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Bioresource Technology 216 (2016) 331–339

Contents lists available at ScienceDirect

Bioresource Technology
journal homepage: www.elsevier.com/locate/biortech

Techno-economic comparison of biojet fuel production from


lignocellulose, vegetable oil and sugar cane juice
Gabriel Wilhelm Diederichs, Mohsen Ali Mandegari ⇑, Somayeh Farzad, Johann F. Görgens
Department of Process Engineering, University of Stellenbosch, Private Bag X1, Matieland, 7602, South Africa

h i g h l i g h t s

 Techno-economic evaluation of the jet fuel production processes from biomass.


 Comparison of 2G jet fuel production vs. 1G (vegetable oil and sugar cane juice).
 Profitability of 1G jet fuel processes are slightly better than 2G processes.
 The thermochemical and hybrid processes are the most promising 2G jet fuel options.
 Ethanol intermediate production processes result less economic viability.

a r t i c l e i n f o a b s t r a c t

Article history: In this study, a techno-economic comparison was performed considering three processes (thermochem-
Received 24 February 2016 ical, biochemical and hybrid) for production of jet fuel from lignocellulosic biomass (2G) versus two pro-
Received in revised form 20 May 2016 cesses from first generation (1G) feedstocks, including vegetable oil and sugar cane juice. Mass and
Accepted 21 May 2016
energy balances were constructed for energy self-sufficient versions of these processes, not utilising
Available online 24 May 2016
any fossil energy sources, using ASPEN PlusÒ simulations. All of the investigated processes obtained base
minimum jet selling prices (MJSP) that is substantially higher than the market jet fuel price (2–4 fold).
Keywords:
The 1G process which converts vegetable oil, obtained the lowest MJSPs of $2.22/kg jet fuel while the
Techno-economic comparison
Renewable jet fuel
two most promising 2G processes- the thermochemical (gasification and Fischer-Tropsch synthesis) and
Ethanol intermediate hybrid (gasification and biochemical upgrading) processes- reached MJSPs of $2.44/kg and $2.50/kg jet
Thermochemical fuel, respectively. According to the economic sensitivity analysis, the feedstock cost and fixed capital
Biochemical investment have the most influence on the MJSP.
Hybrid Ó 2016 Elsevier Ltd. All rights reserved.

1. Introduction on first generation (1G). 1G feedstock conversion processes include


hydro-processed esters and fatty acids (HEFA process) of vegetable
The world consumption of jet fuel is in excess of 800 million oil to jet fuel as well as biochemical conversion of sugars or
litres per day, accounting for around 10% of global transportation starches to intermediates (such as alcohols, hydrocarbons and
energy. Although most of the world’s jet fuel is produced through lipids), followed by upgrading to jet fuel. A promising thermo-
crude oil refineries, the necessity for sustainable jet fuel with chemical conversion process for the conversion of lignocellulose
reduced greenhouse gas (GHG) emissions, has prompted investiga- to jet fuel includes the gasification followed by Fischer-Tropsch
tion of alternative jet fuel production pathways (Hemighaus et al., (FT) synthesis process. Hybrid process pathways, such as gasifica-
2006; Mussatto, 2016). tion followed by syngas fermentation to ethanol, have been studied
Jet fuel produced from plant-derived sources (biojet fuel), as an alternative pathway (Naik et al., 2010; Robota et al., 2013).
has the potential to decrease the net GHG emissions associated Fossil-derived jet fuel for commercial aviation, entails different
with the aviation industry (Agusdinata et al., 2011; Klein- hydrocarbons, ranging mainly between C9 and C15 (Robota et al.,
Marcuschamer et al., 2013) and increase energy security (Bond 2013). It is desirable that biojet fuels are compatible with the exist-
et al., 2014). The focus of biofuel production, initially was intensely ing infrastructure (Klein-Marcuschamer et al., 2011). Three biojet
production processes have already been approved by the ASTM
(American Society for Testing and Materials) for commercial avia-
⇑ Corresponding author. tion use resulting in more than 1600 commercial flights run on
E-mail address: mandegari@sun.ac.za (M. Ali Mandegari).

http://dx.doi.org/10.1016/j.biortech.2016.05.090
0960-8524/Ó 2016 Elsevier Ltd. All rights reserved.
332 G.W. Diederichs et al. / Bioresource Technology 216 (2016) 331–339

