Biorefinery, the bridge between agriculture and chemistry Opportunities for the Biobased industry

Transcription

1 Biorefinery, the bridge between agriculture and chemistry Opportunities for the Biobased industry Bioeconomy in Argentina: Present and Future Buenos Aires, 22 March 2013 Johan Sanders, professor Biobased Commodity Chemicals

2 The New Biomass value chain by biorefinery: 1st Agro logistics Food pretreatment Foodconversion Food production Food Healthy, tasty, sufficient Biomass sources Agro-food production production By products & waste Logistics&storage NL production Imports Existing conversion New production Performance materials Base&platform chemicals Performance chemicals Bio Energy Existing production Biobased Products Biobased materials Bio-based chemicals Bio-fuels Bio-energy Existing non- food: Paper Construction wood Additives Fibres/ clothes Wood for cooking.

3 Biomass use today and in 2050 Mton Food incl. feed* Wood, paper, cotton 2000 Wood for cooking % of 1000EJ in 2050= All bulkchemicals in (= 2000 input!) * Excluding grass and seafood

4 How to compete with fossil under sustainable conditions? Increase field yield but keep components on the field that are required for soil fertility Use all biomass components and choose the right raw material Use each component at its highest value: (molecular) structure is much better than caloric Reduce capital cost to speed up innovation and to benefit from small scale without the disadvantages Reduce integral costs by integrating process steps

5 Production costs /GJ end product How biomass can best compete with fossil feedstocks Capital Oil/gas Coal Value of biomass is 10 times higher as chemical building block than to use it for biogas or bio-electricity

6 F - ladder How to get the best value from biomass? /ton Farma High Fun High Food ingredients Food nutritional Feed young Feed pigs Feed cattle Functional chemical Fibre 500 Fermentation Fermentation bulk Fuel Fertilizer -/ Fire Flare 0 Fill -/- 300

7 Good use of biomass? Value of glycerol: /GJ Epichlorohydrin Transportfuel 10 Electricity 3 Glycerol 25.3 GJ/tonne Per GJ product ca 0.65 GJt input can be saved

8 Epichlorohydrin H 2 C C H C H 3 + C l 2 C H 2 C H C H 2 C l H O C l + HCl Price: per tonne C H 2 O C H C H 2 C l C a (O H )2 C H 2 Cl C H C H 2 C l O H + C H 2 O H Cl C H C H 2 C l Volume: 0.5 mln tonnes per annum Solvay Epicerol process: glycerol to epichlorohydrin

9 Use of plant molecular structures N-Vinylpyrrolidone Acrylonitrile COOH H 2 N COOH Glutamic acid N-Methylpyrrolidone Diaminobutane

10 The route to NMP, new vs conventional New route Biomass hydrolysis, separation COOH NH 2 COOH Glutamic acid step 1 step 2 - CO 2 enzyme, 30 o C NH 2 COOH + CH 3 OH cat, 250 o C CH 3 N NMP O Conventional route Gas CH 3 OH O CH 2 + cat, o C HO OH + H 2 cat, 80 o C HO OH - H 2 cat, o C O O cat + CH 3 OH N H 2 NH o C bar cat 400 o C CH 3 NH o C 100 bar Amino acids contain N and O. Less steps (= factories) & energy for the same product! CH 3 N O

11 Biobased NMP, makes an ethanol plant profitable 500 Million liters bioethanol (~ 400 kton) =200M 360 kton DDGS (~130 / ton) =46M C O O H 36 kton glutamic acid H 2 N O O H 23 kton NMP (~2500 / ton) =58 M /y

12 3D-foamed polylactic structures (Wageningen UR) Expandable bead technique Good cell structure Density <30 g/l Sheet: Karin Molenveld

