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Industrial biotechnology at the Leuna chemical site
Dr. Markus WolperdingerInfraLeuna GmbH, Leuna, Germany
Greenchem Conference, Lund City Hall, 8-9 November 2010Industrial Biotechnology - a platform for sustainable growth in Sweden
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The chemical site Leuna is a modern and highly integrated location for chemical manufacturing
• Located close to the cities of Berlin, Halle and Leipzig
• Over 90 years of tradition in chemical manufacturing
• More than € 5.5 bn of investment since 1990
• One of the largest chemical sites in Germany (approx. 13 km²)
• 100+ companies on-site
• Employs approx. 9.000 people
• Annual turnover € 7,5 bn
• Approx. 12 m tons of goods handled annually
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Leuna main entrance
with office building and
City of Leuna
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More than 100 companies are located in Leuna
1 ADDINOL Lube Oil GmbH2 Agro Service Nord Produktion Leuna GmbH3 ARKEMA GmbH4 BASF Leuna GmbH5 BAUFELD-CHEMIE GmbH6 Quadrimex Sulfur Chemicals GmbH & Co. KG7 Minakem Leuna GmbH8 DOMO Caproleuna GmbH9 Dow Olefinverbund GmbH10 envia THERM GmbH11 FP-Pigments GmbH12 Hexion Specialty Chemicals Forest Products GmbH13 Hexion Specialty Chemicals Leuna GmbH14 InfraLeuna GmbH15 Innospec Leuna GmbH16 Kartogroup Deutschland GmbH17 KataLeuna GmbH Catalysts18 Leuna Carboxylation Plant GmbH19 LEUNA-Harze GmbH20 LEUNA-TENSIDE GmbH21 Linde AG22 Mitteldeutsche Sanierungs- und Entsorgungsges. mbH23 MVV TREA Leuna GmbH24 Quinn Chemicals GmbH25 Evonik Industries AG26 TAMINCO Germany GmbH27 TOTAL Raffinerie Mitteldeutschland GmbH28 WAX Umweltschutz GmbH29 Xentrys Leuna GmbH
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Approximately € 11.5 bn have been invested in the chemical triangle in Eastern Germany since 1990
Schkopau- Polymers- EDC, PVC- Ethylene derivatives
PipelineRostock-Böhlen
Böhlen- Cracker- Aniline
Piesteritz- Urea, ammonia,
nitric acid
Bitterfeld / Wolfen- Chlorine- Inorganic chemicals- Quartz crystal glass
Bitterfeld / Wolfen- Chlorine- Inorganic chemicals- Quartz crystal glass
Hartmannsdorf- Tank farm
PipelineRostock-Schwedt
Litvinov- Cracker- Petrochemicals
(€ 1 bn)
(€ 3 bn) (€ 0.5 bn)
(€ 1.5 bn)
(€ 5.5 bn)"Druschba"-crude pipeline
Crude
Refinery products
HydrogenGases
AmmoniaUrea
Hydrogen,Gases
EthylenePropyleneButadieneAromatics
Ethylene
Refinery products
NaphthaLPG
Gases
Ethylene / Propylene
ChlorineLeuna
- Refinery- Polymers- Basic chemicals- Catalysts- Glues, amines ...
Teutschenthal- Cavern
Stade- Port- Cavern
< 5 kt/y> 5 to 10 kt/y> 10 to 50 kt/y
> 50 to 100 kt/y> 100 to 200 kt/y> 200 to 500 kt/y
> 500 to 1000 kt/y> 1000 to 2000 kt/y> 2000 kt/yPipeline transportationRail transportation
Natural gas
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I N F R A S T R U C T U R E
PA-Compounds
Refinery
Methanol
H2S
DMF
Glues
Methanol
Steam-reformer
Hydrogen-peroxide
H2 H2
Caprolactam,Polyamide 6,
Fiber production
H2
S8
Propylene
Air separation
plantO2
N2O2
LDPENaHS
Plastic-dispersions
Surfactants
Resins
Catalysts
Lubricants
Fine Chemicals
MMA
CO
Crude oil Ammonia EthyleneNatural Gas
Vision: Leuna develops from a petro- to a bio- and petro-chemically integrated site
Amines
EthanolButanoletc.
CO2„Bio-Refinery“
Sugar, Starch, Cellulose, Hemicellulose, Lignin, Algae, etc.
Bio-oils-surfactants
BioEthylen
CO2 H2
Complex Chemicals
AromaticsEnzymesProteinsetc.
New Investors
MethanolPA 6 / PA 6.6
Epichlorohydrin
Glycerin
EBS Power-plant
Formaldehyde
PE-Wax
EVA-Copolymers,
Additives
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Challenges !
