,370,000 1,600,000
Solution for higher efficiency and stability…
Other Lentikats Biotechnology Applications
Lentikats Biocatalysts and applied Lentikats Biotechnology also deliver additional value and benefits in the following sectors :
• waste water treatment – nitrogen removal
• pharmaceutics – production of robust biocatalysts
• food industry – whey processing, production of special sugars carbohydrates and syrups
Biotechnologies are changing the world…
Lentikats Biotechnology services
• Monitoring of specified technological procedures and conditions.
• Periodical monitoring of Lentikats Biocatalyst’s activity.
• Supply and replacement of Lentikats Biocatalyst in such periods and volumes to sustain the required Lentikats Biotechnology parameters.
• Disposal of the used Biocatalyst.
Have we raised your interest in testing LentikatsBiotechnology in your own project?
• We are prepared to supply a sufficient amount of our Biocatalyst and provide full assistance in order to convince you of the obvious advantages our technology has when applied in your distillery.
• For all companies introducing new technologies, the first applications and end results are the most important ones. That is why we offer excellent conditions to potential clients in an effort to eliminate any of their risks.
What can we offer to you?
Guarantee of your investments and the investment return
• You can test our biocatalyst easily by yourself with your substrate in your own plant or plant of your choice to see the results.
• We offer to you our assistance and full support at:
- pilot model installation
- installation into an existing reactor
• Load of Biocatalyst for testing is free of charge.
Our know-how, references and experiences
1. Production of bioethanol from sugar beet molasses in Bioferm Kolín distillery with a capacity of 6 litres of absolute alcohol per hour.
2. Processing of technical-technological documentation for the supply to an agricultural refinery with a production capacity of cca 3 000 m3
of bioethanol per year, based on our concept of Bio Plant 2015.
3. Processing of technical documentation for the delivery of a distillery with a production capacity of cca 450 hl of bioethanol per day utilising corn as a raw material.
4. Production of bioethanol from starch milk of type B in Krnov distillery with a capacity of 12 litres of absolute alcohol per hour.
5. Process optimisation and processing of technical documentation for a reconstruction of the existing distillery in India which uses cane molasses as a substrate.
Our partners in the field of industrial applications
Fermenta Biotech, DIL Complex, Ghodbunder Road, Thane (West) - 400 610, Maharashtra, India
www.fermentabiotech.com
VÚCHZ, a.s., Křižíkova 70, 612 00 Brno, CZwww.vuchz.cz
Gresham’s Eastern (Pvt) Ltd.F-302 Sind Industial Trading EstateKarachi
http://www.gel1947.com
Zinchem, Námestie Slobody 5, 071 01 Michalovce, SK
www.zinchem. sk
geniaLab®, BioTechnologie-Produkte und Dienstleistungen GmbhBüchnerstraße 7, 38118 Braunschweig, Germany
www.genialab.com
Our partners in the field of research
and developmentICT Prague, Department of Fermentation Chemistry and bioengineering, Technická 5, 166 28 Praha 6, CZ
www.vscht.cz
Fermenta Biotech, DIL Complex, Ghodbunder Road, Thane (West) - 400 610, Maharashtra, India
www.fermentabiotech.com
CHEMCOMEX Praha, a.s., Pražská 810/16, 102 21 Praha 10, CZ www.chemcomex.c
z
Institute of Microbiology, Academy of Science of the Czech RepublicVídeňská 1083, 142 20 Praha 4, Krč, CZ
www.biomed.cas.cz
STU Bratislava, Faculty of chemical and food technology, Institute of biotechnology and food technology, Radlinského 9, 81237 Bratislava, SK
www.stuba.sk
Association of Alcohol Producers in Slovakia, Záhradnícka 21, 811 07 Bratislava, SK
www.azzz.sk/clenovia.php?zvez=zvll
Sekab, Box 286, s-891 26 Örnsköldsvik, Sweden
www.sekab.com
Thank you for attentionCompany Headquarters:LentiKat´s a.s.Evropska 423/178160 00 Prague 6Czech republic
Tel.: + 420 224 362 461Fax: + 420 224 362 463 E-mail: [email protected]
Production plant and laboratoriesLentiKat´s a.s.Pod Vinicí 83471 27 Stráž pod RalskemCzech republic
Tel.: + 420 487 851 393Fax: + 420 487 851 399E-mail: [email protected]