lentikats biotechnology in distilleries

Lentikats Lentikats BiotechnologyBiotechnologyin distilleriesin 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

Principles of Lentikats Principles of Lentikats BiotechnologyBiotechnology

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.

Production of Lentikats Biocatalyst

Lentikats BiocatalystProduction plant in Stráž pod Ralskem

Benefits of LBenefits of Lentikats Biotechnologyentikats Biotechnology

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

Lentikats Biotechnology in distilleries

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

Case study – molasses distillery

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


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


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 …


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

.



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


Biotechnology Biotechnology for distillery processing sugar for distillery processing sugar

solutionssolutions



* 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






Case study – corn distilleryCase study – corn distillery

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



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


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



Ethanol yield (L/ton of corn) 344 385




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…

What can we offer?What can we offer?

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.

References and References and experiences, our partnersexperiences, our partners

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]

lentikats biotechnology in distilleries

Documents

lentikats biocatalystgear

lentikats biocatalysts

lentikats biocatalyst

easy separation of enzymes

traditional technologies

higher yields1100

surrounding media

production of bioethanol