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BioreFuture 2008, Tuesday 12 February 2008, Brussels
Project no.: 44336-FP6-2005-SSP-5AAcronym: BIOPOL
Definition and technical status of Definition and technical status of BiorefineriesBiorefineries
presented by:
Prof. Dr. Birgit KammScientific Director, Research Institute biopos e.V., 14513 Teltow-Seehof, Germany, [email protected] Brandenburg University of Technology Cottbus
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Content:1. Introduction2. Definition3. Systems4. Technical objectives and future solicitation5. Technical status6. Platform chemicals7. Summary6. LCF Biorefinery Demonstration Plant
Definition and technical status of Definition and technical status of biorefineriesbiorefineries
BioreFuture 2008, Tuesday 12 February 2008Project no.: 44336-FP6-2005-SSP-5AAcronym: BIOPOL
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Biorefining is the transfer of the efficiency and logic of fossil-based chemistry and substantial converting industry as well as the production of energy onto the biomass industry.
� Kamm B, Gruber, P.R., Kamm, M.;Biorefineries, Industrial Processes and Products, Ullmann’s Encyclopedia of Industrial Chemistry, 7th ed., WILEY-VCH, 2007
Definition and technical status of Definition and technical status of biorefineriesbiorefineries
1. Introduction
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It is absolutely necessary to develop solutions in three sustainable and biobased sectors:
���� Biopower/Bioenergy (electricity and heat)���� Biofuels (transportation fuels)���� Biobased Products (chemicals/materials) in context of a biobased economy.
3-pillar model of a future biobased economy
Biogenic Raw Materials
Biorefineries
Bio
base
dP
rodu
cts
Bio
Fue
ls
Bio
Ene
rgy
/ Bio
Pow
erProduct and Energy Market
Bio Economy
1. Introduction
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Petroleum
Chemistry
Fuels and Energy
Refinery Biorefinery
Fuels and Energy- Bioethanol,- Biodiesel, Biogas- Hydrogen
Material Utilisation,Chemistry- Basic and Fine chemicals,
- Biopolymers and Bioplastics
Biomass
Biobased industrial products can only compete with p etro-chemicallybased products if the raw materials are optimally ex ploited and a variety of value-creating chains are developed and e stablished.
���� development of substance-converting basic product s ystems and multi product systems, especially biorefineries.
1. Introduction
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Biorefinery is the sustainable processing of biomass i nto spectrum of marketable products and energy.
� www.biorefinery.nl/biopol
Definition and technical status of Definition and technical status of biorefineriesbiorefineries
2. Definition
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Biorefineries combine necessary technologies between biological raw materials and the industrial interme diates and final products.
After providing code-defined basic substances (via fractionation) it is necessary to develop industrially relevant Product Family Trees.
� Kamm, B.; Kamm, M.; Principles of Biorefineries. Appl. Microbiol, Biotechnol., (AMB), 64 (2004) 137-145
Conversion ofRaw Material
Raw Material
Carbohydrates
Lignin
Fats
Proteins
Special Substances
Energy
Complex Substances
Primary RefineryAgriculture, Forestry
Biorefinery
Industry
Product lines
Product lines
Product lines
Product lines
Product lines
Inorganic Substances.
Special Substances: Pigments, Dyes, Aromatic Essences, Flavours, Enzymes, Hormones, and other
3. Systems
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Four Biorefinery Systems have been identified and de scribed for research, development and practice:
• The Whole Crop The Whole Crop BiorefineryBiorefinery (WC(WC--BR)BR)raw material : cereals, maize etc..
• The Green The Green BiorefineryBiorefinery (G(G--BR)BR)raw material : ‘nature-wet’ biomasses, green grass, lucerne, clov er,immature cereals a.o..
• The The LignocelluloseLignocellulose Feedstock Feedstock BiorefineryBiorefinery (LCF(LCF--BR)BR)raw material : ‘nature-dry’ biomasses, wood, straw, corn stover, cellulose-containing biomass and waste.
� The TwoThe Two --Platform ConceptPlatform Conceptproduction of syngas and/or sugar as platforms for b iobasedproducts and fuels.