biofuels (Colket et al., 2016). These processes include the HEFA dry weight). The feed-rate of lignocellulose has been chosen based
process, the FT process and the Direct-Sugar-to-Hydrocarbon pro- on previous techno-economic analysis (Bond et al., 2014; Humbird
cess (Menetrez, 2014). A variety of other processes are still in the et al., 2011). The lignocellulose composition used for the process
approval process, including the alcohol-to-jet process (Mussatto, models is based on a study by Petersen et al. (2015) which aimed
2016). to represent a generic lignocellulose. It was specified using a chem-
According to International Air Transport Association (IATA), ical composition for the L-ETH-J process, whereas a proximate and
economic viability and technology maturity is still a major hurdle ultimate analysis was used for the GFT-J and SYN-FER-J processes.
for the commercial production of biojet fuel (IATA, 2014). The mar- The feed-rate of the vegetable oil to the HEFA process and wet
ket price for jet fuel has undergone substantial variability in the sugar cane to the S-ETH-J process, was fixed to 14.9 MT/h, and
past ten years, fluctuating between $0.42 and $1.28 per kg jet fuel 222.5 MT/h, respectively. The feed rate is calculated in a way to
(Colket et al., 2016; IATA, 2014). produce the same amount of jet fuel which can be obtained from
Taking into account the commercialization status and process lignocellulose to jet fuel processes. The composition of the veg-
technology, HEFA process is considered as the most mature process etable oil – which is taken to be similar to jatropha oil- is based
for renewable jet fuel production (Mawhood et al., 2016). Although on a study by Gong et al. (2012). The wet sugar cane, contains a
the jet fuel produced through the gasification and FT synthesis MC of 71.57 wt% and sucrose content of 13.30 wt% (Dias et al.,
(GFT-J) process is already certified by the ASTM, the capital inten- 2009). For the S-ETH-J process scenario, 140 dry kg of tops and
sive nature and operational difficulties of the GFT-J process has trash (MC of 15%) is assumed to be fed along with each metric
delayed wide-scale commercial deployment of this process ton of wet cane (Dias et al., 2009).
(Mawhood et al., 2016). Another pathway consists of the bioetha- The developed processes can be compared based on the con-
nol production as intermediate and then ethanol upgrading to jet sumed feedstock and chemicals and also produced jet fuel. In addi-
fuel. The bioethanol production from 1G and 2G feedstocks, tion, energy balance is applied to study the energy performance of
through biochemical and thermochemical routes have been stud- the developed processes. Among the energy indicators, energy
ied widely (Vohra et al., 2014), however the ethanol upgrading to ratio and overall energy efficiency (Eqs. (1) and (2)) are well
jet fuel process is still on the laboratory and pilot plant stages of applied by researches to evaluate the biofuel processes
development (Mawhood et al., 2016). (Leibbrandt et al., 2011; Petersen et al., 2015).
This study performed techno-economic assessments on five The energy ratios, is defined as the energy ratio of product (jet
processes that convert plant-derived sources – in particular ligno- fuel) to feedstock which can be calculated as follows.
cellulosic biomass and first generation feedstocks (vegetable oil
and sugar cane juice) – to jet fuel. The processes considering ligno- jmfuel  HHV fuel j
ge ¼ ð1Þ
cellulosic feedstock are, 1) the GFT-J (gasification and FT synthesis) jmfeedstock  HHV feedstock j
process, 2) the L-ETH-J (biochemical conversion to ethanol with
upgrading) process and 3) the SYN-FER-J (gasification, syngas fer- where ge is the energy ratio of the process, mfuel is the mass of the
mentation to ethanol with upgrading) process. The processes con- fuel produced, mfeedstock is the mass of the feedstock input, HHVfuel
sidering 1G feedstock are 4) the HEFA (hydroprocessing of and HHVbiomass are the higher heating value (HHV) of the fuel and
vegetable oil) process and 5) the S-ETH-J (sugar cane juice to etha- feedstock, respectively.
nol by sucrose fermentation with upgrading) process. Since the The overall energy efficiency (goverall) determines the efficiency
HEFA process is the most mature technology, it is considered as of the process, considering the energy in the fuels and electrical
baseline. The S-ETH-J process consists of a fully mature technology power produced (Eelec.power) as the product, whilst taking into
for production of ethanol, whilst the ethanol production sections account the energy in the input feedstock and is calculated based
by the L-ETH-J and SYN-FER-J processes – although having been on Eq. (2).
produced commercially- is still under study (Mawhood et al.,
2016). The combination of different intermediate ethanol produc- jmfuel HHV fuel j þ Eelec:power
tion routes and upgrading ethanol to jet fuel is one of the promis- nov erall ¼ ð2Þ
jmfeedstock  HHV feedstock j
ing aspects of this study.
In this study, the different feedstock and pathways for bio jet The economic investigation was performed based on the com-
fuel production are compared through detailed techno-economic plete mass and energy balances from the ASPEN PlusÒ process
analysis of the developed processes. Mass and energy balances models. The cost analysis was performed for process plants located
were constructed for all five processes based on the Aspen PlusÒ in the USA and indexed to 2014 US dollars. In this research, equip-
process simulation, whilst the economics of these processes were ment costs are estimated by Aspen PlusÒ Economic Evaluator pack-
investigated based on cash flow analysis as well as an economic age (Aspen Technology, Inc., USA) for: flash drums, columns,
sensitivity analysis. pumps, compressors, and heat-exchangers, while the special
equipment such as boilers, turbo-expanders, generators, reactors,
waste water treatment basins are estimated based on technical
2. Materials and methods report data, using equipment-specific scaling exponents
(Swanson et al., 2010; Humbird et al., 2011; Dutta et al., 2011;
Simulations were developed for the investigated processes Jones et al., 2013; Klein-Marcuschamer et al., 2013).
using ASPEN PlusÒ (Aspen Technology Inc., USA) process simulator. Installed costs were calculated for the equipment by multiply-
A single scenario was constructed for each process, based on pub- ing the purchased equipment costs by an installation factor. The
lished experimental data. The scenarios were constructed such that fixed capital investment (FCI) and the total capital investment
the processes were steam, power and hydrogen self-sufficient, thus (TCI) were estimated from the total installed costs. The total direct
energy self-sufficient and independent of fossil fuel sources (Dutta cost was determined as the sum of the installed costs and the addi-
et al., 2011). The heat requirements of the process were optimised tional direct costs (10% of total installed costs). The FCI was calcu-
using a pinch analysis, aided by ASPEN Energy AnalyzerÒ. lated as the sum of the total direct costs and the total indirect costs
For the GFT-J, SYN-FER-J and L-ETH-J processes, the feed-rate of (60% of total direct costs) (Humbird et al., 2011). The TCI was sub-
dry, ash-free lignocellulose was fixed to 75 MT/h with a moisture sequently determined as the FCI plus the working capital (10% of
content (MC) of 50 wt% and an ash fraction of 3.70 wt% (based on the FCI) and the cost of land (Humbird et al., 2011).
G.W. Diederichs et al. / Bioresource Technology 216 (2016) 331–339 333

