BUILDING BIORESOURCE SUPPLY CHAINS

Transcription

1 BUILDING BIORESOURCE SUPPLY CHAINS THE CASE OF BIOMASS-TO-FERMENTATIVE BIOHYDROGEN EPROBIO SEMINAR_

2 Hydrogen Vision, 2050 ECN, 2005

3 IP HYVOLUTION Non-Thermal Production of Pure Hydrogen from Biomass ACKNOWLEDGMENTS This work is financially supported by the "Hyvolution" Integrated Project, within the 6th Framework Program of the European Commission.

4 Building Supply Chains Total biofuel chain definition... Bio-H2 Biofuel production Biomass collection agro-forest residues Biomass production for energy applications Local pretreatment Storage Transportation Pretreatment Bio-refining Biomass collection agro-forest industry residues Co-products

5 Modelling biomass-to-biohydrogen logistic chains Approach 1. Security of Supply_ Feedstock: Estimation of Biomass potential in EU for Bio-Hydrogen Production 2. Security of Supply_ Logistics: State of the art in the modeling of biomass logistic chains 3. Security of Supply_ Biorefining : Identification of the crucial parameters of a potential biorefinery approach- handling byproducts

6 Estimation of Biomass potential in EU for Bio-Hydrogen Production Assessment of the theoretical potential From the theoretical to the sustainable potential Additional technical, economic, environmental and social boundaries Competition by other sectors The regional dimension

7 IP HYVOLUTION Non-Thermal Production of Pure Hydrogen from Biomass Water soluble monomeric and oligomeric carbohydrates Major advantage: Potential for feasible and sustainable operation of relatively small units, up to 2ΜW (fed by 8000 dry tons of biomass/a)

8 Assessment of the theoretical potential

9 Security of Supply_ Feedstock Potential Questions to be asked while assessing the theoretical biomass potential for the specific technology: Which is the actual raw material in fermentative hydrogen conversion technology? Water soluble carbohydrates (monomeric, oligomeric sugars) Which are the main crops or industrial by products which can provide, directly or after pretreatment(s), such carbohydrates? - Major sugar, starch crops and their industrial by products - Easily hydrolysable lignocellulosics from farm or agro-industries

10 Mapping the Landscape of potential for EU biomass EU AGRICULTURAL PRODUCTION DATA COEFFICIENTS FOR MAIN/BY PRODUCTS OF AGRICULTURAL PRODUCTION COEFFICIENTS FOR CARBOHYDRATE CONTENT OF POTENTIAL FEEDSTOCKS BIOLOGICAL H2 PRODUCTION TECHNOLOGY GENERAL FEEDSTOCK REQUIREMENTS EU AGRO-INDUSTRY PRODUCTION DATA LAND USE DATA QUALITATIVE IDENTIFICATION OF POTENTIAL FEEDSTOCKS ASSUMPTIONS FOR CHANGES IN LAND AND AGRICULTURAL PRODUCT USE DRY BIOMASS POTENTIAL IN EU COEFFICIENTS FOR MAIN/BY PRODUCTS OF AGRO-INDUSTRIAL PRODUCTION CARBOHYDRATE TO H2 CONVERSION EFFICIENCY TOTAL H2 PRODUCTION POTENTIAL IN EU

11 Mapping the Landscape of potential for EU biomass Assumptions Identification of relevant crops, based on the current land use data The adoption of biorefining approach for these crops in order to identify the relevant biomass sources (main product, crop residues at farm, agro-industrial residues). Quantitative statistical data collection for agricultural and agro-industrial production for regions, countries and EU25. Assumptions for future land use (1/3 of fallow land to be utilized for energy crop production), agricultural production (10% of the current agricultural production to be utilized for Hydrogen production whenever this is technically feasible), for residue availability (100%) and bm2bh conversion efficiency (100 kg Hydrogen for every ton of Carbohydrate). Miscanthus (for Central and North EU25) and sweet sorghum (for South EU25) as potential future energy crops. The relative potential calculations were based on the available yield, carbohydrate and moisture content data for these two crops. Carbohydrate content of the potential feedstocks based on either experimental data or literature. Development of matrices where all the above are presented in a user friendly way