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The transfer of petrochemical-based manufacturing into petrochemical- and renewable-based manufacturing comes along with a number of challenges
© Pictures: www.tecson.de, InfraLeuna GmbH, FhG
• Feedstock availability and logistics
• Feedstock pretreatment• Feedstock utilization• Process development &
scale-up• Integration in value chains• Manufacturing costs & price• Commercial competitiveness• Consumer acceptance
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…the feedstock utilization challenge
Biomass Food &
Feed
Chemistry Energy Fertilizer
Successive, multiple utilization necessary
Sources: JSW Consulting
• Integration in existing manufacturing environments, e.g., for food- and feed production, pulp&paperindustry, utilization of waste- and side-streams. (Step 1)
• Utilization of „non-food“biomass in Bioreferies, integrated in chemical, energy and fuel production. (Step 2)
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Starch-containingfeedstock
Special materials, media
Sugary feedstock
Gases, e.g. CO2
Cellulosic feedstock
Lignocellulosefeedstock
Aquatic biomass
Feedstock
Vegetables oils and fats
…the process-development and scale-up challenge
Products*
Industrial Enzymes
Gases, H2, CO, CO2
Residue treatment
Complex chemicals
Chem. building blocks
Olefin building blocks
Aromatic compounds
Fatty acid products
Others…
* Selected examples
Optimization
Separation of value-added
products and
purification
Directsugarification
Multi-stage sugarification
Conditioning Value generation
Processing, Fractioning
Cultivation, growth
Production of value-added
chemicals by
biocatalysisand
fermentation
Conversion of value-added
materials via physical,
chemical and
biocatalyticalapproaches
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Renewable Resources
ConditioningPre-treatment
HydrolysisExtraction
BiotechnologicalTransformation
ChemicalTransformation
SeparationPurification
The integration of biotechnological, chemical, and thermo-chemical processes is essential
Chemical Building Blocks: C1, C2, C3, C4, C6 - Cn
Quelle: Hirth, IGB
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InfraLeuna spearheads German drive for alternative feedstocks
Germany gears up for biotech future
22 June 2009 00:00 [Source: ICB]
With €50m funding in place and start-up scheduled for 2011, the white biotech research center at the Leuna chemical site looks set to be a major force in Europe's alternative feedstock innovation drive
Consultant's corner John Stokoe/Euro Swiss Research
ACCESS TO scale-up facilities is crucial for utilization of renewable feedstocks for the chemical industry of the future.
The idea to produce today's chemicals, as well as new ones replacing those that are not cost and eco-efficient from renewable resources with the help of industrial biotechnology seems to be quite appealing to a majority of players in the chemical industry. This idea, combined with the concept of lowering greenhouse gas emissions and being sustainable at the same time makes renewable resources even more appealing to all stakeholders.
Consumers seem to embrace "green" products as well, and would adopt them readily if they were available at competitive prices and made from materials that are not used for the food or feed chain.
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At the Fraunhofer Process Center in Leuna state-of-the-art facilities and equipment will be available to all participants
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Lab IILab Chemical site LeunaScale-up and process developmentPilot-scale
Feedstock selection and -
conditioning
Biotransformation and Bioprocess-
development
Product-processing and
Process integration
Process-simulation and
automating
Bioproduct-manufacture and -characterization
Chemical-Biotechnological Process Center - CBP
Industrial Biotechnology
within Fraunhofer
1 L 10 m³Enzyme screening, design
& optimization
Bioprocess-und Bioproduct-
evaluation
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> 8.000 m² total space25 to 10.000 l process volumeFlexible USP & DSP AnlagenFeedstock flexibilityIntegrative processes5+ individual modulesExtension capacity
Technical area with modular units
Offices/Laboratory
Utilities Media
Offices
The new Fraunhofer Process Center - CBP in Leuna
Linde-KCA-Dresden GmbH 14
1: Innovative enzyme processes
2: Lignocellulose-based biorefinery
3: Innovative fermentation processes
4: Microalgae, greenhouse, DSP
5: Bio-Ethylene and biogas
6: Office, utilities and storage
7: Extension space
1 2 3 54
4
6
6
7
The implementation of the CBP follows a multifunctional, modular approach
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The CBP is fully integrated in the site infrastructure
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Main road B91 direct access to highways A38, A14 und A9 (ca.3 km)
Direct access to the railroad system of Deutsche Bahn (DB)
City of Leuna
City of Spergau
Railroad shunting yard
Central waste water treatment plant
Drinking-/Fresh water plant
cCe Culture and congress center
Power generation
Office building
Main entrance for passenger cars (Gate 1)
Main entrance for trucks(Gate 6)
CBP
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Integrated BioproduktionIntegrated Bioproduktion
Enzymes as CatalystsEnzymes as Catalysts
Lignocellulose-Biorefinery IILignocellulose-Biorefinery II
Several projects have been initiated by Fraunhofer
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At the Leuna chemical site, the integration of industrial biotech into chemical manufacturing is under-way
• Fraunhofer -owned and -operated Process-Center - CBP operational in 2012
• Laboratory- to pilot-scale process dimensions
• State-of-the art technologies and equipment: feedstock-pretreatment, conversion, down-stream processing
• Reduction of scale-up time and capital spending
• Integration of activities into chemical manufacturing network
• Subsidies for subsequent investments available
• Nucleus and “role model” for industrial biotech activities
• Open to all interested parties
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InfraLeuna GmbHAm Haupttor
D-06237 Leunawww.infraleuna.de
Dr. Markus WolperdingerDirector Industrial BiotechnologyTel: +49 (0) 3461 / 43 3083Fax: +49 (0) 3461 / 43 42 90Email: [email protected]
Mr. Martin NaundorfVP Site DevelopmentTel.: 03461 / 43 41 67Fax: 03461 / 43 42 90Email: [email protected]
Contact us to learn more about the Fraunhofer CBP and the chemical site Leuna
Prof. Dr. Thomas HirthFraunhofer-Institut für Grenzflächen- und Bioverfahrenstechnik IGB StuttgartTel: +49 (0) 711-9704401FAX: +49 (0) 711-9704006Email: [email protected]