� www.biorefinery.nl/biopol
3. Systems
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Sugar Platform‘biochemical’
SynGas Platform‘gasification’
‘thermal chemical’
Fuels,Chemicals,
Polymers andMaterials
conditioning Gas
Cogeneration( CHP)
Heat and Power
Residues
Clean Gas
Sugar Raw material
Biomass
Grain‘biotechn./chemical’‘physical/chemical’
Fuels,Chemicals,
Polymers and Materials
LignocellulosicRaw material
Flour (Meal)‘physical/chemical’
Straw‘biotechn./chemical’
Whole Crop Cereals
- Dry Mill -
Starch line,Sugar
Raw material
Cogeneration( CHP )
Heat and Power
Residues
Press Juice‘biochemical’
‘biotechnol./physical’
Press Cake‘hydrothermal’
‘enzymatic’‘ thermal chemical’
Feed, Fuels,Chemicals,
Polymers andMaterials
CelluloseLignocellulose
Biogas,Cogeneration
( CHP )Heat and Power
Residues
Residues
Proteins, Soluble Sugars
GreenBiomass
Techn. Press
Cellulose‘biotech./chemical’
Fuels,Chemicals,
Polymers andMaterials
LigninRaw material
Hemicellulose‘biotech./chemical’
Lignin‘chemical’
LignocellulosicFeedstock
(LCF)
Sugar Raw material
Cogeneration( CHP )
Heat and Power
Residues
Who
le C
rop
Bio
refin
ery
(dry
mill
)
Gre
en B
iore
finer
y
Lign
ocel
lulo
sic
Fee
dsto
ckB
iore
finer
y
The
Tw
o-P
latfo
rm C
once
pt
�Kamm, B.; Gruber, P.R.; Kamm, M.; Biorefineries, Industrial Processes and Products, Wiley-VCH, 2006
3. Systems
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2000
Existing StarchBasedBiorefineries: Wet & Dry Mills
2005
Fractionation of the feedstock to access the high value products prior ethanol production
2010
Integrated IndustrialBiorefinery:multiple feedstocksfractionated to high value products for economics and fuel production drive scale
2020
Increase ethanol production by accessto residual starch &increased protein in co-products
Fractionation ofgrain and residues, introduction of energycrops in dry mills
Integrated Biorefinery -Technical Objectives & Future Solicitations
Completed solicitation
Planed solicitation
� Kaempf, D.; 1st International Biorefinery Workshop, Washington D.C.; July 20-21, 2005
Fractionation of residues in DryMills for new co-products fromlignin
3. Technical Objectives & Future Solicitation
11� BIOPOL, WP 1, Assessment Technical Status, 2007
Plants
Sugar and Ethanol production
Corn hydrolysisandEthanol Production
Corn hydrolysis/Sugar andEthanol production
Raw material
Sugar cane
Maize corn
Cereal CornSugar beet
Existing biorefineries, Phase I, (Selection)
Country
Brasilien17 billion litre/a
U.S.A.22 billion litre/a
EU1,5 billion litre/aIn constructiontill mid 20083,4 billion litre/a
12� BIOPOL, WP 1, Assessment Technical Status, 2007
Existing biorefineries, Phase II, (Selection)
Plants
Corn hydrolysis& Lactic acid
Fermentation &PLA production
Corn hydrolysis& 1,3-PropandiolFermentation
Raw material
Maize-Corn
MaizeCorn
Country
U.S.A.200 kt LA/a140 kt PLA/a
U.S. A.45kt/a PDO
In construction biorefineries, Phase II, (Selection )
Plants
Ethanol-Fermentation&Dehydration&PE Production
Raw material
Sugar cane
Sugar cane
Country
Brazil(1) 350 kt/aStart 2011(2) 200kt/a
13� BIOPOL, WP 1, Assessment Technical Status, 2007
Europe: In construction biorefineries, Phase II, ( Selection)
Plants/CompanyCountry
LCF biorefineryAbengoa BioenergySpain
LCF biorefineryIcelandic BiomassIceland
Green biorefineryAustriaIndustrial Consortium
Green biorefineryGermanyIndustrial Consortium
Raw material(Capacity)
Corn stowerWheat strawHay (70t/d)
Alaska Lupine StrawBarley StrawHay (20kt/yr)
Grass(5t/h)
Alfalfa/ wild mix grass(30kt/a)
Main-Products
EthanolLignin
EthanolLignin
Lactic acid, amino acidFibres, biogas
Proteins,Lactic acidAnimal feeds,biogas
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� Kaempf, D.; 1st International Biorefinery Workshop, Washington D.C.; July 20-21, 2005
Hydrolysis Acids, enzymes
Gasification High heat, low oxygen
Digestion Bacteria
PyrolysisCatalysis, Heat, Pressure
Extraction Mechanical, Chemical
Separation Mechanical, Chemical
Sugars and Lignin
Synthesis Gas
Bio-Gas
Bio-Oil
Carbon-Rich Chains
Plant Products
Use:FuelsEthanol BiodieselHydrogen Power Electricity Heat Chemicals Plastics Solvents Chemical Intermediates PhenolicsAdhesives Furfural Fatty acids Acetic Acid Carbon black Paints, Dyes, Pigments, Ink, Detergents etc. Food & Feed
Integrated Biorefinery Options
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BuildingBlocks
SecondaryChemicals
IntermediatesPlatformsPrecursorsBiomass
Starch
Hemicellulose
Cellulose
Lignin
Lipids, Oil
Protein
Carbohydrates
SynGas
Sugar- Glucose- Fructose- Xylose
Lignin
Lipids/Oil
Protein
SynGasC1
C2
C3
C4
C6
Aro-matics
C5
directPolymers
Glycerol
Lactic acid
Propionicacid
Lysine
Carnitine
Products/Uses
Ethanol
MethanolEther Fuel additives
IndustrialSolvents
Olefins Green solvents Transportation
Diacids, Esters
Emulsifiers
Textiles
Dilactid
PLA
Furfural
Levulinicacid
CaprolactamNylons
Furane
…..