The production costs consisted of variable operating costs (raw Table 2


material costs, waste disposal costs, by-product credits and peri- Economic assumptions.

odic costs) and fixed operating costs (including employee salaries, Description Assumed value
labour burden and maintenance). The assumptions for the main Minimum acceptable internal rate of 10%
variable operating costs are given in Table 1. The labour and super- return (cost of capital)
vision costs were based on literature salaries (Dutta et al., 2011), Plant financing debt/equity 60%/40% of total capital
whilst adding a 90% labour burden based on the salaries investment
Plant life 20 years
(Humbird et al., 2011). The additional fixed operating costs were Income tax rate 35%
determined based on the FCI, with maintenance assumed to be Interest rate for debt financing 8% annually
3% of the FCI and property insurance and tax assumed to be 0.7% Term for debt financing 10 years
of the FCI (Humbird et al., 2011). Depreciation schedule 7 years MACRSa schedule
Construction period 3 years (8% 1st year, 60% 2nd year,
A cash flow analysis was performed in Microsoft Excel for each
32% 3rd year)b
process based on the estimated capital and operating costs. The Plant salvage value No value
economic assumptions employed in the cash flow analysis, are Start-up time 6 months
given in Table 2. As there is significant uncertainty about the future Revenue and costs during start-up Revenue = 50% of normal
price of jet fuel (and biojet fuel), the preferred method for eco- Variable costs = 75% of normal
Fixed costs = 100% of normal
nomic comparison of processes is calculation of the minimum jet
On-stream factor 90% (7884 operating hours per
fuel selling price (MJSP) for an acceptable investor return, based year)c
on cash flow analysis. The MJSP was obtained by iterating the jet a
Modified Accelerated Cost Recovery System.
fuel product cost to obtain a net present value (NPV) of zero at a b
The percent expenditure of the project cost during each construction year.
specific minimum acceptable internal rate of return (IRR; i.e. cost c
The only exception is the S-ETH-J process with an on-stream factor of 75% due
of capital). MJSP is useful to compare the investigated processes to sugar cane feedstock availability considerations.
with each other along with determining the economic feasibility
of the processes, by comparison of the MJSP to market jet fuel
prices. Finally, an economic sensitivity analysis was performed to thermodynamic calculations. The syngas is then compressed to
determine the effect of changing economic parameters on the 33 bar before being sent to a Rectisol unit for acid gas-cleaning,
MJSP. which removes 95% of the CO2 in the feed (Sun and Smith, 2013).
After further compression, the clean syngas is converted to syn-
crude in a FT synthesis reactor. The FT reactor, which has condi-
2.1. Process descriptions and simulations tions of 195 °C, 42 bar and a one-pass conversion of 40%
(Petersen et al., 2015), was modelled with a probability of 89%
2.1.1. Gasification and FT synthesis to jet fuel (GFT-J) process on the Anderson-Schulz-Flory distribution (Swanson et al., 2010).
In the GFT-J process, jet fuel is the primary product from ligno- The light gasses (mainly unconverted syngas) from the FT reactor
cellulose by gasification, FT synthesis and upgrading (Fig. 1(a)). The are sent to the auto-thermal reformer. By addition of steam (1:1
simulation of the gasification, FT synthesis and auto-thermal ratio with the hydrocarbons) and oxygen (from an air-separation
reforming sections were performed by updating a simulation unit), the feed to the auto-thermal reformer which has conditions
reported previously (Petersen et al., 2015). The lignocellulose feed, of 1000 °C and 33 bar, is reformed to syngas. The auto-thermal
along with steam, is converted to syngas in a dual-fluidized bed reformer syngas composition was predicted in ASPEN PlusÒ by
(DFB) gasifier. The gasification section of the DFB gasifier is slightly thermodynamic calculations (Petersen et al., 2015). The reformed
above 900 °C, whilst 42% of the biomass is sent to the combustion syngas is recycled to the gas-cleaning section. After the aqueous
to provide process energy (steam, electricity) (Petersen et al., phase is removed from the FT reactor liquid fraction, the subse-
2015). The syngas composition was predicted in ASPEN PlusÒ by quent syncrude is upgraded in a hydrocracker operating at
350 °C and 35 bar (Lundgren et al., 2013). The syncrude along with
excess hydrogen, is cracked and isomerised into mainly jet fuel
Table 1
(77% of fuel product), naphtha (23% of fuel product), and remaining
Main variable operating cost assumptions, ($ 2014).
light and heavy fractions. The fuel fractions are separated in two
Prices for raw materials and waste disposal Source distillation columns. The heavy fraction is recycled to the hydroc-
Lignocellulose 95.6 $/MT Jones et al. (2013), Dutta racker, whilst the light fraction is sent to the steam and power
feedstock (dry) et al. (2011)a plant. The hydrocracker hydrogen feed is obtained by recovery of
Vegetable oil 956.3 $/MT
hydrogen by a pressure-swing adsorption (PSA) unit from hydroc-
Sugar cane (wet) 41.0 $/MT
Trash (dry) 95.6 $/MT –b
racker off-gas, as well as a fraction (1.7%) of the clean syngas. Sur-
Enzymes 692.6 $/MT broth c Kazi et al. (2010) plus electricity (12.5 MW) is produced in a condensing steam
Nutrients 5.00 % of main Humbird et al. (2011) turbine generator using steam generated from the process heat
d
feedstock cost sources as well as incineration of process off-gasses. Over 20 MW
Sulphur dioxide 414.8 $/MT Humbird et al. (2011)
of the produced electricity is used for syngas compression (47%
Solvent make-up 3343 $/MT
(n-heptane) of total electricity demand). The GFT-J process shows a fuel mass
Solids disposal 40.1 $/MT Jones et al. (2013) ratio (kg fuel per MT dry lignocellulose fed to the process) of
Prices of by-products Source 0.13. According to studies by Swanson et al. (2010)) and
Electricity 0.08 $/kWh –a Lundgren et al. (2013), the fuel mass ratio can be increased above
Naphtha 1607 $/MT –e 0.19 if a pressurized gasifier is employed with oxygen in the feed.
Diesel 1597 $/MT –e
a
Based on in-house information (green electricity). 2.1.2. Gasification, syngas fermentation to ethanol with upgrading to
b
Based on lignocellulose cost. jet fuel (SYN-FER-J) process
c
10% broth as specified by (Kazi et al., 2010).
d
For L-ETH-J and SYN-FER-J processes.
The SYN-FER-J process converts lignocellulose into mainly jet
e
With an assumed 50% increase for fuel product cost due to green premium fuel through gasification followed by syngas fermentation to etha-
(http://www.indexmundi.com/commodities). nol and finally ethanol upgrading to jet fuel (Fig. 1(b)). Syngas is
334 G.W. Diederichs et al. / Bioresource Technology 216 (2016) 331–339

