October 2003 • NREL/SR-510-31579 

Lynn Montague 

Harris Group, Inc. 

Seattle, Washington 

Lignin Process Design 

Confirmation and Capital Cost 

Evaluation 

Report 42002/02: Review of Design 

National Renewable Energy Laboratory 

1617 Cole Boulevard 

Golden, Colorado 80401-3393 

NREL is a U.S. Department of Energy Laboratory 

Operated by Midwest Research Institute • Battelle • Bechtel 

Contract No. DE-AC36-99-GO10337 
October 2003 • NREL/SR-510-31579 

Lignin Process Design 

Confirmation and Capital Cost 

Evaluation 

Report 42002/02: Review of Design 

Lynn Montague 

Harris Group, Inc. 

Seattle, Washington 

NREL Technical Monitor: Kelly Ibsen 

Prepared under Subcontract No. ACO-1-30131-01 

National Renewable Energy Laboratory 

1617 Cole Boulevard 

Golden, Colorado 80401-3393 

NREL is a U.S. Department of Energy Laboratory 

Operated by Midwest Research Institute • Battelle • Bechtel 

Contract No. DE-AC36-99-GO10337 
This publication was reproduced from the best available copy 

Submitted by the subcontractor and received no editorial review at NREL

NOTICE

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Report 42002/02, Rev 1 ii 

Project 42002 National Renewable Energy Laboratory 

Lignin Process Design Golden, Colorado 

Confirmation and Capital Cost Evaluation 

Rev 1 

March 28, 2002 

REPORT 42002/02 

REVIEW OF DESIGN 

TABLE OF CONTENTS 

Section Page 

 1 INTRODUCTION ............................................................................................. 1 

 2 LIGNIN EXTRACTION PROCESS ................................................................ 2 

 3 BASE CATALYZED DEPOLYMERIZATION (BCD).................................. 3 

 4 NEUTRALIZATION AND EXTRACTION .................................................. 4 

 5 ACID/BASE RECOVERY ............................................................................... 5 

 6 HYDROPROCESSING ..................................................................................... 5 

Appendix 

 FILTRATION AND WASHING 

 MODELING ESTIMATES 

LM/mlm 
Report 42002/02, Rev 1 1 

Project 42002 National Renewable Energy Laboratory 

Lignin Process Design Golden, Colorado 

Confirmation and Capital Cost Evaluation 

Rev 1 

March 28, 2002 

REPORT 42002/02 

REVIEW OF DESIGN 

1. INTRODUCTION 

 The National Renewable Energy Laboratory (NREL) in Golden, Colorado is 

investigating potential co-products from the biomass to ethanol process. Lignin 

constitutes 10% to 30% of the weight of biomass. Currently lignin is physically 

separated from the sugar fraction and used as a boiler fuel. NREL has developed a 

conceptual design for a process that converts the lignin into a hydrocarbon that can 

be used as a high-octane automobile fuel additive. Harris Group Inc. (HGI) 

evaluated this design for appropriateness, completeness and operability. 

 In the first stage of the NREL process, base catalyzed depolymerization (BCD) 

breaks the lignin polymer into phenolic intermediates that can be hydroprocessed 

into the final product. The depolymerized lignin is a mixture of alkylated phenols, 

alkoxyphenols, and other hydrocarbons. In the second stage, the depolymerized 

lignin is subjected to a sequential two-step hydroprocessing reaction to produce a 

reformulated hydrocarbon gasoline product. 

 In the first reaction step of hydroprocessing, the depolymerized lignin is contacted 

with a hydroeoxygeneation catalyst to produce a hydrodeoxygenated (HDO) 

intermediate product. The second reaction step utilizes a hydrocracking catalyst 

(HCR) to convert the hydrodeoxygenerated intermediate into the reformulated 

gasoline additive. The final product is a mixture of naphthenic and paraffinic 

organics in the gasoline range. 

 The following is a discussion of the process flow diagrams (PFDs) and comments 

from Harris Group on the design review. 

 An additional report (Report 42002/03, Review of Capital and Operating Costs) was 

prepared. This report contains technical specifications for selected equipment and a 

discussion of capital and operating costs obtained from equipment vendors. 
Report 42002/02, Rev 1 2 

2. LIGNIN EXTRACTION PROCESS 

 PFD P500-A1000 

 The lignin feed stream enters the process at approximately 30% solids at 

atmospheric pressure. A typical analysis of this feed stream from NREL’s enzymatic 

biomass-to-ethanol process for a corn stover feed is shown in Table 1. 

 Table 1: Feed Composition 

Component Weight (%) 

Water 70.36 

Lignin 16.03 

Cellulose 3.86 

Xylan 1.28 

Tar 2.28 

Ash 6.17 

Gypsum 0.01 

 Before the BCD operation, the incoming lignin is isolated from the other solids in the 

feed by dissolving into a basic solution. The feed stream is mixed with sodium 

hydroxide in the solubilization tank (T-1000), where it is assumed that lignin is 

completely soluble in the base solution. A belt filter press (S-1010) is used to 

separate the solubilized lignin from the remaining solids. The solubilized lignin in 

the effluent stream is sent to the BCD process. The insoluble solids are sent to a 

co-located boiler or sold as boiler fuel. 