12 Mapping the Landscape of potential Crops already cultivated for nutritional needs Energy crops Potential Feedstocks for Hydrogen Production Crop Category Sugar Crops Starch Crops Other Food Crops Sugar Crops Lignocellulosic crops CROPS, CROP PARTS AND AGRO-INDUSTRIAL RESIDUES AS POTENTIAL FEEDSTOCKS by-products Crop main product leafy biomass stems-stalks pulps-cakes sugar beet sugar leaves - pulp sludges-other wet residues molasses sludge potato tuber leaves - peels starch wheat barley grain grain - - straw straw husks,hulls,bran husks,hulls,bran wet milling wastes wet milling wastes brewery waste maize grain - straw wet milling corn-oil cake cob wastes other cerials grain - straw husks,hulls,bran wet milling wastes rice grain - straw husks,hulls,bran wet milling wastes grapes wine, juice - vine pulp wet residue apples canned prod., juice - wood, trimmings pulp wet residue other fruits canned prod., juice - wood, trimmings pulp wet residue vegetables canned prod., - leaves - juice pulp wet residue oil seeds veg. oil - straw oil cake wet residue sw. sorghum sugar leaves bagasse - sludge Miscanthus stems/stalks leaves - pulp - 15 crop main product and 29 farm or industrial level by-products and residues were considered as potential feedstocks

13 Security of Supply_ Feedstock (A) Annual Biomass Production for EU-27 Crops already cultivated for nutritional needs ANNUAL BIOMASS PRODUCTION (10^6 d.t) FOR EU27 Crop Category Sugar Crops Starch Crops Other Food Crops Crop sugar beet main product 18.1 leafy biomass 7.3 stems-stalks by-products pulps-cakes sludges-other wet residues Total Annual Production for EU27 potato wheat barley maize other cereals rice grapes apples other fruits vegetables oil seeds Energy crops Sugar Crops Lignocellulosic crops sw. sorghum miscanthus Total Annual Production Total Annual Production for crop main products EU27 Total Annual Production for Agricultural Wastes in EU27 Total Annual Production for AgroIndustrial Wastes in EU27

14 Security of Supply_ Feedstock (A) Total Hydrogen Generation Potential in EU-27 Crops already cultivated for nutritional needs HYDROGEN POTENTIAL FOR EU27 (10^6 t H2) Crop Category Sugar Crops Starch Crops Other Food Crops Crop 10% of the main product of crops as feedstock for hydrogen except energy crops where 100% goes for Hydrogen leafy biomass stems-stalks by-products pulps-cakes sugar beet sludges-other wet residues Total Hydrogen Generation Potential potato wheat barley maize other cereals rice grapes apples other fruits vegetables oil seeds Energy crops Sugar Crops Lignocellulosi c crops sw. sorghum miscanthus Total Hydrogen Generation Potential colour scale < >1.00

15 Mapping the Landscape of potential for EU biomass Country Contribution in Total Hydrogen Production Potential in EU-27 SE 5.32% FI 3.73% PT 2.58% HU 2.52% EL 2.48% ES 17.31% FR 16.32% PL 7.56% Rest 13.68% NL 10.13% IT 8.53% UK 8.76% DE 11.21% DK 10.47% IE 11.00% Cz 13.29% AT 14.15% LT 9.83% MT 0.16% LV 7.53% EE 4.33% SK 7.44% Sl 2.80% LU 0.53% Be 7.24% CY 1.09%

16 From the theoretical to the sustainable potential Additional technical, economic, environmental and social boundaries Competition by other sectors

17 Potential Estimation: From Total to Sustainable OTHER NON FOOD PRODUCTS TOTAL BIOMASS POTENTIAL IN EU TOTAL BIOLOGICAL H2 GENERATION POTENTIAL IN EU TECHNICAL FEASIBILTY ECONOMIC FEASIBILTY SOCIAL SUSTAINABILITY ENVIRONMENTAL SUSTAINABILITY TOTAL SUSTAINABLE BIOLOGIAL H2 GENERATION POTENTIAL IN EU a b c d A OTHER ENERGY TECHNOLOGIES FOOD vs. FUEL B = A*a*b*c*d a,b,c,d<1 B

18 Security of Supply_ Feedstock Potential Questions to be asked while assessing the sustainable potential for the specific technology: How to decide which potential feedstock is promising for our application? - Technical suitability - Economic feasibility - Environmental and social sustainability How to quantify these aspects?