Fig. 1. Simplified block flow diagrams of the lignocellulose to jet fuel processes: (a) GFT-J process, (b) SYN-FER-J process and (c) L-ETH-J process.

produced from lignocellulose and steam in a DFB gasifier (simu- dehydrated to ethylene in isothermal fixed bed reactors operating
lated similar to the GFT-J process). The gasification section of the at 350 °C and 1 atm, with an ethylene selectivity of 99.9% and an
DFB gasifier is at 920 °C while 41% of the biomass is sent to the ethanol conversion of 100% (based on (Haishi et al., 2011)). The
combustion section of the DFB gasifier to provide the required ethylene is oligomerized in a two reactor setup to mainly jet fuel
energy. The conditions of the gasifier were chosen as such that pro- (88% of fuel product) and also diesel (12% of fuel product) with
duced syngas meet the specification of fermentation feed (Gaddy recycling of the light hydrocarbon product (C8-) to the second
et al., 2014). A fraction of the produced syngas (13.2%) is sent to oligomerization reactor. The first oligomerization reactor (55 °C
the steam and power plant to satisfy the process plant’s electrical and 22 bar in the presence of a catalyst in n-heptane solvent) con-
power demand (26 MW), whilst the remaining syngas is sent to the verts the ethylene to mainly C4 and also C6 and C8 hydrocarbons,
syngas fermenters. Syngas fermentation with Clostridium ljung- (Mahdaviani et al., 2010). The second oligomerization reactor
dahlii occurs in bubble-loop reactors with recycling of syngas and (Kuechler et al., 2010), operated at 235 °C and 7000 kPa in presence
cells. The fermentation was based on Gaddy et al. (2014), convert- of zeolite catalyst. Hydroprocessing of the jet fuel and diesel frac-
ing syngas (containing 50 mol% H2, 45 mol% CO and 5 mol% CO2) by tions (at 34.5 bar and 185 °C), is performed to ensure the quality
using C. ljungdahlii, to mainly ethanol (23.4 g/l), with acetone of the fuels (Kuechler et al., 2010). The hydrogen required by the
(5.7 g/l) as a by-product. Ethanol is recovered to 93 wt% from the hydroprocessing section, is recovered from the fermentation off-
fermentation broth and off-gas using two distillation columns gas using a membrane and a PSA unit. Electricity is produced by
and a water scrubber. The SYN-FER-J process produces 217 kg the steam and power plant in a condensing steam turbine genera-
ethanol per MT dry lignocellulose fed to the process. These overall tor using steam generated from process heat sources, as well as
yields compare relatively well to yields proposed by syngas fer- incineration of split syngas and process off-gasses while no surplus
mentation companies Ineos Bio (245–330 kg ethanol per dry MT electricity is generated. The SYN-FER-J process achieved an ethanol
lignocellulose) and Coskata (330 kg ethanol per dry MT lignocellu- to jet fuel mass yield of 0.54, which is slightly lower than the the-
lose) (Daniell et al., 2012). The ethanol (93 wt%) is subsequently oretical achievable mass yield of 0.61.
G.W. Diederichs et al. / Bioresource Technology 216 (2016) 331–339 335

2.1.3. Lignocellulose biochemical conversion to ethanol with upgrading 2.1.4. Sugar cane juice to ethanol by sucrose fermentation with
to jet fuel (L-ETH-J) process upgrading to jet fuel (S-ETH-J) process
The L-ETH-J process converts lignocellulose to ethanol via bio- The S-ETH-J process converts sugar cane to mainly jet fuel via
chemical route followed by upgrading ethanol to mainly jet fuel the fermentation of sugar cane juice to ethanol with subsequent
(Fig. 1(c)). The simulation of the pretreatment and conditioning, ethanol upgrading (Fig. 2(a)). The simulation of the sugar cane
hydrolysis and fermentation, steam and power plant as well as juice to ethanol production, as well as the steam and power plant