 Changes 

 The initial design included a screw press on the SOLIDS stream out of the BCD belt 

filter press, which increased the solids from 44% to 65%. There was some concern 

that the screw press could actually accomplish this, so it was decided to remove the 

screw press (plus pump P-1001) and send the solids to the biomass-to-ethanol 

process for additional drying. Pump P-BASEX was removed, as there was a pump 

(P-1310) on PFD P500-1300 that was serving the same purpose. The BCD process 

feed tank (T-1010) was added to collect the solubilized lignin. For clarity, BCD feed 

pump P-1010 was moved from PFD P500-A1100 to this PFD. 

 Harris Group evaluated the filter cake washing of the belt filter press (S-1010) by 

using a WinGEMS process model. This evaluation indicated that over 99% of the 

product could be recovered at a wash rate of 50 % the current rate. Details of this 

modeling are shown in the appendix 
Report 42002/02, Rev 1 3 

 Concerns 

 The minimum concentration of NaOH required to dissolve the lignin into solution 

and the concentration necessary for the BCD reaction is unknown. Further 

investigation is recommended to determine the base requirements. Also of concern 

is the potential for precipitation of lignin as base reacts with carbonic acid (CO2) 

evolved during BCD reaction. 

3. BASE CATALYZED DEPOLYMERIZATION (BCD) 

 PFD P500-A1100 

 The solubilized lignin stream passes through three heat exchangers (H-1110, H-1112 

and H-1114) to raise the temperature from 64°C to 320°C before entering the BCD 

reactor (M-1112). The BCD reactor operates at 320°C, 121 atmospheres with 6.3% 

lignin in 0.24 % (wt) sodium hydroxide solution. During a 10-minute retention time, 

the BCD reactor breaks the lignin polymer into a mixture of alkylated phenols, 

alkoxyphenols and other hydrocarbons. 

 The BCD product stream goes to two flash tanks in series (T-1114 and T-1116). The 

first flash tank (T-1114) operates at 60 atmosphere and vaporizes water. This vapor 

is used in heat exchanger H-1112 to raise the temperature of the solubilized lignin 

stream to the BCD reactor. This vapor is then cooled by heat exchanger H-1118 and 

sent to waste water treatment. The second flash tank (T-1116) reduces the pressure 

to atmospheric and vaporizes much of the remaining water. This vapor is used in 

heat exchanger H-1110 to raise the temperature of the solubilized lignin stream to 

the BCD reactor. The vapor then goes to waste water treatment. The BCD product 

stream leaving the flash tanks is cooled by heat exchanger H-1120 from 100°C to 

50°C before going to the BCD product neutralization tank (M-1120). 

 Changes 

 The area of largest concern in this process was raising the temperature of the 

product steam to 320°C for the reaction in the BCD reactor. The temperatures on 

heat exchangers H-1110 and H-1112 were adjusted to improve the heat balance. The 

BCD feed tank (T-1110) and pump (P-1124) are not required and were removed. 

Heat exchanger H-1114 was added to increase the temperature of the feed stream 

from 211°C to 320°C and also provide heat for start-up. Due to the high 

temperatures, this heat exchanger will use hot oil as the heat transfer medium. 

 The agitators for the BCD reactor (M-1112) and the flash tanks (T-1114 and T-1116) 

were not required and were eliminated. The pump (P-1110) between heat 

exchangers H-1110 and H-1112 was not required, as there are pumps on both sides 

of the heat exchangers. Heat exchanger H-1118 was added to cool the waste water 

before it is sent to waste water treatment. Demisters were added to both flash tanks 
Report 42002/02, Rev 1 4 

to prevent liquid carryover with the vapor. The operating pressure on the flash tank 

(T-1116) was changed from 1 to 2 atm to provide a driving force for vapor flow. 

4. NEUTRALIZATION AND EXTRACTION 

 PFD P500-A1101 

 The BCD product is neutralized with sulfuric acid in tank M-1120. This forms 

significant quantities of sodium sulfate. The BCD product is then extracted from the 

aqueous solution with toluene in tank T-1130. The resultant organic and aqueous 

phases are separated in a decanter (M-1140). The aqueous phase is sent to a belt 

filter press (S-1132). The solids from the belt filter press are sent to a fluidized bed 

combustor and the liquid stream goes to the acid/base recovery process. 

 The organic phase-out of the decanter goes to an evaporator (E-1150) where a 

majority of the toluene is recovered and recycled back to extraction (T-1130). The 

BCD product leaves the evaporator 95% pure, containing only small amounts of 

toluene and sodium sulfate as impurities. It is then sent to storage where it will be 

eventually hydroprocessed into a reformulated gasoline additive. 

 Changes 

 The number of this PFD was changed from PFD P500-A1100A to PFD P500-A1101. 

The belt filter press (S-1132) was relocated to the aqueous stream out of the decanter 

(M-1140). This will facilitate separation of the oligmers. Cooling coils (H-1121, 

H-1122, and H-1123) were added to the lines coming into and leaving the BCD 

product neutralization tank (M-1120) to remove the heat. Pumps P-ACID and 

P-TOLU were removed, as they were duplicated on PFD P500-A1300. Toluene 

recycle condenser (H-1153) was added. 