19 FEEDSTOCK SELECTION COST TECHNICAL SUITABILITY SUSTAINABILITY

20 Biomass Technical Suitability Index (BTSI) Category Name Definition 1 Yield Potential Maximum Hydrogen yield based on two-step stoichometric hydrogen fermentation, assuming 80% conversion to hydrogen and 20% to microbial biomass production and other byproducts 2 Mobilisation Efficiency Percentage of all carbohydrates in the feedstock that can be converted into fermentable sugars 3 Fermentability Tendency of pretreated feedstock to inhibit or improve fermentation to hydrogen 4 Coproduct value & yield Characterisation of both the value and the volume of the co-product from pretreatment or fermentation

21 Biomass Technical Suitability Index (BTSI) Sugar beet (juice) Yield Potential Co-product Application & Yield 0.0 Mobilisation efficiency Fermentability Yield Potential Sugar beet (juice) Wheat grain Miscanthus Reed Canary Grass Coproduct Value & Yield Mobilisation efficiency Fermentability

22 Biomass Cost Index (BCI) Cost A ( /wet t) Primary production or opportunity cost of feedstock ( /wet t) Dry Matter Content (dm) % water (moisture) content of feedstock Carbohydrate Content % non-carbohydrate content of feedstock Transport Distance Feedstock transportation distance (km) BioH2 Plant Capacity Plant capacity (dry t biomass/h) Cost C (index) Refining Index (refining difficulty due to the type of Carbohydrates see above) Co-product C Credit (Index) Co-product A Credit (Index) Biomass Cost Index (BCI) Credit of refining co-products (euro/gj carb) Credit of primary production co-products (euro/gj carb) (on a Scale, where 100 for zero credit) Index of the Interaction of the 8 Cost Parameters expressed by the surface area of the spider graph (the highest the Index, the less cost efficient the biomass-tobiohydrogen supply chain)

23 Biomass Cost Index (BCI) Opportunity Cost Credits of Biomass Production %dm Sugar Beet (juice) Wheat grain Miscanthus Reed Canary Grass Credits of Refining %carb Refining Index Transportation Distance Plant Capacity (dry t/day)

24 Biomass Sustainability Index (BSI) BSI-A BSI-B BSI-C 1. Soil (erosion vs. conservation practices) 2. Nutrients (losses vs. rational management) 3. Fossil fuels ( hidden links vs. de-coupling) 4. Water (wasting/degrading vs. efficient use) 5. Mobilisation of elements (pollution vs. control) 6. Impact on climate (GHG vs. green accounting) 7. Land use ( fuel or food vs. biorefineries) 8. Biodiversity (monoculture vs. agroecosystem) 9.Social acceptance (concerns vs. consensus) 10. Human Health (ecology vs. economy) 11. Employment (human vs.development and technology ) 12. Regional Development BSI ={ [BSI-A] +[BSI-B] +[BSI-C] }/3

25 Biomass Sustainability Index (BSI) BSI Sugar beet 1. Soil (erosion vs. conservation practices) Nutrients (losses vs. rational 12. Regional Development management) BSI-A BSI-B BSI-C 11. Employment (human vs.development and technology ) Fossil fuels ( hidden links vs. decoupling) 10. Human Health (ecology vs. economy) Water (wasting/degrading vs. efficient use) 9.Social acceptance (concerns vs. consensus) 5. Mobilisation of elements (pollution vs. control) 8. Biodiversity (monoculture vs. agroecosystem) 7. Land use ( fuel or food vs. biorefineries) 6. Impact on climate (GHG vs. green accounting)

