Biorefinery, the bridge between Agriculture and Chemistry - - PowerPoint PPT Presentation

Biorefinery, the bridge between Agriculture and Chemistry

Amsterdam, Brokerage Event 18 Januari 2007 Johan Sanders Professor Valorisation of Plant Production Chains Wageningen University and Research center

Energy consumption past and future

Jaartal

A2 A1F1 Scenario A1F1: Global economy, fossil fuel intensive Scenario A2: Regional economy 1900 2000 2050 500 750 1000 250 1250 1500

Yearly energy production, EJ

1950

Opportunities for the Netherlands

3 main lines

 Savings  Sustainability  Clean fossil fuels

Platforms

Biobased raw materials Sustainable mobility Chain efficiency New gas, clean fossil fuels Sustainable electricity supply Built environment

Energy transition

Platform Groene Grondstoffen

 30% substitution of fossil by Biomass in 2030

• 25% chemical resources (140 PJ)
• 60% transportation fuels (324 PJ)
• 17% heat (65 PJ)
• 20% electricity (203 PJ)

How to get there?

Transition paths

• 1. Sustainable development and production of biomass in the

Netherlands as well as abroad

• 2. Realisation of the biomass import chain
• 3. Co-production of chemicals, transport fuels, electricity and heat
• 4. Production of synthetic natural gas (SNG) for the natural gas

infrastructure

• 5. Innovative use of biobased raw materials for non-food and non-

energy purposes and sustainable chemical products and processes.

30% Dutch fossil substitution by biomass in 2030: 900PJ

3550 1250 (300) 2300 Absolute land requirement (kha) 3 5 (2)** 9 Land requirement (kha/PJ) 55/36 *** 100 75 50* Import (%)

* No additional import ** no land required *** additional import

chemicals

• il

fermentation/ethanol electricity/heat/synth. natural gas

Total

261 69 114 73 70 78 24 44 10 57 37 112 70 36 81 50 100 150 200 250 300 350 400 450

enhancing efficiency present biomass development (new )crops aquatic cultures import raw and intermediate products

reduction fossil PJ

+ + +

How can Biomass best substitute fossile derived products?

Integral cost prices (€/GJ end product) Raw material cost fossile (€/GJ) Electricity 22 6 (coal) Transport fuel 10 8 (oil) Average bulk chemicals 75 30 (oil) Other industry Heat 4 3 (coal) Netherlands energy is 3000PJ +/- 20% +/- 20% +/- 20% +/- 20% +/- 20%

Biomass can bring different contributions to the farmer (€/ha)

Assuming a yield of 10 tonnes dry weight per hectare, being 160 GJ, using whole crop and GAP up to 20 tonnes whole crop yield, 320 GJ/ha : 640 --- : 1360 --- : 6400 --- : 1800 – 3600 : 2080 - 4160

• All Energy at coal value
• All transportfuel
• All bulkchemical
• 20% bulkchemical, 80% Energy
• 20% bulkchemical, 40% fuel, 40% Energy

€/hectare

Pilot biorefinery line Foxhol (Groningen) (Prograss Consortium)

Green grass protein compound feed white grass protein

Grass protein (products)

+ .....

compound feed

Grass juice concentrate

Ethanol

HTU- Biofuel

Construction material + paper Polymer extrusion products

Grass juice Protein Fibers

Functionalised chemicals can be made from Biomass without major enthalpy differences, but not from naphtha

CxHzOy(OCHz)v

Oil / gas

lignin protein

Biorefinary way Petrochemical way Biomass CxHy chemicals

naphtha

CxHzOyN Sv CxHzN

CxHzN

CxHzOy

carbohydrate

CxHzO

Enthalpy

• ne raw material

many raw materials products many

• il / fat

CxHyOz

CxHy

amine

(Energy) efficient routes to industrially important diamines

C NH2 NH2 H2NCH2CH2CH2CH2NH2 NH3 NH3

Urea

Nafta

1,4-Butanediamine: polymers e.g. nylon-4,6

H2C=CHCH3 + + 1.5 O2 H2C=CHC N HCN + CH4

+

Biomass C

H2NCH2CH2CH2CH2NH2 COOH

1,2-Ethanediamine : rubber chemicals, pharma, lubricants,detergents

ClCH2CH2C l

NH3 Cl2 NH3 NH3 CH2

H2NCH2CH2OH H2NCH2CH2NH2 H2NCH2CH2NH2

CH2 O2 O

Biomass B

COOH Nafta H2NCH2CH2OH

Biomass A ethanol

Costs breakdown of Bulkchemicals (€/ton) at 40$/bbl

Raw materials Capital Operational Recovery

Total

non-functionalised functionalised 200 300-500 50 50-100 650 400-650 50 50-100

725 1300

Derived from J.P. Lange (Shell)

C1 C2 C3 C4 C5 C6 (aromatic) Functionalised

Timescale

Short Medium Long

Technology:unclear, possibly new and established, large and small scale, fermentation of pre-cursors or use of biomass components from bio-refinery, can integrate into existing production processes Feedstocks: glucose / ligno(cellulosic) or specific component in biomass Technology:new, un-established, large- scale, thermal (and chemical) Feedstocks: predominently lignin Technology:new and established, large and small scale, fermentation of pre-cursors or use of biomass components from bio- refinery, can integrate into existing production processes Feedstocks: glucose / ligno(cellulosic) or specific component in biomass - chemical and biomass correlation