13 to n /h a Total crop yields W e t W e ig h t a n d D r y W e ig h t Y ie ld s T o ta l B io m a s s P ro d u c tio n B e s t P ra c tic e Y ie ld s W e t W e ig h t D ry W e ig h t Above 30ton/ha/a dry weight = Fantastic Above 20ton/ha/a dry weight = Great Above 10ton/ha/a dry weight = Good 0 C a s s a v a G ra s s L u c e rn e M a iz e O il p a lm P o ta to R a p e s e e d S o rg h u m S o y a b e a n S u g a r b e e t S u g a r c a n e S u n flo w e r S w itc h g ra s s T o b a c c o W h e a t W illo w tre e

14 k g /k g Proportion of constituents C o n s titu e n ts P r o p o r tio n s 100% 80% 60% 40% F a t 20% P ro te in L ig n in C o m p le x C a rb o h y d ra te s (C.C.) S im p le C a rb o h y d ra te (S.C.) 0% C a s s a v a G ra s s L u c e rn e M a iz e O il P a lm P o ta to S o rg h u m S o y a B e a n s S u g a r B e e t S u g a r C a n e S u n flo w e r S w itc h g ra s s T o b a c c o W h e a t W illo w T re e

15 Lignocellulose hydrolysate, not an ideal substrate yet mixing problems, low oxygen transfer, low substrate concentrations, fermentation inhibitors Complex: implications for product recovery

16 Biorefining of agricultural residues.. Protein content 0 5 % 15 % 35 % 50 % Examples Wheatsstra w cocoahulls Corncobs Sugarcane leaf Coffee pulp Rape straw Beet leaf Rape meal Soy meal Cost ( /ton)

17 /GJ /ton Biorefinery enables power generation at 45 /ton and high quality 2 nd generation fermentation raw materials for 200 / ton Wood chips Straw (field) Straw (collected) Straw (washed) Rape meal Multiproduct biorefinery Protein Animal feed Amino acids Ferment. substrates Lignocellulose Fibres Phosphorus Rest

18 Integrated production of chemicals & power Rape meal Protein + K NaOH BBE parc Cuijk & Renkum Agricultural residues Cellulase Ca(OH) 2 95 C 1 day Amino acids Lignocellulose Ferm Amino acids + phosphate Fibres Recalc.lignocellulose Ca(lactate) 2 Ferm Ca(lactate) 2 Prec Ethanol Recalcitrant Lignocellulose Waste paper/caco 3 heat CHP Electricity Heat CaO

19 Income per tonne rape meal Product Mass Income Protein Amino acids Animal feed Ethanol (200) (20) Fibres PO Lignocellulose Total Costs rape meal = 180 /tonne ( November 2011)

20 6 Mtonnes oil seed meal will enable 2.5 TWh (3 Mtonnes of protein, 1.5 Mton fermentation raw materials and 0.75 Mton fibers) World production of: Rape meal Sunflower meal Palm kernel meal 42 Mtonnes/y 22 Mtonnes/y 130 Mtonnes/y Dutch import of seeds and meals is 7.8 Mtonnes/y

21 Small scale can be competitive Output (kton/y) Investment (M ) Turnover (M /y) Investment/ ton ( ) Neste Oil Turnover/investm ent ( / ) 2 nd generation ethanol 2 nd generation multi product

22 Small scale biorefinery reduces transport cost and seasonality Fields Farm Processing Present 100% 100% Return flow 10% concentration fermentation Concept 100% Small scale processing 30% Return flow 70%

23 protein/oil/ethanol/biogas from small scale corn-biorefinery Stem Maize Biogas fermentation Biogas biogas CHP heat Electricity minerals Grain Pretreatment & Ethanol fermentation Filtration Distillation 60% ethanol Less investment costs/liter ethanol than American ethanol production that operate at 200 x larger scale Protein Feed/food Corn oil

24 Byosis/Zeafuels (Lelystad, Netherlands)

25 The separated components of grass value /ton as compared to /ton raw materials Fresh grass Fibers 30 % 100 Oligo-saccharides 3% 1500 Lipids 3 % 2000 water % Organic acids 5% 2000 Mono/di- saccharides 150 Protein / Amino acids 20 % 1000 dry substance 10-20% Minerals 10 % Polysaccharides 15 % 1500