26 Comparative Assessment and Selection of Feedstock BTSI BCI BSI Miscanthus Reed canary grass Sugar beet Wheat grain

27 Competition - Alternative Biomass-to- Hydrogen Pathways High Carb Low DM: High Carb High DM: Biomass -> BioH2 (HYVOLUTION) Biomass -> Bioethanol -> Reforming -> H2 Low Carb Low DM: Low Carb High DM: Biomass -> Biogas -> Reforming -> H2 Biomass -> Thermochemical Gasification -> H2

28 The regional dimension

29 Regional dimension EU Policy National Policy Potential regional implementation of Hyvolution technology

30 Stakeholders and policy aspects TODAY 2010 THESSALY FUTURE 2030 BIOFUEL EU BIOFUEL ROADMAP ROADMAP THESSALY THESSALY EU CAP CURRENT BIOMASS AND BIO-H2 PRODUCTION POTENTIAL DEVELOPMENT OF HYVOLUTION TECHNOLOGY EU HYDROGEN ROADMAP THESSALY BIOFUEL PLANTS SUSTAINABLE BIO-H2 GENERATION INDUSTRIAL INFRASTRUCTURE INDUSTRIAL INFRASTRUCTURE, BIOREFINERY, BIO-H2 INTEGRATION ENERGY NEEDS CURRENT BIOENERGY APPLICATIONS OTHER H2 TECHNOLOGIES H2 SUPPLY AND END- USE TECHNOLOGY 1 ST GENERATION TO H2 HYDROGEN SUPPLY & END USE SUSTAINABILITY TECHNOLOGIES (WATER, SOIL etc.) BIOLOGICAL H2 IN H2 BALANCE COMPETITION / OTHER TECHS ETOH PLANT (UNDER CONSTRUCTION) BIOFUEL TARGETS BIODIESEL FROM 1 ST GENERATION TO H2 COMPETITION FOR LAND AND RESIDUES CONVERSION EFFICIENCY FEEDSTOCK SUITABILITY LAND USE CHANGE (COTTON, SUGAR BEET) SUSTAINABILITY FALLOW LAND SUBSIDIES ENERGY NEEDS, BIOENERGY IN ENERGY BALANCE COMPETITION BETWEEN BIOENERGY APPLICATIONS OTHER H2 TECHNOLOGIES H2 SUPPLY AND END- USE TECHNOLOGY

31 Stakeholders and policy aspects Best Case Scenario 2030 Worst Case Scenario BIOREFINERIES SUSTAINABILITY... ENERGY CROPS IN FULL DEVELOPMENT COMBINED LARGE - SMALL SCALE APPLICATIONS NEW GENERATION BIOFUELS IN THE REGION... BIOFUEL TARGETS HYDROGEN TECHNOLOGY PENETRATION LOCAL SMALL SCALE APPLICATIONS IN THE REGION... DEVELOPMENT OF HYVOLUTION TECHNOLOGY NEW CAP LAND AVAILABILITY OIL CROPS BIOETHANOL PLANT AND ITS SUCCESS IN THE REGION... Thessaly Best Case Scenario Rotterdam 2030 BIOREFINERIES SUSTAINABILITY (BIOMASS vs NATURAL GAS, BIOFUEL vs FOOD & FEED)... NATURAL GAS TRANSPORT AND DISTRIBUTION INFRASTRUCTURE FOR H 2 COMPETITION IN H 2 GENERATION IMPORTED AGRI-BULK LOCAL PRETREATMENT PLANTS RESIDUE PRODUCTION AND AVAILABILITY COMPETITION COMPLEMENTARY USE WITH OTHER BIOFUEL TECHNOLOGIES PORT EXTENSION EFFECT ON INDUSTRIAL ACTIVITIES EFFECT ON LAND AVAILABILITY FOR FURTHER ACTIVITIES Worst Case Scenario

32 Security of Supply_ Logistics: State of the art in the modeling of biomass logistic chains

33 Security of Supply_ Feedstock Transport&Handling (B) Agricultural biomass supply logistics are characterized by : - Wide areal distribution of biomass sources - Variable biomass yield - Time and weather-sensitive crop maturity - Variable moisture content - Time-sensitive, variable biomass quality (carbohydrate content) - Low bulk density of biomass material - Short time window for collection with competition with concurrent harvest operations