Polyurethanes
……
Acrylate
Polyacrylate1,3-PDO
THF
Safe Food Supply
Environment
Communication
Housing
Recreation
Health a. Hygiene Gallic acid
Polysaccharides
Resins
Chemicalintermediates
Phenolics
….
Model of biobased Flow-chart for Biomass Feedstock
� Kamm, B.; Gruber, P.R.; Kamm, M.; Biorefineries, Industrial Processes and Products, Wiley-VCH, 2006
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Synthesis of bifunctional aromatic and aliphatic chemical building blocksvia LCF-Biorefinery
� Project: Production segmented technical thermoplastic from renewable resources. Dow Deutschland, Rheinmünster; FHG-ICT, Pfinztal, FI Biopos, Teltow, 2004-2007
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One fundamental task in the biorefinery topic is the d evelopment of biorefinery demonstration plants, close to Industry, agro-industry, and forest-industry.
Biorefineries present :� Complex and integrated systems of sustainable techno logies
based on biological raw materials.���� Economically self-consisting enterprises and economi c entities.���� Bearing pillars of the future biobased economics.���� Motors of research and development in the 21th centur y.
One example will be presented
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Types of Feedstocks
• Grains(such as corn)
• LC-Biomass(Lignocelluloses)
Softwoods GrassesHardwoods
Crop residues (e.g., corn stover, cereal straw, sugar cane bagasse, etc.)
Future Vision for biobased products
Sources: Glassner, D.; NatureWorks LLC, 2005
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Future Vision for biobased products
The whole plant-based (botanical) biomass consists of approx. 70% carbohydrates!
45%5%
25%
25%
Lignin
Other
Cellulose(Chains of sugar)
Hemicellulose(Chains of sugar)
(Young clean coal)
Biomass Composition
Biobased Carbohydrates Economy
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The Icelandic ethanolThe Icelandic ethanol --oriented oriented biorefinerybiorefinerybased on lignocellulosesbased on lignocelluloses
Model project Model project –– Demonstration Plant Demonstration Plant ––20.000 tons lignocelluloses/year20.000 tons lignocelluloses/year
LCF Biorefinery Demonstration Plant
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Cellulose‘biotech./chemical’
Fuels,Chemicals,
Polymers andMaterials
LigninRaw material
Hemicellulose‘biotech./chemical’
Lignin‘chemical’
LignocellulosicFeedstock
(LCF)
Sugar Raw material
Cogeneration( CHP )
Heat and Power
Residues
General Scheme of a Lignocellulose Feedstock Biorefi nery
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Tab. : Sources of lignocelluloses
timber (Bauholz), used wood, recovered paper, cellulosic municipal solid waste
used materials and wastegroup 5
straw, corn stover, press cake from crop drying plant, ethanol plants and oil mills, by-products from cereal mills, whole crop refineries, paper mill and pulp industry
process lignocellulosesgroup 4
old forest, residual wood and under-wood from forestry, switch grass, dry grasses, hay, straw
landscape conservationgroup 3
poplar (Pappel), willow (Weide), locust (Robinie), wood grass, eucalyptus, sudan grass
fast-growing plantationsgroup 2
softwood, hardwood, reed (Schilf), reed grass, switch grass, dry grasses etc.
existing landscape speciesgroup 1
ExamplesSource GroupsNo.
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Regional Farmers• Biomass Producer
Barley, Hey, Lupine
• Vegetables ProducerSalad, Tomato, a.o.