the evaporator units were performed by updating a simulation unit, was developed. The sugar cane is initially cleaned, followed
reported previously (Petersen et al., 2014). The lignocellulose is by sucrose extraction in a diffuser. The resulting bagasse is dewa-
pre-treated by SO2 impregnated steam explosion with a maximum tered to a moisture content of 50%. Dirt is removed from the
temperature of 205 °C and then hydrolysed enzymatically, with a sucrose liquid by means of physical treatment using screens and
cellulose to glucose conversion for SO2 pretreated biomass achiev- hydrocyclones. The sucrose is then concentrated in a multiple
ing up to 87% (Carrasco et al., 2010). Continuous fermentation effect evaporator to a concentration of 22 wt% followed by steril-
using a promising co-fermenting strain of Saccharomyces cerevisiae ization. Employing S. cerevisiae, the sucrose liquid is fermented to
was subsequently employed, which had conversions of xylose to ethanol in a fed-batch manner with fermentation time of 8 h, fer-
ethanol of 44% and glucose to ethanol of 88%, with an ethanol con- mentation yield of about 91%, and ethanol concentration of 13%
centration of 3.9 wt% in the fermentation broth (Martín et al., (w/v) is obtained. The fermentation yield of 91% is in good agree-
2007). Ethanol is recovered to 93 wt% from the fermentation broth ment with literature (Dias et al., 2009; Macrelli et al., 2012). Etha-
and off-gas, using two distillation columns and a water scrubber. nol is recovered to 93 wt% from the fermentation broth and off-gas
The L-ETH-J process produces 192 kg ethanol per MT dry lignocel- using two distillation columns and a water scrubber. Ethanol
lulose fed to the process, whilst, the ethanol production rate can be (93 wt%) upgrading to jet fuel by proceeds as described for the
increased up to around 250 kg ethanol per MT dry lignocellulose SYN-FER-J process. Similar to the L-ETH-J process, steam reforming
fed to the process (the increased yield is mainly possible due to of 3.8% of the ethanol is carried out to satisfy the hydrogen require-
the increase of the xylose to ethanol conversion of S. cerevisiae) ment of the hydroprocessing section. Surplus electricity (52.6 MW)
(Humbird et al., 2011). Upgrading Ethanol (93 wt%) to mainly jet is produced in a condensing steam turbine generator using steam
fuel by dehydration, oligomerization and hydroprocessing pro- generated, mainly from the combustion of the dewatered bagasse
ceeds as described for the SYN-FER-J process. Steam reforming of and additional trash fed.
3.8% of the ethanol product is performed to satisfy the hydrogen
requirement of the hydroprocessing unit. The composition of the 2.1.5. Hydro-processed esters and fatty acids (HEFA) process
reformed gas is adjusted in a shift reactor followed by hydrogen The HEFA process implements hydroprocessing of vegetable oil
recovery in a PSA unit. The products of the steam reformer and to produce jet fuel as the primary product (Fig. 2(b)). The vegetable
shift reactor were predicted in ASPEN PlusÒ by thermodynamic cal- oil is deoxygenated to hydrocarbon by catalytic hydrotreating. The
culations (Jones et al., 2013). The solid residue from the separation hydrotreating occurs in a fixed bed reactor (350 °C, 3 MPa) with a
section is concentrated by evaporation, a pneumatic press and a liquid hourly space velocity of 2 h1 and a H2/feed volume ratio (v/
multiple effect evaporator. Excess electrical power (19.1 MW) is v) of 600 (based on (Gong et al., 2012)). The hydrocarbon product
produced in a condensing steam turbine generator using steam (mainly C15–C18) is subsequently cracked and isomerised by the
generated mainly from the combustion of solids. addition of H2, while the hydrocracker conditions is set to achieve