34 Security of Supply_ Feedstock Transport&Handling (B) Crucial parameters affecting the feedstock Transport&Handling Plant scale Biomass productivity Collection/harvesting area Geographical and Geometrical specifications of the feedstock collection area Average haul distance Maximum extent of feedstock collection Feedstock Characteristics (DM, C/H Content, bulk density) Cost The feedstock type itself has a slight influence on this part of the chain (only the storage and handling conditions are feedstock dependent) Quality of feedstock at the gate of the refinery An optimized collection, storage and transport network can ensure timely supply of optimum biomass quality with minimum cost

35 Security of Supply_ Feedstock Transport&Handling (B) State of the Art Example of transport cost calculation model from the literature

36 Security of Supply_ Feedstock Transport&Handling (B) State of the Art Example of an Agri-Fuel Chain

37 Security of Supply_ Feedstock Transport&Handling (B) State of the Art From Agri-Food Chain to Agri-Fuel Chain

38 Security of Supply_ Biorefining : Identification of the crucial parameters of a potential biorefinery approach- handling by-products

39 Security of Supply_ Refining (C) The crucial parameters affecting the sustainability of the bio -refining stage of the whole chain: - Range of the feedstock type which can be processed (one or multiple feedstock types) - Seasonality of the plant operation (optimization of the feedstock selection for the full year operation) - Capacity optimization - Optimization of the process location (on-site or centralized) - Exploitation of Co-Products - Plant location

40 Fermentation Security of Supply_ Refining (C) Washing Slicing Extraction Sugar Beet Pulp Sugar Juice Sugar Crystallization Molasse Wheat Bran Potato steam peels Sugar Feedstock Liquefaction Hydrolysis Solid residue Hydrolysate Refining processes of the selected feedstocks Lignoellulosic Feedstocks Barley Straw Starchy Feedstocks Alkaline Pretreatment Lignin Enzymatic Hydrolysis Solid residue Hydrolysate Cutting Milling

41 Building Supply Chains (ABC) Mapping the complexity of biomass supply chains 1/2 Questions to be answered while building the bm2bh chain - Plant site and size selection- Balancing the plant scale and location for cost optimization depending on: Biomass availability and security of its supply Biomass spatial dispersion Site infrastructure - Location of each process (centralized vs. decentralized?) - Dealing with the feedstock seasonality maximizing the duration of the plant operation period multifeedstock refineries? - Securing the feedstock quality during the transport and stock period - Building the biomass supply chain by optimizing the benefits of the stakeholders - Feedstock availability scenarios and their effects on the feasibility of the whole bm2bh chain - Building the biomass supply chain by optimizing the social benefits (regional employment, value addition ) - Machine, resource and process handling in a way that minimizes cost (e.g. by creating a harvest and pretreatment program which optimizes the machine and infrastructure use) - Building a multi feedstock-multi product, a single feedstock-single product system or any of the other possible combinations in order to improve the overall sustainability - Sensitivities against the price of the key products Base case Assumptions Mapping all the possible chains Identifying the most promising one(s)

42 Building Supply Chains (ABC) Mapping the complexity of biomass supply chains 2/2 List of materials - Feedstock(s) - Intermediate products - Possible End products List of possible processes - Transport treated as process step - The steps also have an indication for the respective logistical handling. : material _: process step Example from the literature (single feedstock case) Maximal structure of the base case synthesis Basic cost functions from the literature Optimal structure for the base case

43 Building Supply Chains (ABC) Total agro-fuel chain definition Bio-hydrogen production plant Biomass collection agro-forest residues Biomass production for energy applications Local pretreatment Storage Transportation Pretreatment Bio-refining Biomass collection agro-forest industry residues Co-products

44 Building Supply Chains (ABC) Potato Steam Peels for BioHydrogen Chain Definition Bio-hydrogen production plant Biomass collection agro-forest residues Biomass production for energy applications Drying of peels Transportation Liquefaction Hydrolysis Purification Potato steam peels from potato processing industry Solid residue