26 Mobile grass refinery unit Grassa (the Netherlands) Grass protein (products) white grass protein Protein compound feed Green grass protein Grass juice concentrate Grass juice Fibers compound feed Ethanol +... HTU- Biofuel Construction material + paper Polymer extrusion products

27 Mobile Cassava starch refinery in Africa Source: Duteso

28 Bio-commodities is a necessity for the industry to start! Pyrolysis oil Torrefaction pellets HTU biocrude Non purified syngas (hydrous) ethanol lactate Biodiesel Pure plant oil Rape seed Soy beans Cereal grains Crude protein (hydrolysates)

29 Carbohydrates as the building blocks Why do aerobic fermentations have low Y s Lysine: 0.45 g/g Glutamic acid: 0.48 g/g While anaerobic fermentations have high yields Lactate: 0.95 g/g Ethanol: 0.95 J/J

30 Anaerobic fermentations Productivity: up to 5 times higher as compared to aerobic Less cooling equipment No compressor Much less stirring Leading to much lower capital costs per ton of product

31 Bulk chemicals from Biomass: e.g. lysine fermentatio n State of the art ADM, Degussa, Ajinomoto Anaerobic fermentation direct plant products Plant GMO Biorefinery from Plant residues Fossil chemical reference GJ GJ/ton /ton GJ/ton /ton GJ/ton /ton GJ/ton /ton Fossil raw materials (fermentation) Fossil raw materials (recovery) Biomass raw materials Capital (fermentation) Capital (recovery)

32 conclusions Use of all biomass components at their highest value enables even to compete with coal and natural gas Use of molecular structures needs much less capital and energy Anaerobic fermentation gives high substrate yield and low capital costs Economy of scale is loosing its competitiveness Earthscan, ISBN

33 Why soy? Important food crop can we use it also for non-food? Biorefinery is the key: co-production of food/feed/other products Soy is a good binder of Nitrogen from air Crops available both natural and genetically modified Substantial crop: 91 mio ha globally, 2,2 ton/ha soy seeds AND 6 ton soy-hay and soy rests per ha: valuable components! 1,7-3,4 ton soy/ha normal conditions; 4 ton/ha optimal conditions

34 Soy biorefinery Soy: food and feed Decentral (on spot) pressing of waste, selling the protein juices Sugars: more centralised production of ethanol through fermentation Ligno cellulose: second generation bioethanol Biorefinery gives access to chemical industry and higher outputs in terms of money.

35 Soy for example Soy contains: celluloses 17% hemi celluloses 4% sugars 7% proteins 41% oil 18% Soy seeds: only 1/3 of total dry plant mass => plant adds enormous quantities of valuable products

36 Summary Use of ag residues (soyleaf/stems, cane-leaf, etc) for the production of protein, animal feed and bulkchemicals Protein hydrolysates and the crystallization of pure aminoacids for feed, chemicals and pharma Yeast Coproduction of chemicals and ethanol Small scale biorefining of rapeseed/ Jatropha/ oil crops in rural areas for the production of biodiesel, protein and minerals Small scale production of ethanol and protein from starchy crops Low capital and operational cost anaerobic sugar fermentations to bulkchemicals In planta (Cane/ Soy/..) production of bulkchemicals by GMO

37 Ethanol and Cyanophycin building blocks from yeast: two products for the price of one Cyanophycin mainly in cyanobacteria as nitrogen and energy reserve material = Asp + Arg Granule 35% (wt/wt) and slow growth

38 Our daily food needs a twenty fold higher energy input Biomass 635PJ Net Import 160 Fossil 575PJ Food Industry 150 Household 165 Dutch Agriculture 475 Transportion Food kcal/day = 55 PJ Greenhouses/Food 100 Other Agriculture 60