Fig. 2. Simplified block flow diagrams of the 1G feedstock to jet fuel processes: (a) S-ETH-J process and (b) HEFA process.
336 G.W. Diederichs et al. / Bioresource Technology 216 (2016) 331–339

maximum jet fuel production (Robota et al., 2013). The hydroc- total fuel) of 0.88. That is because these processes (with a biochem-
racker reactor, (278 °C, 55.16 bar), has liquid hourly space velocity ical process step) generate an ethanol intermediate, which after
of 1 h1 and a H2/feed volume ratio (v/v) of 850 (Robota et al., dehydration to ethylene is upgraded to jet fuel via oligomerization,
2013) and fractions the hydrocarbon into jet fuel as well as diesel, with a very high jet fuel selectivity. In contrast, the HEFA and GFT-J
naphtha and a light fraction. About 55% of the naphtha product is processes crack large hydrocarbons, resulting in significant
sent to the hydrogen unit in order to meet the process plant’s amounts of by-products (low molecular weight hydrocarbon), thus
hydrogen and electricity demand. The make-up hydrogen of the decreasing the jet fuel fraction in the final product. Both the HEFA
process plant is generated by steam reforming (simulated in ASPEN and GFT-J process achieved jet to fuel mass ratios below 0.8. How-
PlusÒ similar to L-ETH-J process) of a fraction of the naphtha pro- ever, the jet fuel to feed energy ratio of the lignocellulose fed pro-
duct (29%), together with the light fraction from the separation cesses were very similar (25–26%). The HEFA process obtained
unit. Hydrogen recovery from the hydrotreater and hydrocracker a jet fuel to feed energy ratio of 60%, whilst the low jet fuel to feed
off-gas, as well as the reformed gas, is achieved by two PSA units. energy ratio of the S-ETH-J process (22.6%) is due to its fibre residue
Only sufficient electrical power is produced in a condensing steam fed, which enabled the production of a very large amount of sur-
turbine generator to meet the process plant’s total usage of plus electricity (50 MW). Both the L-ETH-J and GFT-J processes
2.60 MW. Gas compression accounts for over 72% of the total elec- also produced significant quantities of excess electricity
trical power usage. The fuel produced through HEFA process, con- (19.1 MW and 12.5 MW, respectively). For the L-ETH-J process
sists of 3% diesel, 78% jet fuel and 19% naphtha. The HEFA process due to high amounts of unfermentable solids (mainly lignin) sur-
achieved an overall yield of 480 kg jet fuel per MT vegetable oil fed, plus electricity is generated while the GFT-J process requires signif-
which is in good agreement with similar studies (Klein- icant amounts of high temperatures heat sources, therefore
Marcuschamer et al., 2011; Pearlson et al., 2013) with yields of electricity is produce along with high pressure steam production.
480–494 kg jet fuel per MT vegetable oil fed. The HEFA and SYN-FER-J processes did not produce any surplus
electricity, as both processes required combustion of intermediate
products (naphtha and syngas, respectively) to attain electricity
3. Results and discussion self-sufficiency.
The HEFA process had the highest specific hydrogen usage
3.1. Overall mass and energy balances (hydrogen usage per total fuel produced) of 65.3 kg-H2/MT-fuel,
whilst the three processes with an ethanol intermediate had the low-
The mass and energy balances for the investigated processes est specific hydrogen usage of 12.1 kg-H2/MT-fuel. The high specific
resulted from simulations (ASPEN PlusÒ), is summarized in Table 3. hydrogen usage of the HEFA process, required the reforming of a sig-
Among the lignocellulose fed processes, the GFT-J process achieved nificant fraction of produced naphtha for hydrogen generation.
the highest fuel mass ratio of 0.14 (ratio of total fuel to feed ligno- Comparison of energy consumptions (cooling, heating and elec-
cellulose) and overall process energy efficiency of 37.2%, which com- tricity) of the processes demonstrates that processes with interme-
pares well with other researches (Leibbrandt et al., 2011). The diate ethanol production, consume significantly higher energy due
overall energy efficiency achieved by the HEFA process was high to drastic energy consumption of lignocellulosic ethanol produc-
(75%) which can be ascribed to the fact that, the vegetable oil tion (Cardona Alzate and Sanchez Toro, 2006). Since GFT-J process
feed is much more similar to the final fuel products, thus requires is direct process for jet fuel production, its energy consumption is
less processing than the other feedstocks (lignocellulose or sugar milder compared to other processes, therefore the overall energy
cane syrup). Although all of the investigated processes designed efficiency of this process stands as second preferred process after
to produce mainly jet fuel, the L-ETH-J, SYN-FER-J and S-ETH-J pro- HEFA.
cesses achieved the highest jet to fuel mass ratios (ratio of jet fuel to