Left to right : decreasing volumes AND the thicker the line the higher the volume

Technology::new and established, large and small scale, predominently fermentation of pre-cursors, direct transformation of some (abundent) biomass components possible, integrate into exisiting production processes Feedstocks: glucose / ligno(cellulosic), biomass components e.g. glycerine Technology:un-established, large-scale, thermal (syngas, Fischer Tropsch, gasification etc..) combination with existing (subsequent steps) possible Feedstocks: various plant biomass

Technology: un-established, large-scale, thermal, combination with existing (subsequent steps) possible Feedstocks: various plant biomass and by-products

Biomass potential for (partial) substitution of current bulk chemicals

Biomass Glycerol Propylene glycol Isopropanol

Chemical Physical /

Chemical

Chemical

Acetone Ethylene glycol

• Scheme. Chemical production in Rotterdam - a bio-based alternative for butadiene and ethylene.

Current production by Shell Chemical and Lyondell

Many ‘Rotterdam’ chemicals can be produced from Biomass

Example of short term substitution potential

epichlorhydrin methanol

BbP: From biomass to product

Developed by BbP Wageningen UR

Developments that should improve the biomass route

 Lower raw material price  better refinery/ separation

technologies/downstream processes

 More efficient fermentations  Plant GMO to tailor make products  new material-properties  small scale technology and integrations that can

give more income to the farmer

Effect of Pretreatment of Corn Stover Representation of Physical Changes

Source: Michael R. Ladisch, Nathan Mosier, Gary Welch, Bruce Dien, Andy Aden, Phil Shane, Purdue University

Upscaling-30L lime pretreatment of straw + cellulase

Reactor during enzymatic hydrolysis at t = 0 and t=24 h after adding enzymes

EET project with consortium of 3 R&D institutes, 3 companies, 1 university

Pilot fermentation facilities

Pilot-schaal fermentatie bij A&F

Bakker et al., 2004

Project examples Fibre Processing

Two 100% percent paid follow-up projects of a successful PPS Fibre Raw Materials-project

 Enzymatic upgrading recycled fibres

 Mill trials at two companies

 Development compression refining

 5 partners: Sappi, SmurfitKappa, BTS, KCPK &

WUR

 Building of continuous laboratory machine (2004)  First commercial machine in November 2006  ROI via the construction of BV

Other co-products as a consequence of biofuel production

 if 10% of the WW transportation fuels are

produced from corn, wheat, rape, palm, sunflower, cane this will supply 100 million tonnes

• f proteins

 Several bulkchemicals might be produced from

amino acids

 Enzyme and/or fermentation technology will

enable efficient processes

Source: PERP Report Ethanol 04/05-8

From gluten to bulkchemicals

380 kg glutamic à 400/tonne = 155 70 kg serine à 700/tonne = 50 70 kg leucine ? = 150 kg essential aa’s à 1000/tonne = 150 300 kg other aa’s à 500/tonne = 150 Gluten products: total 500+ €/ha 3.5 m3 ethanol à 250/m3 = 875 €/ha

2005: USA 5,5 Mtonnes DDGS à 60-110 $/ton; (90€/ha) 2012: 15 M tonnes (only from ethanol) Byproduct value almost equal to ethanol value:

Development of Dutch BbE can be build on Dutch pilars: Agriculture, Chemistry, Ports.

1980/1995 6 Mton soy cake 2007/2015 5 Mton wheat compound feed compound feed compound feed chemical (100.000 ton lys, trp, thr, met glu, asp, s accessable lignocellulo electricity 50 PJ ethanol 2012? 2009? 2006 2007/2015 3 Mton rape seed lignocellulose 1 Mton protein lignocellulose 2 Mton protein manure 50 PJ ethanol 50 PJ biodiesel N, P, K N, P, K fertilizer

Collagen-like protein polymers for nanostructured thermoreversible gels Marc Werten, Helena Teles, Gerrit Eggink, Frits de Wolf WUR-BbP: Winner B-basic Innovation Trophy 100.000€

Forward integration and small scale operation reduces transport cost and seasonality and will give more income to the farmer

Fields Processing Present 100% 100% Return flow 10% Farm Concept Small scale processing 100% Return flow 70% 30%

Beethanol: small scale ethanol and sugar production from sugar beets, beet residues, leaf and wheat

Farm process enables 2500 – 3000 €/ha gross income by:

 low transport costs  lower Lang factor (relates equipment costs to installed

factory costs)

 By-product valorization:

 Supply greenhouse or houses with heat < 1 km  Supply greenhouse with CO2 < 3 km  Return abundant compound K2O in fertilizer back to land < 5 km  Use of waste products for biogas for subsidized electricity

Mobile Cassava starch refinery in Africa

Source: Duteso

Conclusions: Biorefinery, the bridge between Agriculture and Chemistry

 Biorefinery increases the value of the individual

biomass components

 (platform) chemicals can be derived from biomass

under economic conditions. For the moment functionalized chemicals offer the best chances to compete with petrochemical processes