The development of the Biorefinery and the SUSTOIL project

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1 The development of the Biorefinery and the SUSTIL project Ray Marriott Green Chemistry Centre of Excellence University of York

2 Contents Biorefinery evolution The SUSTIL project Project objectives Preliminary data Future developments

3 Biorefineries Integrated facilities that can convert a variety of renewable feedstocks into energy, chemicals and other valuable materials cleanly and efficiently maximising the value of the biomass and minimizing waste Feedstock(s) biological raw materials Food and feed grain Ligno-cellulosic biomass Waste Environmentally benign Processing Technologies Green Chemical Processes Bio-processes Thermal processes Physical processes Food, chemical products and energy

4 Biorefinery evolution Raw material should be readily available from the local area Most biorefineries are predicated on a single main product stream By-products are crucial to the viability of the refinery even if they are low-value commodities Increasing economic viability can be achieved by adding value to the by-products

5 Phase 1 Biorefinery (ethanol) (Fixed processing capabilities) Corn Hammer mill Cooker Energy Fermentation Yeast + C 2 Centrifuge Distillation Dryer Bioethanol DDGS

6 Bioethanol economics (Corn) Average data from six US bio-ethanol plants

7 Phase 1 Biorefinery (biodiesel) (Fixed processing capabilities) il seed rape Seed Pretreatment Seed meal Methanol + catalyst Transesterification Methanol recovery Crude glycerine Glycerine refining Crude Biodiesel Refining Glycerine Biodiesel

8 Phase II Biorefinery (Flexible processing capabilities single source) Cereal grains single feedstock Multiple products Physical separation Pre treatment Enzymatic process Fermentation Chemical and/or biochemical catalysis Multi processes Hydrocolloids Polymers Vitamins Amino acids Platform molecules Biofuels

9 Phase II Biorefinery (Flexible processing capabilities single source) Corn Biorefinery patent: W

10 Phase III Biorefinery Most developed biorefinery Mix of biomass feedstocks Wide range of products Combination of technologies The Whole Crop Biorefinery (WC-BR) - cereal, maize, rape The Green Biorefinery (G-BR) - green biomass such as grass, lucerne and clover The Lignocellulose Feedstock Biorefinery (LCF-BR) - dry lignocellulosic biomass such wood, straw, corn stover, etc. Phase III biorefineries are mostly still in research and development

11 Phase III Biorefinery LCF BR Processum (Sweden) Beverages Extraction solvent Textiles Concrete additive Paints Coatings Bioethanol Ethyl acetate Acetaldehyde Acetic acid

12 Whole Crop Integrated Biorefineries FRAMEWRK 7 - AREA ENERGY.3.3: BIREFINERY (Ends May 2010) Expected impact: Expand range and volume of bio-products on the market Improve the economics of bio-refinery plants ptimising their energy and environmental performance Enhance the cost-competitiveness of bio-fuels. Deployment of integrated bio-refineries is expected beyond 2020.

13 Whole Crop Integrated Biorefineries

14 SUSTIL Bio-refinery (Biodiesel from SR) Yield improvement Separation technologies New products and markets Extraction of Valuable metabolites Fibre products ptimised Sugar extraction il seed rape SR Straw Digestion Fermentation Distillation Seed Pretreatment il extraction Transesterification Crude glycerine Glycerine refining Glycerine Crude Biodiesel Refining Seed hulls Seed meal ptimised catalysis Sterols Tocopherols Anaerobic digestion Methane New products and markets Bioethanol New products and markets Platform molecules Biodiesel

15 SUSTIL Bio-refinery (Biodiesel from SR) EU is the largest producer (18mt) 70% of all oilseeds Average EU yield t/ha China & Canada = 1.8 t/ha India = 0.8 t/ha Realistic potential = 6.5 t/ha (Berry & Spink 2006) 9.2 t/ha where water not restricting Doubling yield in countries currently above EU average = extra 12.4 m tonnes

16 SUSTIL Bio-refinery (Biodiesel from SR) Finland Estonia Italy Spain Latvia Greece Romania Lithuania Bulgaria Slovakia Hungary Slovenia Sweden Poland France Czech R Austria UK Belgium Denmark Ireland Germany Netherlands EU average yields (t/ha)

17 SUSTIL Bio-refinery (Biodiesel from SR) Improving yield Address Sulphur deficiency Maintaining rotational gaps (> 1 in 3) Increase seed number by optimising resource capture Bring flowering forward Reduce light interception by flowering canopy Increase leaf area (photosynthetic area) Develop improved cultivars

18 SUSTIL Bio-refinery (Biodiesel from SR) Fermentation Densification Extraction C 2 C12 Fatty acids H C18/ C18:1 Fatty alcohols H C29 C18:2 Alkanes C31 C33 C28 Sterols H unknown Wax esters Digestion C14 C16 C18:3 C20 C22 C24 C26 C24 Functional extracts

19 SUSTIL Bio-refinery (Biodiesel from SR) Seeds Cleaning Cracking Dehulling Flaking PREPARATIN Flakes Cooking Pressing Cake Hexane Pressing oil Pelletizing Extraction EXTRACTIN Marc Miscella Desolventisation Distillation Meal Pelletizing Extraction oil Pellets Crude oil

20 Hulls SUSTIL Bio-refinery (Biodiesel from SR) Valorising seed hulls and meal Rapeseed 15 % of proteins - possible use as substitute of dehydrated alfalfa Lignocellulosic fraction - biofuels Seed cake Proteins - 44 % of defatted kernel mass Phenolic compounds ligosaccharides Glucosinolates Direct HTP thermoforming

21 SUSTIL Bio-refinery (Biodiesel from SR) ptimised biodiesel production and by-product streams

22 SUSTIL Bio-refinery (Glycerol as a C3 building block) H H H H H H C 2 H Glycidol 1,3-Propanediol H H 3 C Propylene glycol Glyceric acid H R 2 H Propanol CH 3 H Glycerol H R 1 Mono-, di-, or triglycerate R 3 H H H Diglyceraldehyde H Glycerol carbonate H H Branched polyesters and nylons Applications: Humectant, plasticizer, emollient, thickener, solvent, dispersing medium, lubricant, sweetener, bodying agent, antifreeze, and processing aid.

23 Summary Economic viability of Biorefineries can be substantially improved by diversification at all levels A wider range of feedstocks and products increases competitive advantage and financial security Some process technologies still need to be improved further but we are getting there SUSTIL will provide information on improving existing process facilities and in the design of future biorefineries

24 Green Chemistry Centre of Excellence Thank you for your attention

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