Table 3
Summary of mass and energy balances results for investigated processes.

Parameter Process
L-ETH-J SYN-FER-J GFT-J HEFA S-ETH-J
Feed Lignocellulose (dry MT/hr) 77.88 77.88 77.88 – –
Vegetable oil (MT/hr) – – – 14.87 –
Sugar cane (dry MT/hr) – – – – 63.27
Trash (dry MT/hr) – – – – 31.16
Energy Cooling demand (MW) 145.58 202.32 109.09 12.43 156.48
Heating demand (MW) 88.75 81.99 39.33 7.62 72.92
Electric power demand (MW) 23.79 25.94 42.11 2.6 15.46
Product Jet fuel (MT/hr) 7.75 7.94 7.93 7.14 7.76
Naphtha (MT/hr) – – 2.39 1.71 –
Diesel (MT/hr) 1.01 1.04 – 0.31 1.01
Electricity (MW) 19.1 – 12.5 – 52.6
Specific hydrogen usage (kg-H2/MT-fuel)a 12.1 12.1 23.2 65.3 12.1
Jet Fuel to Feed Energy Ratio (Eq. (1)) 25.3% 26.2% 26.1% 58.6% 22.6%
Overall Energy Efficiency (Eq. (2)) 33.3% 29.6% 37.2% 75.3% 37.1%
Overall Energy Efficiency (Eq. (2)) Value –c –c 41,9–52,2% 63,30–71,50% 43.70%
On literatureb Reference –c –c (Swanson et al., 2010) (Klein-Marcuschamer (Klein-Marcuschamer
et al., 2011; Pearlson et al., 2011)
et al., 2013)
a
Ratio between process hydrogen usage and total fuel produced.
b
Process efficiencies of literature which investigated similar processes.
c
No similar processes were found to be investigated in literature.
G.W. Diederichs et al. / Bioresource Technology 216 (2016) 331–339 337

Table 4
Summary of economic results for investigated processes.

Parameter Process
L-ETH-J SYN-FER-J GFT-J HEFA S-ETH-J
Variable Operating Costs (million US$ per year) Raw materials and waste disposal 120.23 69.75 62.51 112.60 85.36
By-product credits 24.77 13.03 38.16 25.44 38.28
Fixed Operating Costs (million US$ per year) 24.78 22.09 27.85 10.52 18.92
TIC (million US$) 274.2 232.8 321.3 91.7 184.1
FCI (million US$) 482.6 409.7 565.5 161.4 324
FCI/Annual Jet Fuel Kilogram ($/kg) 7.90 6.54 9.05 2.87 5.30
TCI (million US$) 532.7 452.5 623.9 179.4 358.3
MJSP ($ per kg jet fuel) 3.43 2.49 2.44 2.22 2.54

