BREWGeneric Approach

byMartin Patel (Un. Utrecht)

Tim Nisbet (Shell)Peter Nossin (DSM)

BREW plenary meeting - September 9, 2003

Content

• Problem Definition• Generic Approach• Structuring the work

Problem Definition -1Objective BREW Project:

To prepare a study about the opportunities and risks of applying biotechnology to produce bulk chemicals and chemical intermediates from renewable raw materials.

Time horizon: Medium (10-20 yrs) to long-term (until 2050) development

Deliverables:Overview of:

Technical optionsSustainability PIs (3Ps)

• Economics• Ecology• Society

Problem Definition -2Stage gate process (Cooper):

1. Discovery stage2. Scoping 3. Built business case4. Development5. Testing and validation6. Launch

Majority of projects are in stage 1-2Level of uncertainty: HIGH

Generic approach- based on current insights (proven technology)- translation to future prospects (expert insights)

Reference to current commercial technology (chemical,

fossil based)

Purpose of the meeting

1. Gain consensus on selection of products and processes to apply for a generic approach.

2. Agree on structuring of the work

Generic ApproachExisting chemicals: Cradle to gateNew chemicals: Cradle to grave

HarvestingTransportStorage

Processing

Conversion to chemical

Biomass

Chemical

Ferm. sugarVegetable oil

Conversion to end product

End product

EnergyWater

EmissionsBy-products

Consistent energy and mass balance required

Biomass-Water-Energy Future feedstocks:

Ligno-cellulosics: Agricultural residues Energy crops

Current feedstocks:Starchy crops: Corn

Wheat Rice Cassava

Sugar crops: Sugar cane Sugar beets Molasses

Water: Water management issues? - modeling? Energy: Fixed energy mix (EU) – no modeling

Include other C-sources such as glycerol or natural oil/fats?Design of representative EU-scenarios

Harvesting, transport, storageLocation: EU 15

EU 30 (incl. Ukrain)

Way of collecting/harvesting/transportingYield per ha

average or per individual country

Net available biomass potentialprice-availability relation

other uses may be:Hidden useFuelFodder

Percentage of arable landPlant capacity Land Surface

Design 3-4 reference cases

Processing

Design 2 reference cases

Current case: Starch glucose (enzymatic hydrolysis) Sugar cane sucrose (extraction)

Crop vegetable oil (extraction)

Future case: Ligno-cellulosics fermentable sugars (chemical/enzymatic hydrolysis)

Conversion to chemicalConversion:

• Fermentation aerobic/anaerobic fed batch/(semi-)continue bacteria/yeast/fungi

• Followed by a conventional chemical or enzymatic step

f.e. hydrogenation free/immobilized enzyme

Make assumption on: Fermentation selectivity Fermentation yield % Cell mass Cycle time/residence time Product concentration Productivity micro-organism Number of metabolic steps

Down stream processing:

• Biomass separation• Biomass processing

anaerobic digestion incineration food landfill

• Protein separation ultra/nanofiltration

• Recovery evaporation in effect distillation crystallization membrane separation extraction

• Packaging liquid/solid

Emissions To water

BOD…….

To airGHGToxic …….

To soilsolid waste……..

Case based on- input parameters up/down stream process - guestimate on input parameters conversion to chemical

By-products Lignine energy (steam/electricity)

saving of depletable energy sourcesreference year - 2000 (realized)

- 2020-2050 (projection)

Lignine upgrading to higher added value chemicalsaving of depletable carbon sourcesreference: oil (hydrocarbons),

natural gas (ammonia, H2)

Other by-products

4 scenarios ?

Cradle-to-grave

Only for new end products (not commercial yet)

Recycling material recycling back-to-monomers back-to-feedstock thermal recycling (incineration = energy recovery)

4 recycling scenarios ?

ConsensusLocation

Focus Europe

Current technology 2 model products (citric acid, ethanol)

Future Technology year 2020 and 2050

Products and processes