Commercial Implementation of Steam Explosion Integrated Fractionation Refining Technology

Stalk is heterogeneous, the same as its conversion property. According to the het­erogeneous characteristics of stalk, three platforms have been set up including low pressure, non-pollution steam explosion platform, solid-state fermentation platform and solid enzyme hydrolysis, fermentation, and separation coupling platform. For each platform, pilot test apparatus are designed, as well as industrial equipment. By process integration, multi-layered stalk refining has been established and indus­trialized in plant about ethanol, sheet, spinning. Especially, in September, 2010, Laihe Chemcial Co., Ltd., located in Jilin Province, China introduced this integrated process (Fig. 4.4 and 4.5). Steam explosion-alkali extraction-mechanical carding integrated pretreatment is applied. Its capacity is 300 thousand tons corn stalk annu­ally. The products from this technology are 50 thousand tons butanol, acetone, and

ethanol, 30 thousand tons pure lignin which could be converted into 20 thousand tons phenol formaldehyde resin adhesive, 120 thousand tons cellulose which could be converted into 50 thousand tons biological polyether polyol. The cost of solvent products reduce more than 50 % after cost apportion by lignin and cellulose. Many other stalk refining plants are also on the way.

Cost apportion Cost Multiple products oriented model Single product oriented model

Table 4.1 Economic comparison between multiple products oriented fractionation technology and single product oriented technology [39]

Butanol Acetone Ethanol Lignin Cellulose Butanol Acetone Ethanol

11

0.281

0.141

0.96 t

3.6 t

It

0.28 t

0.14 t

Raw material

Corn stalk (RMB)

4,715

788

221

110

757

2,838

3,320

929

465

Corn (RMB)

2,400

1,690

473

237

1,690

473

237

Industrial sulfuric acid (RMB)

177

124

35

17

124

35

17

Alkali (RMB)

650

650

Activated carbon (RMB)

1,200

1,200

Kinetic energy consumption

Steam (RMB)

2,800

468

131

66

450

1,686

1,972

552

276

Water (RMB)

470

79

22

11

76

283

331

93

46

Electricity (RMB)

750

125

35

18

120

452

528

148

74

Labour cost (RMB)

6,000

1,500

650

50

2,800

1,000

4,091

1,773

136

Total cost (RMB)

19,162

5,447

1,755

603

5,498

9,878

14,887

4,795

1,649

Cost price (RMB/t)

5,447

6,268

4,306

5,727

2,744

14,887

17,126

11,776

Market price (RMB/t)

8,000

6,000

4,000

10,000

2,200

8,000

6,000

4,000

Total value (RMB)

27,7760

8,000

1,680

560

9,600

7,920

8,000

1,680

560

Profit and tax (RMB)

8,598

3,225

113

51

4,748

462

-6,887

-3,115

-1,089