From fossil- to bio-based refineries Case Study Biorefinery Leuna. Uwe Welteroth Director Biotechnology Plants Linde-KCA-Dresden GmbH
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1 From fossil- to bio-based refineries Case Study Biorefinery Leuna Uwe Welteroth Director Biotechnology Plants Linde-KCA-Dresden GmbH
2 IEA-Bioenergy Task 42 Biorefinery German Workshop Worms, September 15th, 2009 Agenda From fossil- to bio-based refineries Key drivers Status and development trends From TODAY'S bio-based production to FUTURE integrated Biorefineries Vision "Biorefinery Leuna" "Bioethylene" as an example for the integration into the value chain Why Bioethylene? Future integrative scenario Conclusion & Outlook Linde-KCA-Dresden GmbH 2 August 2009/Uwe Welteroth
3 From fossil- to bio-based refineries Key drivers Feedstock change trend to renewable raw materials securing supply (shortage of fossil feedstocks) rising costs of fossil feedstocks autonomy of supply Sustainability neutral/positive C02-balance energy, water, resources, environmental burdon Political will to establish a bio-based economy in Europe to keep Europe in a leading position in White Biotech to support European agriculture Triple P principle Economics new/innovative products cheaper production processes Linde-KCA-Dresden GmbH 3 August 2009/Uwe Welteroth
4 From fossil- to bio-based refineries Status & development trends Use of renewable raw materials TODAY FUTURE trends A 1G Biorefineries (e.g. Bioethanol, starch, pulp & paper) Source: Press photo Südzucker 2nd/next generation Biorefineries B (petro)chemical sites with individual biotech plants Source: Press photo BASF fully integrated biotechnological and chemical production sites Linde-KCA-Dresden GmbH 4 August 2009/Uwe Welteroth
5 From TODAY'S 1G bio-based refineries to FUTURE Biorefineries A expansion of raw material basis LC biomass new integrative plant concept improve efficiency improve sustainability Quelle: Pressefoto Südzucker expansion of product range chemical intermediates Linde-KCA-Dresden GmbH 5 August 2009/Uwe Welteroth
6 From TODAY's chemical sites to FUTURE integrated bio/chem sites Leuna as an example B Leuna chemical site Refinery at night Site internal network companies and major feedstock/product lines Linde Gas/Linde Gas shareholder Source of picture and diagram: Infraleuna Infraleuna owner & operator of Infrastructure/utilities facilities on site Linde-KCA-Dresden GmbH 6 August 2009/Uwe Welteroth
7 Leuna chemical site infrastructure & service on site Advantage for bio-based processes upon integration: use of existing site facilities (infrastructure, utilities, services) integrated energy concept support in approval processes Site boundary Production units and service provider on site Power plants Road Terminals Rail Stations Pipe racks Energy production and distribution Vehicle cleaning service Water supply Logistic service Waste water ZAB Waste Disposal Road Fire brigade Security Security and emergency management Site coordination Site development Facility management Communication Medical Service cheaper than greenfield investment! Laboratory Road Rail National grid River Saale Source: Infraleuna Linde-KCA-Dresden GmbH 7 August 2009/Uwe Welteroth
8 Vision Biorefinery Leuna Integration of Bioethylene in the value chain Crude oil Natural Gas Ammonia Ethylene Glues DMF Catalysts NaHS MMA Formaldehyde Amines Lubricants Surfactants Resins H 2 S Methanol Ethanol Butanol etc. CO Bio-oils -surfactants Glycerin Epichlorohydrin Complex Chemicals Refinery Methanol Methanol H 2 H 2 S 8 H 2 Propylen O 2 N 2 O 2 CO 2 H 2 Aromatics Enzymes Proteines etc. Air separation plant Caprolactam, Polyamide 6, Fiber production Bioethylene New Investors PA- Compounds PA 6 / PA 6.6 CO 2 EBS LDPE PE-Wax Steamreformer Hydrogenperoxide EVA- Copolymere, Additives Fine Chemicals Plasticdispersions Bio- Refinery Powerplant Sugar, Starch, Cellulose, Hemicellulose, Lignin, Algae, etc. I N F R A S T R U C T U R E Source: InfraLeuna Linde-KCA-Dresden GmbH 8 August 2009/Uwe Welteroth
9 Expansion of the product range Ethanol as Biofuel or building block for chemical intermediates Lignocellulosic Biomass 1. via enzymatic treatment and fermentation 2. via gasification and syngas fermentation Cellulosic Ethanol BIOFUEL CHEMICAL BUILDING BLOCK Ethylene Acetic acid Acetaldehyde others Chemicals & Polymers Linde-KCA-Dresden GmbH 9 August 2009/Uwe Welteroth
10 Ethylene market a heterogeneous business with potential for renewable raw materials Bioethylene t/a ethylene Mega plants 1 m t/a ethylene ~ 1 bn invest volume ca /t when transported by pipeline and in between? ca /t when produced on site with a kta plant Container & Cylinder < t/a ethylene + liquefaction/filling (300 /t) + transport (400 /t) around /t when transported by trucks Linde-KCA-Dresden GmbH 10 August 2009/Uwe Welteroth
11 Biorefinery potential future integrative scenario for Leuna first project phase - 2G Bioethanol plant central module Existing Production in Leuna Refinery / Linde Gas / Polymers / Chemicals Biomass Disintegration 2G Bioethanol Plant Ethanol Production 20 kta 12 kta Bioethylene 18 kta 30 kta Bioethylene Existing Infrastructure InfraLeuna 30 kta Ethanol purchase Linde-KCA-Dresden GmbH 11 August 2009/Uwe Welteroth
12 Biorefinery potential future integrative scenario for Leuna future extension adjustment to the needs of the site Existing Production in Leuna Refinery / Linde Gas / Polymers / Chemicals Step 1 Biomass Disintegration 2G Bioethanol Plant Ethanol Production Bioethylene Existing Infrastructure InfraLeuna 2G Bioethanol Plant Step 2 Biomass Disintegration Ethanol Production Linde-KCA-Dresden GmbH 12 August 2009/Uwe Welteroth
13 Integration bioethanol & bioethylen Real life scenario Linde-KCA-Dresden GmbH 13 August 2009/Uwe Welteroth
14 Conclusion & outlook Future trend - from fossil based sites to integrated next generation Biorefineries Fossil based refinery Challenge bio-based highly integrated mature technologies technology development well known fossil raw materials complex new raw materials established products and value chain partially new products for value chain Option: replacement of fossil-based refineries by new large-scale greenfield biorefineries? feasible short to midterm solution: Integrative bio/chemical "Verbund" concept tapping the full synergy potential of existing sites an ideal place: the Leuna Biorefinery Linde-KCA-Dresden GmbH 14 August 2009/Uwe Welteroth
15 Thank you for your interest. Uwe Welteroth Director Biotechnology Plants Phone +49.(0) Fax +49.(0) LINDE-KCA-DRESDEN GMBH Bodenbacher Strasse Dresden Germany
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