45 Sugar beet to BioHydrogen Logistic Chain Value added product Sugar beet Residue Processing Soil enhancement Foliage Defoliation Mud Local washing Beet root (clean) Local slice Local extraction Beet root Beet root Beet root Local washing Local washing Beet root (clean) Mud Mud I II Beet root (clean) III Local transport Central transport/storage LOCAL HYDROGEN PLANT Beet root (clean) Beet root Washing Sugar juice Pulp Beet root (clean) Beet root Beet root (clean) Beet root Washing Beet root (clean) Mud Drying Mud Local Storage Slicing Animal feed Beet root (clean) Beet root Extaction Concentration Hydrolysis Sugar juice Pulp Central transport and storage Drying Animal feed Concentrated sugar juice Dissolved oligomers non soluble solid residue Beet root (clean) Beet root Concentration Concentrated oligomers Washing Beet root (clean) Mud Dissolved oligomers Hydrolysis non soluble solid residue Slicing Transportation to a central Hydrogen Plant Extraction Sugar juice Concentrated sugar juice Pulp Concentrated oligomers Sugar juice Pulp Hydrolysis Hydrolysis Drying Animal feed Dissolved oligomers non soluble solid residue Dissolved oligomers non soluble solid residue CENTRAL HYDROGEN PLANT CENTRAL HYDROGEN PLANT CENTRAL HYDROGEN PLANT

46 Sugar beet to BioHydrogen Logistic Chain I: Processing the feedstock as close as possible to the production site having the Hydrogen plant either at local or central level II: Only the initial transport and storage at local level, all feedstock processing steps at the central Hydrogen plant III: Central transport, storage and processing without any local involvement The present sugar beet for sugar chain concept is either II or III depending on the local conditions

47 Building Supply Chains (ABC) Total complex chain definition Players /stakeholders Consumer Hydrogen plant Farmer (Agro-residue) Farmer (energy plant) Storage Transporter Storage Refiner Agro-industry (Residues) Present user Potential user Co-products

48 Building Supply Chain (ABC) Spatial dimension Hydrogen plant Fermentable sugar syrup Fermentable sugars (FS f ) Dry Matter (DM f ) Total Cost (ΣC i ) Initial quality parameters: Fermentable sugar content (FS 0 ) Dry Matter Farmer (DM 0 ) Bulk (energy density plant) (BD 0 ) -if solid- Particle size (PS 0 ) -if solid- Initial cost-cost A- (C 0 ) A FS 1 DM 1 BD 1 PS 1 C 1 B FS 2 DM 2 BD 2 PS 2 C 2 T 1 T 2 T f-1 T f FS f-1 DM f-1 BD f-1 PS f-1 C f-1 C Setting Quality Standards According to the End-use A: Farm-Feedstock source B: Transport-Handling C: Biomass Refining Plant Co-products

49 Concluding Remarks 1/2 Types of EU regions for BioH2 plants Rural (field residues, energy crops, wastes) Agro-Industrial (wet residues, energy crops) Integrated (linked to a source or energy crop) Mixed (combinations of the above) Types of biomass-to BioH2 systems One feedstock, e.g., potato wastes More feedstocks of the same type, e.g., starchy Multi-feedstock, of various types

50 Concluding Remarks 2/2 Utilising less than 10% of the EU27 potential will be enough to satisfy the targets In the short term, the use of food crops for non-food purposes does not seem necessary On the other hand, utilising wet residues and agro-food industrial wastes is an immediate option Sugar-rich energy crops - e.g., sweet sorghum or energy beet - will play a major role in the medium-to-long run More than 50% of the potential is linked to cereal crops, esp. straws, i.e., another strategic option for the EU A key finding is that the potential can support the operation of small BioH2 plants (1 dry t/h) with ALL types of biomass feedstocks assessed (local/regional/ applications)

51 What to take home with you! Enough biomass production in EU27 without the need for major land use change System complexity should be considered and dealt when designing biomass-to-biofuel supply chains Decision making which will be based on technical, economic, environmental and social aspects Regional dimension is crucial for the success of any emerging biofuel technology