 Harris Group evaluated the filter cake washing of the belt filter press (S1101) by 

using a WinGEMS process model. This evaluation indicated that over 99% of the 

product could be recovered at a wash rate of 50 % the current rate. Details of this 

modeling are shown in the appendix. 

 Concerns 

 Currently the lab process extracts the BCD from the water solution using ether in a 

two-stage extraction process where both the liquid BCD and the solid BCD products 

are extracted. The design proposes performing the process in a single extraction 

step using toluene as the solvent. Testing of the extraction process with toluene as 

opposed to ether should be investigated. Solvent extraction should be tested on the 

mixed neutralized material to determine if both the high (intermediate a) and low 

(intermediate b) viscosity BCD material are extracted or if dewatering of the high 

viscosity BCD solids are required prior to extraction. 
Report 42002/02, Rev 1 5 

 NREL has stated that the solid remaining after BCD extraction is of similar chemical 

make-up to the BCD, indicating that this material is not simply char from the BCD 

reaction. This material might either be converted to BCD by recycle to the front of 

the process, or treated in the hydrotreater directly to RHG if the physical properties 

of the material are suitable. We recommend further testing of this material to 

determine if either the material will convert further upon recycle or if this material 

becomes a liquid at hydrotreating reaction temperatures where it might become 

feasible to feed this material to the hydrotreating/hydrocracking process to increase 

overall process yield. We are also concerned with the high level of Na2SO4 in the 

BCD product considering the expected low solubility of the salt in the organic phase. 

5. ACID/BASE RECOVERY 

 PFD P500-A1200 

 

 An electrodialysis system (ED-1220) regenerates sulfuric acid and sodium hydroxide 

from the sodium sulfate of the decantered aqueous stream. The resultant dilute acid 

is recycled to neutralization of the BCD products and the dilute base stream is 

utilized for lignin solubilization. 

 Two vendors have provided quotes for an electrodialysis process to recover the acid 

and base from the sodium sulfate solution. The uninstalled prices ranged from $3.5 

to $5 million. They did stress that from an economical sense this separation did not 

make sense. Harris Group will investigate the economics of not doing the 

separation and using fresh acid and base. 

6. HYDROPROCESSING 

 PFDs P500-A1500 AND P500-A1501 

 In the second stage, the depolymerized lignin is subjected to a sequential two-step 

hydroprocessing reaction to produce a reformulated gasoline additive. In the first 

step, the BCD product is subjected to exhaustive hydrodeoxygenation (HDO) which 

yields hydrodeoxygenated products. Immediately following HDO, the 

hydrodeoxygenated product is subjected to a partial ring hydrogenation and mild 

hydrocracking (HCR) to produce the final reformulated hydrocarbon gasoline 

(RHG) product. The mixture of alkylbenzenes, branched paraffins, and alkylated 

naphthenes is combined into one component called HDO for the Aspen simulations. 

 Following hydroprocessing, the reformulated gasoline additive (RHG) stream is 

cooled (H-1570 and H-1580) from 380°C to 125°C and then flashed to 60 atm of 

pressure in the product flash tank (T-1550). The flash vapor, consisting primarily of 

hydrogen, is recycled to the HDO reactor. The RHG-rich flash bottoms are sent to 

distillation where the RHG product is pulled off the top of the distillation column 

and sent to storage. 
Report 42002/02, Rev 1 6 

 Changes 

 The original PFD (PFD P500-A1500) was separated into two PFDs for clarity. The 

BCD product stream was routed to heater H-1570 and heater H-1560 was added in 

order to raise the temperature prior to the HDO reactor (M-1550). Pumps P-1540 

and P-1570 were no longer required and were removed. Compressor C-1520 was 

added to increase the pressure or the recycle stream back to the HDO reactor 

(M-1550). The vapor cleanup system M-1570 was added in the recycle line to the 

HDO reactor (M-1550). Heater H-1580 was added to cool the stream into the HDO 

distillation column (D-1550). Pump P-1551 was added to transport water from the 

HDO distillation column (D-1550) to waste water treatment. The HDO condenser 

column T-1560 was also added. 

 Originally, the design incorporated a large recycle of RHG back into the reactor 

train. Harris Group modified the design to a once-through system typical of 

hydroprocessing. 

Concerns 

 Extraction and evaporation should be investigated to determine how much toluene, 

water and Na2SO4 remain with the BCD product to be hydrotreated. Evaporation 

testing should also be designed to provide an estimate of the amount of BCD 

product (if any) that goes overhead with the solvent. 

 In laboratory processing, the BCD goes through a cleanup to remove salt and water 

prior to hydrotreating in lab testing. This level of cleanup is not designed in the 

proposed commercial process. Hydrotreating with a more realistic BCD will help 

understand the effects of Na2SO4 on the catalyst as a possible poison and/or 

hydrogen load. 

 Off gas (hydrogen) from these reactors should be analyzed to determine the extent 

of H2S, water, and light cracking products that need to be removed/purged from the 

recycle hydrogen. The composition of the off gas will help determine the method 

and design for treating of the recycle hydrogen gas. 
APPENDIX 

FILTRATION AND WASHING 

MODELING ESTIMATES 
Project 42002 A-1 

Project 42002 National Renewable Energy Laboratory 

Lignin Process Design Golden, Colorado 

Confirmation and Capital Cost Evaluation 

December 12, 2001 

APPENDIX 

FILTRATION AND WASHING 

MODELING ESTIMATES 

Per NREL’s request HGI has performed some evaluation of the filter cake washing to 

provide a more realistic estimate of wash efficiency than the 100% efficient removal that 

NREL had estimated in the process model. This effort is summarized below. 

