Biomass conversion to hydrocarbon fuels using the MixAlco™ process at a pilot-plant scale

Texas A and M University has built a MixAlco™ pilot plant that converts biomass to hydrocarbons (i.e., jet fuel, gasoline) using the following steps: fermentation, descumming, dewatering, thermal ketonization, distillation, hydrogenation, and oligomerization. This study describes the pilot plant and reports results from an 11-month production campaign. The focus was to produce sufficient jet fuel to be tested by the U.S. military. Because the scale was relatively small, energy-saving features were not included in the pilot plant. Further, the equipment was operated in a manner to maximize productivity even if yields were low. During the production campaign, a total of 6.015 Mg of shredded paper and 120 kg of chicken manure (dry basis) were fermented to produce 126.5 m³ of fermentation broth with an average concentration of 12.5 kg m⁻³. A total of 1582 kg of carboxylate salts were converted to 587 L of raw ketones, which were distilled and hydrogenated to 470 L of mixed alcohols ranging from C3 to C12. These alcohols, plus 300 L of alcohols made by an industrial partner (Terrabon, Inc.) were shipped to an independent contractor (General Electric) and transformed to jet fuel (∼100 L) and gasoline (∼100 L) byproduct. - Highlights: • We produce hydrocarbons from paper and chicken manure in a pilot-scale production using the MixAlco™ process. • About 100 L of jet fuel were produced for military testing. • High production rates and good product quality were preferred rather than high yields or energy efficiency. • The MixAlco™ process converted successfully lignocellulosic biomass to hydrocarbons and viable for commercial-scale production