• Animal husbandrySheep, Cattle
EnergyRegional SourcesGeothermal Heat
InhabitantsRegional Jobs
TourismEducational Leave
Hotel Sector
Ethanol
Proteins
Carbon dioxide
Icelandic BiorefineryBiomass Conversion Mill
Biobased Products FactoryChemical/Enzymatic Hydrolysis
Conversion, Fermentation, DistillationSeparation, Packaging, Storage
Fertilizer
Fuel IndustryChemical and
Producing Industry
Carbon dioxideProteins, Yeast
FertilizerCarbon dioxide
Proteins
Biomass
Lignin
Model of the Icelandic ethanol-oriented biorefinery based on lignocelluloses
Gre
en S
eeP
ark
Mýv
atn
Mod
ern
Life
, Wor
king
and
Rec
over
y w
ith N
atur
e in
Nor
ther
n Ic
elan
d
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Main Seat : Reykjavik, ISIcelandic Biomass Company
Operating Company
notesamount / prizes
10 Mio €
7 Mio litres/year
40.000 t /year
1,25 €/ton
20.000 tons/year
Plant basis/Location
steam: 170°C /7 barGeothermic steam
Main Process Energy
modified “Bergius/Rheinau” processAcid hydrolysis, Sugar fermentation
Main Technologies
hey, lupine straw, barley strawLignocellulosic biomass (mix)
0,46 €/litresEthanol for E10 Fuel
Main Product (Phase I)
Northern Iceland, near sea MyvatnFormer Diatomite (Kieselguhr) Plant
Incl. accompanying R&DTotal costs
Raw Material
The Icelandic ethanol-oriented biorefinery (demonstration plant) - corner data
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Advantages of the production of Ethanol
Ethanol is not only a fuel, but also a basic chemic al for a lot of solvents, products and materials
Ethanol
Solvents
Fuels
Fuel additive
Mobile Process
Steam cracker
Synthetic Naphtha
Esterification DehydratingOxidation
Keton synthesis
Ether formation
LebedewProcess
Acetaldehyde
Butadiene Acetic acid
Ethene
Acetic anhydride
Vinyl acetate
PolymersRubber
Diethyl ether
Acetone
Ethyl lactate
Ethyl levulinate
other
� Ethene� Propylene� C4-cut� Benzine� Crack gas� Aromatics
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Summary
Regional Biorefineries are also in other regions - wi thout geothermic energy- profitable.
For process energy it’s possible to use:
���� The Lignin fraction, approx. 30% in lignocelluosethe heating value (calorific value) of Lignin lies between 13 MJ/kg and 19 MJ/kg (DM) (wood: 18 MJ/kg, heating oil: 30-35 MJ/kg).
� Biogas Cogeneration: Heat and Power (Electricity).
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The Icelandic Ethanol-oriented Biorefinery (demonstration plant) can produce 7 Mio litres Ethanol/year.
The Icelandic Ethanol-oriented LCF-Biorefinery is profitable!
7 Mio l Ethanol (pure) is equivalent to 70 Mio E10 petrol.E10 petrol is normal petrol with 10% Ethanol.
Each Icelandic Inhabitant could to refuel approx. 233 Litres E10 petrol per year.
The Icelandic Ethanol-oriented biorefinery – Summary
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The Icelandic Ethanol-oriented Biorefinery – Summary
Why is such (small scale) Ethanol-oriented LCF-Bioref ineryprofitable?- Research and development supported by European Commis sion (BESUB project) and the Icelandic Government.
- Iceland has a very efficient and low price non-fossi l energy market (geothermic energy). Hence, energy-intensive processes (e.g. acid recovery) are so economically and environme ntal-friendly.
- Private Operating Companies, Finance and Government to act in concert.
- Economical biomass and product markets could be organized (without subsidy).
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Presentation Summary
Several requirements to enter the phase of development of Industrial Biorefinery Technologies and Biobased Product s:
� To increase the production of substances on the base of biogenic raw materials in the ordinary plants of produ ction ofcellulose, starch, protein, sugar and oil.
� To get the commitment of the chemistry, particularly the organicand technical chemistry, for the concept of biobased productsand biorefinery systems.
���� To force the combination of biological and chemical conversion of substances.
���� To introduce and establish biorefinery demonstration pl ants.
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Contact
Prof. Dr. Birgit KammDirector of the Institute Biopos e.V.and BTU CottbusResearch Centre Teltow-Seehof, Kantstraße 55, D-14513 TeltowEmail: [email protected]: www.biopos.de
Potsdam and Teltow in the Greater Berlin, Germany
biorefinery.de company (GmbH)Main Seat: Stiftstraße 2, D-14471 Potsdam, GermanyEmail: [email protected] Laboratories Teltow-SeehofKantstraße 55, D-14513 TeltowWeb: www.biorefinery.de, www.biorefinica.de
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Thank you for the invitation and your attention
City of Potsdam - Market SquareState of Brandenburg,
Greater Berlin, Germany