1. SUMMARY 

 Several methods were used to estimate more realistic wash efficiencies ranging from 

a simple reslurry to modeling a displacement wash based on Norden efficiency 

methods. We recommend that a N=2 efficiency wash be utilized for the cake wash 

for both filtration steps in the NREL Lignin conversion process and that the water 

used for cake washing be reduced to 50% the existing model flow. We believe that 

this efficiency is a realistic best case performance based on experience for a 

displacement wash device. This efficiency still provides for over 99% recovery of the 

liquid products from the solids cake. It warrants pointing out that the single most 

important factor in determining product recovery is the effectiveness of the filtration 

method at “squeezing” liquid from the cake. Changes in predicted cake dryness 

levels can have a significant impact on wash performance. A brief discussion of the 

methods used, results and recommendation are presented here. 

2. METHODS 

 In the current NREL model, a 100% wash efficiency is employed. To better estimate 

a realistic range of washing effectiveness, HGI has modeled the cake washing 

process using the WinGEMs process simulator. WinGEMs, a process simulator 

typically used in the pulp and paper industry, is programmed to handle filter cake 

washing calculations. Both filtration steps in the NREL lignin process were 

investigated. For each filtration case several options were investigated as listed 

below. 
Project 42002 A-2 

 Cases 

• Base case, filtration without washing 

• Ideal wash consistent with current model 

• Simple reslurry wash 

• Displacement wash modeled using the Norden efficiency method with 

efficiencies from 2 to 4, for example 

 Each case was modeled both at the wash water flow in the current model and at 50% 

the current flow of wash water for comparison. 

 In the base case the slurry was filtered to a fixed dryness and the amount of product 

lost with the cake was calculated assuming the product was not adsorbed onto/into 

the solids material and only remained in the cake as a fraction of the free liquid at 

the same concentration as in the filtrate. This case is used as a comparison to the 

washing calculations to evaluate wash efficiency. 

 The ideal wash represents 100% removal of the liquid product from the cake 

consistent with the current model parameters. 

 In the simple reslurry method the cake is essentially mixed with the wash water and 

filtered again to the prescribed cake dryness. This effectively models a lower limit 

on the recovery of a displacement type wash. The simple reslurry is a worst-case 

scenario for a cake wash given a wash water rate. 

 A more realistic way to model a displacement wash is to use a model employing a 

“wash efficiency”. In these calculations, a wash efficiency referred to as the Norden 

efficiency was used. Basically the Norden efficiency is a measure of the number of 

countercurrent reslurry type wash steps that the displacement wash is equivalent to. 

Figure 1 shows the WinGEMs model calculations demonstrating the Norden 

efficiency and its equivalence to a countercurrent reslurry type wash. In the upper 

part of the figure the slurry is filtered and washed in a countercurrent reslurry wash 

mode of two stages. The lower section show the application of a Norden efficiency 

of 2 to the cake wash process yielding equivalent results. 

 Unfortunately, this efficiency parameter cannot be derived for a particular 

application but needs to be determined experimentally for a specific piece of 

equipment and application. However, certain “typical” values can be applied for 

specific equipment based on experience. A more detailed discussion of the Norden 

efficiency can be found in the Handbook for Pulp and Paper Technologists (Smook, 

p. 99). This source indicates that a vacuum drum washer will have an efficiency of 

2.5 to 4. Without any more information relative to the filtration equipment, we 

modeled efficiencies from 2 to 4 for comparison. 
Project 42002 A-3 

3. RESULTS AND DISCUSSION 

 Attached are printouts from the process simulator used to simulate various wash 

methods and efficiency to provide support for any modification within the process 

model as a whole. Figures 2a and 2b represent calculations based on the first 

filtration step, S-1010. Figure 3a and 3b represent calculations for the second 

filtration step, S-1132. 

 The most important factor in determining the effectiveness of product recovery is 

the actual dryness of the filter cake. Without any indication as to the ease of 

filtration, we assumed a 65% cake solids in the first application investigated and a 

50% cake solids in the second application. The 65% solids for the first application 

was used based on the current NREL processing model which uses 65%. The 50% 

used in the second application was chosen as a more conservative estimate than the 

85% solids that is currently in the model. Our results show that even at 50% with a 

reduced wash, a significant percentage of the product is recovered. It is also our 

experience that an 85% cake solids is unlikely to be achieved commercially. 

 Each figure set 2a and 3a, shows the base case, the ideal wash case, the simple 

reslurry and wash stages with efficiencies of 2, 3, and 4. In figure sets 2b and 3b, the 

same filtration models are shown but at 50% the wash water rate. The results are 

tabulated in the Tables 1 and 2 for the two filtration processes modeled. These 

tables summarize the results for each case based on the current model flow rates and 

solids loading as well as calculations with half the wash water rate as a comparison. 

