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Beta Renewables – commercial plant in Crescentino, Italy
Introduction
Beta Renewables is a leader in the field of advanced
biofuels and biochemical compounds at competitive
costs. It was established at the end of 2011 as a joint
venture between Biochemtex, a company of the
Mossi Ghisolfi Group, and the U.S. fund TPG (Texas
Pacific Group) with a total investment of 250 million
Euro (350 million dollars). Beta Renewables owns the
ProesaTM
technology, applied to the field of biofuels
and chemical intermediates. Beta Renewables
manages the plant in Crescentino (VC), the first
commercial facility in the world for the production of
second-generation ethanol. The Crescentino
biorefinery was launched under the NER300
bioenergy project.
Technology description
Proesa™ belongs to the so-called “second-
generation” technologies which allow the use of the
sugars present in lignocellulosic biomass to obtain
fuel and other chemicals with lower greenhouse gas
emissions and at competitive costs compared to fossil
fuels (oil, natural gas).
It is the result of an investment of over 150 million
Euro, started by Biochemtex in 2006. The Proesa™
technology was designed to use non-food biomass,
like rice straw and sugarcane bagasse. Thanks to the
efficiency of the Proesa™ process, non food sugars
can be obtained at competitive costs and without
incentives, thus enabling a widely spread use of bio-
products from renewable sources.
The advantages of Proesa™:
The cost of the product is competitive compared
to oil (70 dollars / barrel)
The industrial plants can be adapted to local
conditions.
The separated lignin is used to obtain energy.
During the processing, biogas is generated as
another energy source.
No land is subtracted to food crops and this does
not affect their price to the consumer.
Dependence on fossil fuels is reduced as well as
the impact on greenhouse gas emissions.
The technology is protected by 14 patent families, 4
of which are public.
Technical Details
Project owner Beta Renewables (joint venture with the Mossi Ghisolfi Group)
Project name Crescentino
Location Crescentino (VC), Italy
Technology Biochemical conversion
Raw Material Lignocellulosic crops (rice straw, wheat straw and from Arundo Donax, the common giant reed)
Input Capacity 200,000 t/y
Product(s) Ethanol
Output Capacity
40,000 t/y
Facility type Commercial
Project Funding
The project was supported by the European Commission under the Seventh Framework Programme for research and technological development
Status Operational
Start-up Year 2013 (october)
Web http://www.betarenewables.com
Figure 1: Beta Renewables plant in Crescentino
All trademarks, registered designs, copyrights and other proprietary rights of the organisations mentioned within this document are acknowledged. While the information in this fact sheet is believed to be accurate, neither EBTP members nor the European Commission, accept any responsibility or liability whatsoever for any errors or omissions herein nor any use to which this information is put. EBTP-SABS activities in support of Advanced Biofuels Stakeholders in Europe are funded by the EC under Concerted Support Action 609607. However, the information expressed on this fact sheet should not under any circumstances be regarded as stating an official position of the European Commission. Design and content of this fact sheet are copyright © European Biofuels Technology Platform 2016.
Beta Renewables & Biochemtex –
More projects
Project name Bioflex 1
Owner/Operator GranBio
Location Brazil
Technology Biochemical
Raw Material Sugar Cane Straw
Product(s) Ethanol
Output Capacity 65,000 t/y
Facility type Commercial
Status Operating
Start-up Year 2014
Project name Fuyang Bioproject
Location China
Technology Biochemical
Raw Material Wheat straw and corn stover
Product(s) Ethanol
Output Capacity 185,000 t/y
Facility type Commercial
Status Planned
Start-up Year 2018
Project name Alpha
Location North Carolina, USA
Technology Biochemical
Raw Material Energy Grasses
Product(s) Ethanol
Facility type Commercial
Status Planned
Start-up Year 2017
Figure 2: Beta Renewables – flow chart of PROESATM technology
Project history
The first-of-a-kind commercial scale industrial
production of second-generation bioethanol was
started up in Crescentino, province of Vercelli, at the
end of 2012. For the development of this technology,
agronomic studies and logistics modelling have been
conducted. Before being applied in Crescentino,
Proesa™ was tested at length in the Rivalta Scrivia
(Alessandria) pilot plant, which boasts a capacity of
1t/day of biomass treated.
2010
• Authorization request: 2010
• Company starts buying critical materials: September 2010
2011
• Permits obtained: April 2011
• Ground breaking: April 2011
• Beginning of works: end of June 2011
2012
• Completion of mechan. work, energy section: Aug. 2012
• Start up of boiler: October 2012
• Completion of mechan. work, ethanol section: Dec. 2012
2013
• Start up – ethanol section: October 2013
• Operational
Borregaard – commercial plant in Sarpsborg, Norway
Introduction
Borregaard is a Norwegian company, established in
1889 in Sarpsborg in the Østfold County.