3.2. Economic evaluation (between $0.42 and $1.28 per kg jet fuel during last ten years
(Colket et al., 2016)). The base MJSPs of the HEFA and S-ETH-J
The economic analysis results for the investigated processes are processes of the 1G route resulted $2.22 and $2.54 per kg jet fuel
summarized in Table 4. From Table 4, it is clear that the GFT-J pro- which are lower and similar to the best performing lignocellulose
cess has the highest FCI with $566 million, while both processes fed processes respectively. The GFT-J and SYN-FER-J processes
with 1G feed have significantly lower FCI in comparison to the lig- achieved the lowest base MJSPs for the lignocellulose fed pro-
nocellulose processes. cesses ($2.44 and $2.50 per kg jet fuel, respectively), whilst the
Fig. 3 illustrates the distribution of the installed equipment L-ETH-J process requires the highest base MJSP of $3.44 per kg
costs for the investigated processes based on process units. As jet fuel.
demonstrated in Fig. 3, hydrogen plant and hydrocracking units The breakdown of the base MJSPs are also given in Table 5. A
account for over 85% of the installed equipment costs of the HEFA major portion of the MJSP for the 1G processes consists of biomass
process. The main installed equipment costs for the S-ETH-J pro- feedstock cost, consisting of 89.6% for the HEFA process’ MJSP and
cess is determined as the sugar cane to ethanol unit (30.9%), etha- 61.4% for the S-ETH-J process’ MJSP. In contrast, biomass feedstock
nol upgrading unit (37.0%) and the cogeneration unit (18.5%). The cost consists of only between 28% and 39% of the MJSP for the lig-
ethanol upgrading units are demonstrated as major capital costs nocellulose fed processes. Table 4 illustrates that enzyme cost is a
for the SYN-FER-J and L-ETH-J processes (30% and 25% of capital significant burden for the L-ETH-J process accounting for 21% of
costs, respectively), whilst wastewater treatment (WWT) unit cost the MJSP. As there is significant uncertainty surrounding the
is also substantial (both over 10% of capital cost), due to the large enzyme cost (Humbird et al., 2011), further investigation is recom-
amount of recycled water. The installed equipment cost of the lig- mended. All the processes have substantial fuel by-product credits,
nocellulose to ethanol unit for the SYN-FER-J and L-ETH-J processes (i.e. up to 20% of the MJSP for the HEFA and GFT-J processes). The L-
does not vary significantly ($102 million and $100 million, ETH-J, GFT-J and especially the S-ETH-J processes, also have signif-
respectively). The high FCI of the GFT-J process is because of icant electricity by-product credits (21% of the MJSP for the S-
required equipment with high capital cost, including gasification ETH-J process). As reported in Table 5, except for the SYN-FER-J
plant, gas cleaning unit, upgrading and separation unit as well as process, the MJSP’s of the investigated processes compared well
the auto-thermal reformer. to literature (IATA, 2014). It can be seen that MJSP determined
The base MJSPs determined for the investigated processes (see by IATA is somewhat lower. This is most likely due to difference
Table 5) are considerably higher than the market jet fuel price in economic assumptions, which are not provided by IATA.

Fig. 3. Installed equipment costs of investigated processes by section (as a percentage of total).
338 G.W. Diederichs et al. / Bioresource Technology 216 (2016) 331–339

Table 5
MJSP breakdown for the investigated processes, in cents per kg of jet fuel.

Parameter Process
L-ETH-J SYN-FER-J GFT-J HEFA S-ETH-J
Main feedstock 96.1 93.8 94.0 199.2 117.5
Trash – – – – 38.4
Enzymes 72.2 – – – –
Catalysts 17.7 17.6 13.6 1.8 19.1
Other raw materials 21.5 11.0 2.3 0.1 4.6
Waste disposal 2.7 2.9 2.6 0.1 4.4
Grid electricity 19.7 0.0 12.6 0.0 54.2
Fuel by-products 20.8 20.8 48.4 45.2 20.8
Fixed costs 40.6 35.3 44.6 18.7 37.1
Capital depreciation 12.0 11.8 11.8 14.3 14.4
Average income tax 17.3 14.3 19.1 6.2 14.2
Average return on investment 103.5 83.6 117.4 27.1 79.4
Total 343.5 249.5 244.2 222.3 254.0
Literature MJSP b, 248.1 – 243.2 148.1 169.1
Fossil jet fuel pricea Minimum 42
Maximum 128
a
In last ten years (between April 2005 and March 2015).
b
(IATA, 2014).

Fig. 4. Economic sensitivity analysis of investigated processes.

3.3. Economic sensitivity analysis increase in overall yield or ethanol broth concentration could also
significantly improve its prospect and there is continual improve-
Economic sensitivity analysis is carried out by investigating the ment in these various aspects (Humbird et al., 2011). In all the pro-
effects of economic parameter’s variation on the MJSP and the cesses, variation in feedstock and FCI cost caused a larger than 10%
results are demonstrated in Fig. 4 (base MJSPs are displayed in overall change in MJSP. Except for the HEFA process (with the low-
Fig. 4 by vertical black lines). Although fifteen sensitivity analysis est FCI), the investigated processes also underwent a larger than
parameters were adjusted across their uncertainty range, only 10% overall change with varying minimum acceptable IRR. Chang-
the parameters which caused a change of more than 10% in the ing vegetable oil feedstock cost had a major effect on the HEFA pro-
MJSPs are reported in Fig. 4. cess (changes in MJSP ranging from $1.37 to $3.36 per kg jet fuel),
The economic viability of the L-ETH-J process with the highest indicating that feedstock cost presents a significant source of
base MJSP, did not increase significantly at the favourable param- uncertainty for the HEFA process which have been mentioned by
eters considering that its lowest MJSP of $3.02 per kg jet fuel is other researches as well (Pearlson et al., 2013). The S-ETH-J process
much higher than the base MJSPs of the other investigated pro- showed larger than 10% overall change of the MJSP over six param-
cesses. To increase the potential associated with the L-ETH-J pro- eters, including feedstock cost (sugar cane and trash), FCI, stream
cesses, it is crucial for the enzyme cost to be reduced, whilst an factor, minimum acceptable IRR and electricity product price. As
G.W. Diederichs et al. / Bioresource Technology 216 (2016) 331–339 339

noted in Table 1, the on-stream factor for S-ETH-J process is 75% Hemighaus, G., Boval, T., Bacha, J., Barnes, F., Franklin, M., Gibbs, L., Hogue, N., Jones,
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