 The results from the S-1010 filtration modeling presented in Table 1 show that, 

assuming a wash efficiency of 2, 99.8% of the total product is recovered. In 

comparison, in the base case without washing, 96.9% of the product is recovered, 

and in a simple reslurry 99.3% is recovered. Cutting the wash water rate to 50% 

with an efficiency 2 wash still results in over 99.5% recovery of the liquid product, 

an 84% improvement over the case without cake washing (based on total product 

remaining in the cake). Similarly, Figure 2 shows the model results for the S-1132 

filtration, in this case at an efficiency of 2 and a 50% wash rate result in just under 

99.8% product recover. 

 In each of the modeled filtration processes, the recapture of the product in the liquid 

stream utilizing a wash efficiency of 2 results in a greater than 99% recovery of 

product. Given this high rate of recovery at a reduced washing rate, it seems 

reasonable to reduce the predicted wash rate in the current process parameters. 

Considering the high recovery of product, even without washing, it is worth 

pointing out the underlying reasons. High overall product recoveries are seen in 

each of this filtration processes due to the very low solids to liquid ratios, resulting 

in a small percentage of the total liquid remaining in the cake after filtration. In 

S-1010, less than 5% of the feed is suspended solids and in S-1132 the solids feed rate 

is less than 1% the total feed. 
Project 42002 A-4 

4. CONCLUSIONS 

 Even a simple reslurry wash method results in a product recovery (based on the 

dissolved solid in the liquid) of over 99% in both filtration applications. This 

suggests that the wash water rate may be reduced without a significant loss in 

product recovery. Improved recoveries are observed when a displacement style 

wash is modeled using the Norden efficiency factor method. 

 We suggest that, for purposes of the model at this stage in the project development, 

a wash with an efficiency factor of 2 be applied and the rate of wash water be 

reduced to 50% the current rate. The efficiency factor of 2 appears realistic if not 

conservative based on literature reported values for equipment employing 

displacement type washing. 

42002_Rpt02 Appendix 
1

 2 

2

2 16 

2

1

2 23 

1

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2

1

2 43 

2

1 66 

2 70 

2

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2

1 72 2

2

2

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2 86 

1

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1

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1

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1

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1

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1

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2

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1

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1 1

2

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1 2

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1 1 1

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1

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1

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1

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1 1

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2

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2

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1

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1

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1 1

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1

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1 1

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1

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1

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2

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1

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SPLIT

Split1~1

1

MIX

Mix4

4

SPLIT

Split3

5

MIX

Mix2

6

SPLIT

Split1

10

MIX

Mix2~1

11

SPLIT

Split3~1

12

MIX

Mix4~1

13

SPLIT

Split3~2

16

MIX

Mix33

33

MIX

Mix33~1

34

MIX

Mix33~2

42

WASH WATER

CAKE

FILTRATE

SLURRY

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

23215 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0% DISS SOLIDS

218776 KG/HR

0% SUSP SOLIDS

6% DISS SOLIDS

WASH WATER

CAKE

FILTRATE

SLURRY

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

23215 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0.02% DISS SOLIDS

218776 KG/HR

0% SUSP SOLIDS

5.99% DISS SOLIDS

 EFFICIENCY FACTOR = 4

SLURRY

FILTRATE

CAKE

WASH WATER

218776 KG/HR

0% SUSP SOLIDS

5.96% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

1.37% DISS SOLIDS

23215 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

ALL OF THE SOLIDS

AND NO LIQUID

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

213280 KG/HR TO GET 65% CONSISTENCY

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

6.5% DISS SOLIDS

195561 KG/HR

0% SUSP SOLIDS

6.5% DISS SOLIDS

SLURRY

FILTRATE

CAKE

REV. A

Figure 2a

HARRIS GROUP INC.

Suite 800

1000 Denny Way

Seattle, WA 98109

(206) 494-9529

www.harrisgrp.com 11/05/01-7:42 AM

S-1010

BCD FEED FILTER

NREL

National Renewable Energy

Laboratory

 EFFICIENCY FACTOR = 3

218776 KG/HR

0% SUSP SOLIDS

5.99% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0.09% DISS SOLIDS

23215 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS SLURRY

FILTRATE

CAKE

WASH WATER

WASH WATER

CAKE

FILTRATE

SLURRY

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

23215 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0.35% DISS SOLIDS

218776 KG/HR

0% SUSP SOLIDS

5.98% DISS SOLIDS

 EFFICIENCY FACTOR = 2

Prepared by: SLL

Project No. 42002

WASH WATER FLOW SET EQUAL 

TO FLOW IN CURRENT MODEL

DISPLACEMENT WASH USING THE NORDEN EFFICIENCY METHOD

RE-SLURRY WASH

IDEAL WASH

BASE CASE
2 5 

2

1 6 2

2 44 

2 55 2 55 1

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2

2

2

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1

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1

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1 1

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1 1

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1 1

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1

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1 2

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1 1

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1

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MIX

Mix33~3

2

SPLIT

Split1~3

23

MIX

Mix2~3

24

SPLIT

Split1~4

25

MIX

Mix26

26

MIX

Mix30

30

SPLIT

Split1~5

31

 EFFICIENCY FACTOR = 2

218776 KG/HR

0% SUSP SOLIDS

5.98% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0.35% DISS SOLIDS

23215 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS SLURRY

FILTRATE

CAKE

WASH WATER

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

23215 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

218776 KG/HR

0% SUSP SOLIDS

5.98% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0.35% DISS SOLIDS

Prepared by: SLL

Project No. 42002

NREL

National Renewable Energy

Laboratory

S-1010

BCD FEED FILTER

11/05/01-7:42 AM

Suite 800

1000 Denny Way

Seattle, WA 98109

(206) 494-9529

www.harrisgrp.com

HARRIS GROUP INC.