Traditionally, Borregaard has been engaged in pulp
and paper processing. Borregaard’s core business is
based on the concept of a biorefinery that processes
chemical products based on different types of
lignocellulosic feedstock.
The bioethanol that is produced in Borregaard's
biorefinery is based on extracting sugar from wood
(spruce), which is then fermented to make ethanol.
The production started already in 1938. This means
that Borregaard has never been engaged in
producing first generation biofuels but only second
generation bio-ethanol or more precise ‘advanced
bioethanol’. The bio-ethanol process in the
commercial operation is technically almost the same
as it was from the start in 1938. Among others,
Borregaard supplies bio-ethanol to Statoil, a leading
retail chain for petrol and diesel, but most of volumes
are sold for use in chemical products or as solvents.
Technology description
Figure 2 illustrates the processing of biomass in
Borregaard. Ethanol is one of several products
coming out of the total process. The pulp for specialty
cellulose is produced by cooking spruce chips with
acidic calcium bisulfite cooking liquor. Hemicellulose
is hydrolyzed to various sugars during the cooking
process. After concentration of the sulfite spent liquor,
the sugars are fermented and ethanol is distilled off in
several steps. A part of the 96% ethanol is
dehydrated to get absolute ethanol.
The ethanol process have low energy consumption,
as most of it is recovered and used in other
processes on site. Fossil fuels for energy production
for the whole refinery have been replaced by
renewable energy sources over the last 15 years.
Technical Details
Project owner Borregaard AS
Project name ChemCell Ethanol
Location Sarpsborg, Norway
Technology Chemical/biochemical
Raw Material Lignocellulosic spruce (Norwegian spruce)
Project Input Sulfite spent liquor (SSL, 33% dry content) from spruce wood pulping
Input Capacity 400,000 t DS (spruce)/a
Product(s) Ethanol
Output Capacity 15,800 t/y; 20 Ml/y
Facility type Commercial
Status Operational
Start-up Year 1938
Web http://www.borregaard.com
Figure 1: Borregaard plant in Sarpsborg
All trademarks, registered designs, copyrights and other proprietary rights of the organisations mentioned within this document are acknowledged. While the information in this fact sheet is believed to be accurate, neither EBTP members nor the European Commission, accept any responsibility or liability whatsoever for any errors or omissions herein nor any use to which this information is put. EBTP-SABS activities in support of Advanced Biofuels Stakeholders in Europe are funded by the EC under Concerted Support Action 609607. However, the information expressed on this fact sheet should not under any circumstances be regarded as stating an official position of the European Commission. Design and content of this fact sheet are copyright © European Biofuels Technology Platform 2016.
Borregaard- BALI Biorefinery Demonstration
Plant
Project name BALI Biorefinery Demo
Location Sarpsborg,, Norway
Technology Chemical/biochemical
Raw Material Lignocellulosics (sugarcane
bagasse, straw, wood, energy
crops)
Product(s) Ethanol, lignin performance
chemicals, single cell protein, sugar
based chemicals
Output Capacity 110 t/y
Facility type Demo
Status Operational
Start-up Year 2012
Project background
Borregaard has been operating as a biorefinery for
over 50 years, but the advanced ethanol production
started already in 1938. Borregaard has been
interested in optimizing these processes over the last
decades. Borregaard has an additional 6 production
plants around the world, and they do not produce bio-
ethanol but only lignin performance chemicals. For
bio-ethanol production Borregaard has only two
plants and both located in Norway, the commercial
plant producing between 20 million liters advanced
bio-ethanol per year and the BALI demo plant. The
experience gained over years in the commercial plant
has been a valuable knowledge input into the demo
project. The main difference to the commercial plant
is that Borregaard will use all of the cellulosic fiber for
cellulosic sugars or ethanol production, not just the
hemi-cellulose as in the commercial plant
Figure 2: Borregaard – chart of products
Figure 3: Borregaard – The timeline of Borregaard transformation from a
conventional paper plant to a biorefinery
1889
• Traditionally, Borregaard has been engaged in pulp and paper processing
1938
• At the end of the 1930s the company started producing chemicals based on timber (spruce) as a raw material exploiting the hemi-cellulose in the feedstock
• Start to produce bioethanol
1950
• Since the 1950s Borregaard used also the lignin components of the feedstock for producing chemicals
UPM Biofuels – commercial plant in Lappeenranta, Finland
Introduction
UPM plans to become a major player in Europe in the
production of renewable, high quality advanced
biofuels. UPM produces its advanced biofuel, UPM
BioVerno, at the biorefinery in Lappeenranta, Finland,
based on its own innovations.
