small scale opportunities in Biobased Economy

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1 small scale opportunities in Biobased Economy AgriForValor, BioEconomy mission 2018, Febr 15, Wageningen Johan Sanders, Em professor Biobased Commodity Chemicals, Wageningen UR

2 Biomass use today and in 2050 world wide Mton Food incl. feed* Wood, paper, cotton 2000 Wood for cooking % of 1000EJ in 2050= * Excluding grass and seafood

3 Design rules for a sustainable Bio-economy People, Planet, Profit Improve efficiency of use of raw materials and energy 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

4 Dry matter (Mton/year) Actual and potential harvest in Europe If all European hectares in 2030 would have Dutch yields of 2012 Mega hectares 2007 Corn 13.5 Barley 14.5 Wheat 56 Beet 3.6 Rape 8.1 Grass 69.4 Miscanthus Additonal BBE yield Mton Food crops Mton Agricultural residues Mton= 17EJ= 20% Proteins high in essential amino acids can come from:grass, rape seed, sugar beet Bos, Sanders BioFPR 2013;

5 Our daily food needs a twenty fold higher energy input Biomass NL 635 PJ EU PJ Fossil NL 575 PJ EU PJ Net Import 160 Food Industry 150 Household 165 Dutch Agriculture Transportion Food EU PJ 2500 kcal/day = 55 PJ Greenhouses/Food 100 Other Agriculture 60 Total energy NL fossil PJ EU fossil PJ

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

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

8 Capital cost ( /ton) ( /ton) Capital costs per ton of bulkchemical product vs heat dissipation Capital Raw material Energy input product caloric value Energieverlies (GJ/ton) (GJ/ton)

9 Epichlorohydrin from glycerol leads to little heat exchange and valuable product H 2 C CHCH 3 + Cl 2 C H 2 C CHCH 2 Cl O Ca(OH)2 H 2 H 2 C CHCH 2 Cl Cl OH CHCH 2 Cl HOCl + + HCl H 2 C CHCH 2 Cl OH Cl Price: per tonne Volume: 0.5 mln tonnes per annum Solvay Epicerol process: glycerol to epichlorohydrin At glycerol prices of 350 / ton the margins are 40-50%

10 Use of plant molecular structures leads to little heat exchange and valuable product N-Vinylpyrrolidone Acrylonitrile COOH H 2 N COOH Glutamic acid N-Methylpyrrolidone Diaminobutane

11 The route to NEP, new vs conventional NMP New route Biomass hydrolysis, separation COOH NH 2 COOH Glutamic acid step 1 step 2 - CO 2 enzyme, 30 o C NH 2 COOH ethanol + CH 3 OH cat, 250 o C CH3 CH 3 N NEP 2 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

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

13 Second generation ethanol costs a lot of capital and energy and will not give much value! False hope? Wheat straw pretreated and Enzymatic treatment

14 M /year Heat exchange requires high capital cost and 60 does not leave room for high raw material cost 50 Mid West raw materials EU raw materials US labour, Turnover Capital 10% US Raw material cost insurance and Positive Margin EU Raw Material cost EU labour, insurance and Negative margin

15 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)

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

17 Anaerobic fermentation of bulkchemicals Yield: 0.95 g/g or J/J Productivity: up to 5 times higher lower capital requirements 4 projects running

18 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%

19 small scale beet sugar production(2-500ha) can beet large scale factories! Much lower energy inputs Lower transport Equal costs Less energy Less transport Minerals recycled to field Kolfschoten et al

20 Small scale biorefinery Lower costs for transportation towards factory and back! Year around for the precious unit operations Water and minerals stay on site Less waste treatment on factory More income to farmers Gradual development of market as well as sourcing raw materials Can cope with environmental regulation in the NL

21 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

22 Byosis/Zeafuels (Lelystad, Netherlands)

23 3 generations Grassa!refining 1 st Generation (2011) (Friesland) 2 nd Generation (2015) (Uganda) 3 rd Generation (2016) (Netherlands) 23

24 Grassa DEMO draait sinds november 2016

25 Just protein is not sufficient to cover the costs bioraffinery 3 products 8 products income costs income costs Grass costs Process costs protein fibers Juice components 55 minerals 75 Organ. acids 60 Amino acids 75 sugars 12 FOS 225 Vitamines A, E 50 Unsat fatty acids 60 totaal

26 Conclusions Biorefinery for feed, materials and chemicals will create good income for agriculture and enables even to compete with coal, natural gas and Brazilian biomass! Avoiding heat exchange and small scale processing reduces capital as well as costs for energy and transportation and will lead to higher employment Earthscan, ISBN

27 Economische dragers in de BioEconomy High value per ton Veel waarde, te weinig volume Cleantech Biotechnologie Materialen/ Chemie Land & Tuinbouw Non food Veel waarde, en veel volume! Eiwitten Chemicaliën Materialen High volume Veel volume, te weinig waarde 27