Figure 1

REV. A

TWO STAGE COUNTERCURRENT

 RE-SLURRY TYPE WASH

NORDEN EFFICIENCY METHOD
2 40 

2

1 41 2

2

2

1 95 

2 101 

2 103 

2

1 104 

2 112 

2 114 

2

1

1

 122 

2 125 

1

 130 

2

1

2

2

 40 

1

 42 

1

 46 

1 1

 50 

 91 

1

 92 

1 1

 93 

 94 

1

 96 

1

 100 

2

 101 

1

 102 

2

 103 

1

 105 

1

 106 

1 1

 110 

1

 111 111 

 112 

1

 113 

2

 114 

1

 116 

1 1 1

 121 

 122 

1 2

 123 

1

 124 

2

 125 

1 2

 126 

 130 

1 1

1

 132 

1

 134 

 135 

1

 136 

1

 140 

MIX

Mix33~4

21

MIX

Mix33~4

46

MIX

Mix33~4

50

SPLIT

Split3~3

52

MIX

Mix4~2

53

SPLIT

Split3~3

54

MIX

Mix2~2

55

SPLIT

Split1~2

56

MIX

Mix2~2

60

SPLIT

Split3~3

61

MIX

Mix4~2

62

SPLIT

Split1~2

64

 EFFICIENCY FACTOR = 2

207169 KG/HR

0% SUSP SOLIDS

6.3% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

1.02% DISS SOLIDS

11607.5 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS SLURRY

FILTRATE

CAKE

WASH WATER

WASH WATER

CAKE

FILTRATE

SLURRY

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

11607.5 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0.5% DISS SOLIDS

207169 KG/HR

0% SUSP SOLIDS

6.32% DISS SOLIDS

 EFFICIENCY FACTOR = 3

CAKE

FILTRATE

SLURRY

195561 KG/HR

0% SUSP SOLIDS

6.5% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

6.5% DISS SOLIDS

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND NO LIQUID

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

11607.5 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

2.26% DISS SOLIDS

207169 KG/HR

0% SUSP SOLIDS

6.26% DISS SOLIDS

WASH WATER

CAKE

FILTRATE

SLURRY

 EFFICIENCY FACTOR = 4

207169 KG/HR

0% SUSP SOLIDS

6.32% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0.26% DISS SOLIDS

11607.5 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS SLURRY

FILTRATE

CAKE

WASH WATER

207169 KG/HR

0% SUSP SOLIDS

6.3% DISS SOLIDS

17719 KG/HR

65% SUSP SOLIDS

0% DISS SOLIDS

11607.5 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

213280 KG/HR

5.4% SUSP SOLIDS

6.5% DISS SOLIDS

SLURRY

FILTRATE

CAKE

WASH WATER

WASH WATER FLOW SET EQUAL T

O 50% OF FLOW IN CURRENT MODEL

DISPLACEMENT WASH USING THE NORDEN EFFICIENCY METHOD

RE-SLURRY WASH

IDEAL WASH

BASE CASE

Prepared by: SLL

Project No. 42002

NREL

National Renewable Energy

Laboratory

S-1010

BCD FEED FILTER

11/05/01-7:42 AM

Suite 800

1000 Denny Way

Seattle, WA 98109

(206) 494-9529

www.harrisgrp.com

HARRIS GROUP INC.

Figure 2b

REV. A
1

 2 

2

2 16 

2

1

2 23 

1

 26 

2

1

2 43 

2

1 66 

2 70 

2

 71 

2

1 72 2

2

2

1 83 

2 86 

1

 1 

 2 

1

 3 

1

 4 

1

 12 

 13 

1

 14 

1

 15 

2

 16 

1

 21 

1 1

2

 23 

1 2

 24 

1 2

 25 

 26 

1 1 1

 31 

1

 33 

 43 

1

 45 

1

 51 51 

1 1

 65 

2

 70 

2

 71 

1

 73 

1

 74 

1 1

 75 

 76 

1

 80 

1 1

 81 

 82 

1

 84 

1

 85 

2

 86 

1

 90 

SPLIT

Split1~1

1

MIX

Mix4

4

SPLIT

Split3

5

MIX

Mix2

6

SPLIT

Split1

10

MIX

Mix2~1

11

SPLIT

Split3~1

12

MIX

Mix4~1

13

SPLIT

Split3~2

16

MIX

Mix33

33

MIX

Mix33~1

34

MIX

Mix33~2

42

WASH WATER

CAKE

FILTRATE

SLURRY

128020 KG/HR

0.6% SUSP SOLIDS

6.5% DISS SOLIDS

1641 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0% DISS SOLIDS

128020 KG/HR

0% SUSP SOLIDS

6.458% DISS SOLIDS

WASH WATER

CAKE

FILTRATE

SLURRY

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS

1641 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.025% DISS SOLIDS

128020 KG/HR

0% SUSP SOLIDS

0.783% DISS SOLIDS

 EFFICIENCY FACTOR = 4

SLURRY

FILTRATE

CAKE

WASH WATER

128020 KG/HR

0% SUSP SOLIDS

0.781% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.263% DISS SOLIDS

1641 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS

ALL OF THE SOLIDS

AND NO LIQUID

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 50% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 50% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET50% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