The UPM Lappeenranta Biorefinery, producing wood-
based renewable diesel from forestry residues, has
started commercial production in January 2015. A
significant portion of the raw material used at the
UPM Lappeenranta Biorefinery - crude tall oil - comes
from UPM's own pulp mills in Finland, such as the
UPM Kaukas mill site located next door.
UPM BioVerno is high quality renewable diesel that
can be used as a blending component or as 100%
fuel in all diesel engines. It reduces greenhouse gas
emissions by 80% compared to fossil diesel.
Technology description
The production of UPM BioVerno renewable diesel
from wood-based tall oil is an advanced biofuel
production process. This innovative production
process has been developed in the UPM Biorefinery
Research and Development Centre in Lappeenranta,
Finland.
The technology is based on hydrotreatment. Phases
are pretreatment of crude tall oil, hydrotreatment,
separation of hydrocarbons, recycle gas purification,
and fractionation to produce renewable diesel and
small portion of renewable naphtha as end products.
Pretreatment:
Crude Tall Oil is purified; salts, impurities, solid
particles and water are removed.
Hydrotreatment:
Pretreated Crude Tall Oil is fed together with
make-up and recycled hydrogen to the reactor
where the chemical structure is modified.
Reaction water is separated and directed to
waste water treatment.
Fractionation:
Remaining hydrogen sulfide and uncondensable
gases are removed. The remaining liquid is
distilled to separate renewable diesel suitable for
all diesel engines.
Technical Details
Project owner UPM Biofuels
Project name UPM Lappeenranta biorefinery
Location Lappeenranta, Finland
Technology Oleo chemical conversion
Raw Material Wood-based residue of pulp production; tall oil
Product(s) Renewable diesel similar to HVO
Output Capacity 100,000 t/y or 120 million litres/y
Facility type Commercial
Total Investment 175,000,000 EUR
Status Operational
Start-up Year January 2015
Web http://www.upmbiofuels.com
All trademarks, registered designs, copyrights and other proprietary rights of the organisations mentioned within this document are acknowledged. While the information in this fact sheet is believed to be accurate, neither EBTP members nor the European Commission, accept any responsibility or liability whatsoever for any errors or omissions herein nor any use to which this information is put. EBTP-SABS activities in support of Advanced Biofuels Stakeholders in Europe are funded by the EC under Concerted Support Action 609607. However, the information expressed on this fact sheet should not under any circumstances be regarded as stating an official position of the European Commission. Design and content of this fact sheet are copyright © European Biofuels Technology Platform 2016.
UPM – More projects
In advanced biofuels UPM has been
developing, together with Andritz Carbona,
the gasification technology needed to
produce biofuel from wood biomass. The
initial testing programme was completed
in the USA at the Gas Technology Institute
as planned.
UPM, Metso and Fortum together with the
VTT Technical Research Centre of Finland
have developed a new concept for the
production of wood biomass-based bio
oil to replace fossil fuels in heating and
power generation. Production of bio oil is
integrated into biomass-based power
plants. The long-term goal is to use bio oil
for the production of transportation fuel.
UPM, Fortum and Valmet are jointly
developing technology to produce
lignocellulosic advanced biofuels. The
project is called Lignocat (lignocellulosic
fuels by catalytic pyrolysis)
UPM is planning the production of
advanced biofuels from wood biomass in a
BtL (Biomass-to-Liquid) refinery to be
constructed in Strasbourg, France. The
European Union has awarded UPM a NER
grant of EUR 170 million for the project.
Project background
In 2008, with the popularity of printing paper
declining, UPM decided to transform itself in a bold
way and look for new businesses. Biofuels was a
prevalent trend and UPM had suitable wood-based
residue available from their own pulp production as
feedstock. Product development of wood-based
UPM BioVerno diesel started in-house. UPM utilized
its 120 years of experience in making products from
wood at its site in Lappeenranta.
Investment decision to build the world´s first
biorefinery producing wood-based renewable diesel
was made in February 2012. Construction of the
biorefinery started during summer 2012 in
Lappeenranta, Finland. UPM’s total investment cost
for the renewable diesel biorefinery is about
EUR 175 million and was completed without any
public investment grants. NIB is co-financing the
project with a 7-year maturity loan of EUR 50 million.
The technology to refine tall oil into renewable diesel
is based on the company’s own innovation and co-
operation with Danish catalysis company Haldor
Topsøe A/S, another loan customer of NIB. The
company’s biofuel plant integrates nicely with the pulp
and paper plant, saw mill, and research centre at the
site. The local resources in know-how, raw materials
and energy can be utilized in a way that makes
logistical sense.
UPM employs around 21,000 people, its annual sales
are approximately EUR 10 billion, and it has
production plants in 14 countries. UPM shares are
listed on NASDAQ OMX Helsinki
UPM – flow chart of UPM Lappeenranta biorefinery