39 k g /k g Proportion of constituents C o n s titu e n ts P r o p o r tio n s 100% 80% 60% 40% F a t 20% P ro te in L ig n in C o m p le x C a rb o h y d ra te s (C.C.) S im p le C a rb o h y d ra te (S.C.) 0% C a s s a v a G ra s s L u c e rn e M a iz e O il P a lm P o ta to S o rg h u m S o y a B e a n s S u g a r B e e t S u g a r C a n e S u n flo w e r S w itc h g ra s s T o b a c c o W h e a t W illo w T re e

40 Decentrale optimalisatie van raapschilfers verdund loog zuur, 90 C oliemolen raapschroot raapschilfers Eiwitoplossing kalium, opgeloste stof K, organische stof onopgeloste vezels eiwit (50% ds) veld 95 C varkens ontsloten vezels (50% ds rundvee

41 Example: Glutamic acid and other aminoacids in byproduct streams Amino acids in residual proteins 100% 80% 60% 40% 20% 0% Maize DDGS Wheat DDGS Sugarbeet vinasse Sugarcane vinasse Rapeseed meal Soybean meal Jatropha meal Palmoil meal Chlorella microalgae Ala Pro Glu Asp Tyr Phe Ser Gly Arg His Val Leu Ile Trp Thr Cys Met Lys

42 The Chemical Products of the Port of Rotterdam

43 Bulkchemicals from Waste 2 Resource: Upstream integration, downstream benefits Treated water Waste water Polymer development PHB Chemical conversion

44 400 km Brazil from feed to doubled feed + biobased Soy Protein Biodiesel Cattle feed 24 Mton 12 Mm3 24 Mton Mton /ton M PJ Protein Biodiesel Cattle feed Total /ha = 510 4% of GNP 600 km Soy Protein Biodiesel Cattle feed 18 Mton 9 Mm3 18 Mton Grass Protein 24 Mton Bioethanol 36 Mm3 Cattle feed 24 Mton Pigfeed 24 Mton Mton /ton M PJ Protein Bioethanol Biodiesel Cattle feed Pig feed Total /ha = % of GNP Soy Protein Biodiesel Cattle feed 12 Mton 6 Mm3 12 Mton Protein 24 Mton Grass Bioethanol 36 Mm3 Cattle feed 24 Mton Pigfeed 24 Mton Cane Bioethanol 36 Mm3 Chemicals 12 Mton Protein 4 Mton Mton /ton M PJ Protein Biodiesel Bioethanol Cattle feed Pig feed Chemicals Total /ha = % of GNP J.W.A.Langeveld and J.P.M. Sanders in Langeveld et al, The Biobased economy, Earthscan, 2010; chapter 21

45 Economics food chain (sugar beet) Suiker (100% ds) 10 ton/ha á 410 /ton Voedsel 4100 /ha Biomassagrondstof (65 ton bieten per ha a 27 ton) 1755 /ha Betacal (65% ds) 4 ton/ha á 20 Perspulp (28% ds) 11 ton/ha á 20/ton Grondverbeteraar Laagw. veevoer 80 /ha 220 /ha Melasse (80% ds) 2.4 ton/ha á 90/ton Veevoer of EtOH 216 /ha 4616 /ha

46 Economics biobased chain (Sugar beet) Betacal 4 ton/ha á 20 Grondverbeteraar 80 /ha Biomassagrondstof (65 ton bieten per ha a 27 ton) 1755 /ha HW Chemicalien 1.3 ton/ha á 800 /ton Melasse (80% ds) 14.9 ton/ha Perspulp (28% ds) 11 ton/ha 5470 kg (6924 L) EtOH 1016 kg (1286 L) EtOH Chemie (58 GJ) Ethanol (8210 L EtOH/ha; a 0.35/L (174 GJ/ha) 1040 /ha 2874 /ha Blad (12% ds) 40 ton/ha 120 /ha 31 GJ (8.6 MWh) stroom + 70 GJ warmte (~2690 m 3 gas) Stroom ( 0.032/ kwh) Warmte ( 6.71/GJ) 275 /ha 469 /ha 4738 /ha

47 Mobile Cassava starch refinery in Africa Source: Duteso