128020 KG/HR TO GET 50% CONSISTENCY

0.6% SUSP SOLIDS

0.8% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.788% DISS SOLIDS

126379 KG/HR

0% SUSP SOLIDS

0.788% DISS SOLIDS

SLURRY

FILTRATE

CAKE

REV. A

Figure 3a

HARRIS GROUP INC.

Suite 800

1000 Denny Way

Seattle, WA 98109

(206) 494-9529

www.harrisgrp.com 11/05/01-7:46 AM

S-1132

ACID/BASE RECOVERY FILTER

NREL

National Renewable Energy

Laboratory

 EFFICIENCY FACTOR = 3

128020 KG/HR

0% SUSP SOLIDS

0.783% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.053% DISS SOLIDS

1641 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS SLURRY

FILTRATE

CAKE

WASH WATER

WASH WATER

CAKE

FILTRATE

SLURRY

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS

1641 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.113% DISS SOLIDS

128020 KG/HR

0% SUSP SOLIDS

0.782% DISS SOLIDS

 EFFICIENCY FACTOR = 2

Prepared by: SLL

Project No. 42002

BASE CASE

IDEAL WASH

RE-SLURRY WASH

DISPLACEMENT WASH USING THE NORDEN EFFICIENCY METHOD

WASH WATER FLOW SET EQUAL 

TO FLOW IN CURRENT MODEL
2 40 

2

1 41 2

2

2

1 95 

2 101 

2 103 

2

1 104 

2

 112 

2

 114 

2

1

1

 122 

2 125 

1

 130 

2

1

2

2

 40 

1

 42 

1

 46 

1 1

 50 

 91 

1

 92 

1 1

 93 

 94 

1

 96 

1

 100 

2

 101 

1

 102 

2

 103 

1

 105 

1

 106 

1 1

 110 

1

 111 111 

 112 

1

 113 

2

 114 

1

 116 

1 1 1

 121 

 122 

1 2

 123 

1

 124 

2

 125 

1 2

 126 

 130 

1 1

1

 132 

1

 134 

 135 

1

 136 

1

 140 

MIX

Mix33~4

21

MIX

Mix33~4

46

MIX

Mix33~4

50

SPLIT

Split3~3

52

MIX

Mix4~2

53

SPLIT

Split3~3

54

MIX

Mix2~2

55

SPLIT

Split1~2

56

MIX

Mix2~2

60

SPLIT

Split3~3

61

MIX

Mix4~2

62

SPLIT

Split1~2

64

 EFFICIENCY FACTOR = 2

127200 KG/HR

0% SUSP SOLIDS

0.786% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.263% DISS SOLIDS

821 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS SLURRY

FILTRATE

CAKE

WASH WATER

WASH WATER

CAKE

FILTRATE

SLURRY

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS

821 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.197% DISS SOLIDS

127200 KG/HR

0% SUSP SOLIDS

0.787% DISS SOLIDS

 EFFICIENCY FACTOR = 3

CAKE

FILTRATE

SLURRY

126379 KG/HR

0% SUSP SOLIDS

0.788% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.788% DISS SOLIDS

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 65% CONSISTENCY

ALL OF THE SOLIDS

AND ENOUGH LIQUID

TO GET 50% CONSISTENCY

ALL OF THE SOLIDS

AND NO LIQUID

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS

821 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.394% DISS SOLIDS

127200 KG/HR

0% SUSP SOLIDS

0.785% DISS SOLIDS

WASH WATER

CAKE

FILTRATE

SLURRY

 EFFICIENCY FACTOR = 4

127200 KG/HR

0% SUSP SOLIDS

0.787% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0.157% DISS SOLIDS

821 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS SLURRY

FILTRATE

CAKE

WASH WATER

127200 KG/HR

0% SUSP SOLIDS

0.788% DISS SOLIDS

1641 KG/HR

50% SUSP SOLIDS

0% DISS SOLIDS

821 KG/HR

0% SUSP SOLIDS

0% DISS SOLIDS

128020 KG/HR

0.6% SUSP SOLIDS

0.8% DISS SOLIDS

SLURRY

FILTRATE

CAKE

WASH WATER

DISPLACEMENT WASH USING THE NORDEN EFFICIENCY METHOD

RE-SLURRY WASH

IDEAL WASH

BASE CASE

Prepared by: SLL

Project No. 42002

NREL

National Renewable Energy

Laboratory

S-1132

ACID/BASE RECOVERY FILTER

11/05/01-7:46 AM

Suite 800

1000 Denny Way

Seattle, WA 98109

(206) 494-9529

www.harrisgrp.com

HARRIS GROUP INC.

Figure 3b

REV. A

WASH WATER FLOW SET EQUAL T

O 50% OF FLOW IN CURRENT MODEL
Table 1

S-1010 Filtration

NREL Lignin Conversion Process

8/20/2001

Feed Characteristics 

Total Flow kg/hr 213280

Suspended Solids % 5.40%

Disolved Solids (Products) % 6.50%

Total Product kg/hr 13114.59

Assumptions 

Cake dryness (as suspended solids) % 65%

Base Wash Rate kg/hr 23215

Suspended Solids removal % 100%

Wash Cake Out Efficiency Product in Product Percent Total Improvement

Rate Factor Cake liquid Lost Lost Recovery Over

Wash Method Factor kg/hr % kg/hr Baseline

No Wash (Baseline) 17719 6.50% 403.11 3.07% 96.93% 0.00%

Simple Reslurry 1 17719 1.37% 84.96 0.65% 99.35% 78.92%

Simple Reslurry 0.5 17719 2.26% 140.16 1.07% 98.93% 65.23%

Displacement Wash A 1 17719 2 0.35% 21.71 0.17% 99.83% 94.62%

Displacement Wash A 0.5 17719 2 1.02% 63.26 0.48% 99.52% 84.31%

Displacement Wash B 1 17719 3 0.09% 5.58 0.04% 99.96% 98.62%

Displacement Wash B 0.5 17719 3 0.50% 31.01 0.24% 99.76% 92.31%

Displacement Wash C 1 17719 4 0.02% 1.24 0.01% 99.99% 99.69%

Displacement Wash C 0.5 17719 4 0.26% 16.12 0.12% 99.88% 96.00%

Ideal Wash 1 17719 0% 0.00 0.00% 100.00% 100.00%
Table 2

S-1132 Filtration

NREL Lignin Conversion Process

8/20/2001

Feed Characteristics 

Total Flow kg/hr 128020

Suspended Solids % 0.60%

Disolved Solids (Products) % 0.80%

Total Product kg/hr 1018.015

Assumptions 

Cake dryness (as suspended % 50%

Base Wash Rate kg/hr 1641

Suspended Solids removal % 100%

Wash Cake Out Efficiency Product in Product Percent Total Improvement

Rate Factor Cake liquid Lost Lost Recovery Over

Wash Method Factor kg/hr % kg/hr Baseline

No Wash (Baseline) 1641 6.50% 53.33 5.24% 94.76% 0.00%

Simple Reslurry 1 1641 0.24% 1.94 0.19% 99.81% 96.37%

Simple Reslurry 0.5 1641 0.39% 3.23 0.32% 99.68% 93.94%

Displacement Wash A 1 1641 2 0.11% 0.93 0.09% 99.91% 98.26%

Displacement Wash A 0.5 1641 2 0.26% 2.16 0.21% 99.79% 95.95%

Displacement Wash B 1 1641 3 0.05% 0.43 0.04% 99.96% 99.18%

Displacement Wash B 0.5 1641 3 0.20% 1.62 0.16% 99.84% 96.97%

Displacement Wash C 1 1641 4 0.03% 0.21 0.02% 99.98% 99.62%

Displacement Wash C 0.5 1641 4 0.16% 1.29 0.13% 99.87% 97.58%

Ideal Wash 1 1641 0% 0.00 0.00% 100.00% 100.00%
REPORT DOCUMENTATION PAGE Form Approved 

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Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. 

1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE

October 2003 

3. REPORT TYPE AND DATES COVERED 

Subcontract Report – December 12, 2001 

4. TITLE AND SUBTITLE

Lignin Process Design Confirmation and Capital Cost Evaluation; 

Report 42002/02: Review of Design 

6. AUTHOR(S) 

Lynn Montague 

5. FUNDING NUMBERS

BFP2-3602 

Subcontract # 

ACO-1-30131-01 

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 

Harris Group, Inc. 

1000 Denny Way, Suite 800 

Seattle, WA 98109 

8. PERFORMING ORGANIZATION 

REPORT NUMBER 

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Renewable Energy Laboratory 

1617 Cole Blvd. 

Golden, CO 80401-3393

10. SPONSORING/MONITORING 

AGENCY REPORT NUMBER

NREL/SR-510-31579 

11. SUPPLEMENTARY NOTES

NREL Technical Monitor: Kelly Ibsen 

12a. DISTRIBUTION/AVAILABILITY STATEMENT

National Technical Information Service 

U.S. Department of Commerce 

5285 Port Royal Road 

 Springfield, VA 22161

12b. DISTRIBUTION CODE

 

13. ABSTRACT (Maximum 200 words)

Harris Group prepared this report on NREL’s conceptual design for a process that converts lignin into a hydrocarbon that can 

be used as a high-octane automobile fuel additive. 

15. NUMBER OF PAGES

14. SUBJECT TERMS 

lignin, biomass, hydrocarbon, automobile fuel additive, hydroprocessing 16. PRICE CODE

17. SECURITY CLASSIFICATION 

OF REPORT

Unclassified 

18. SECURITY CLASSIFICATION 

OF THIS PAGE

Unclassified

19. SECURITY CLASSIFICATION 

OF ABSTRACT

Unclassified

20. LIMITATION OF ABSTRACT

UL 

 NSN 7540-01-280-5500 Standard Form 298 (Rev. 2-89) 

Prescribed by ANSI Std. Z39-18 

298-102