Overview about green biorefineries in Europe: the Biowert concept of biocomposites

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2 The SMIBIO project is implemented in the framework of ERANet-LAC, a Network of the European Union (EU), Latin America and the Caribbean Countries (CELAC) co-funded by the European Commission within the 7th Framework Programme for Research and technology Development (FP7). The sole responsibility of this publication lies with the author. The European Union is not responsible for any use that may be made of the information contained therein. Small-scale Integrated BIOrefineries IV REUNIÓN NACIONAL DE LA RED TEMÁTICA EN BIOENERGÍA XIII REUNIÓN NACIONAL DE LA RED MEXICANA DE BIOENERGÍA "3ER Taller SIMBIO Overview about green biorefineries in Europe: the Biowert concept of biocomposites 15 November 2017 Cuernavaca Mexico Ingo Ball WIP Renewable Energies

3 Content Biorefinery definition, classification Grass information Value pyramid Existing GBR in Europe NewFoss Grassa Biofabrik Biowert 3

4 Biorefineries - definition Definition : Biorefining is the sustainable processing of biomass into a spectrum of marketable Biobased Products and Bioenergy. Biobased Products: chemicals & materials, but also human food & animal feed Bioenergy: fuels, power and/or heat In general both Energy-driven and Product-driven Biorefineries can be distinguished. Product-driven Biorefineries The main goal of PdBs is the production of one of more Biobased Products chemicals, materials, food and/or feed from biomass. Process residues are used for the production of Bioenergy for internal/external use to maximise the economic profitability of the full biomass-to-products chain. IEA Bioenergy Task 42 21/11/2017 4

5 Green biorefineries Green biorefineries (GBR) are seen as integrated technologies and technology systems for production of materials and energy processing of green plants and part of green plants. The potential of this feedstock is considered to being large, as green plants are an almost inexhaustible raw material source and available worldwide. Kamm et al. (ed.), 2010: /11/2017 5

6 Biorefinery classification IEA Bioenergy Task 42 biorefinery classification system (IEA Bioenergy, 2014: 4) 21/11/2017 6

7 Green biorefineries - basic processes Primary refinary (Silage production) Wet fractionation technology (isolate substances in native form) Separation by mechanical pressing into: - fibre-rich press cake - nutrient-rich press juice Secondary refinary Press juice and press cake > further processing press juice: direct use in a biogas plant fractionation of component substances (e. g. lactic acid, amino acids, proteins) by separation technologies press cake: directly processed into animal feed raw material for fibre-based products (insulation materials, fibres for bio-composites) co-substrate in biogas plant GBR is typically coupled with biogas plant > recovery of residual parts (from press cake, press juice or fibre processing) Kamm et al. (ed.), 2010: /11/2017 7

8 Grass - what s in it? Grass consists mainly of water. ca % of the grass is dry matter (DM), with a yearly average of 16.3% DM DM mainly consists of protein, amino acids, carbohydrates, minerals and fats [g/kg DM] the average crude protein content is 23% of the dry matter. most abundant protein is called ribulose-1,5-bisphosphate carboxylase oxygenase, or simply Rubisco presence of polyphenol oxidase (PPO) and proteases in grass (enzymes that break down other proteins) essential that after cutting, the grass is either processed rapidly or preserved well enough to prevent degradation largest component of DM of grass is the fibre fraction. It includes cellulose, hemicellulose and lignin molecules annual production of 10.4 t DM per hectare (Europe, the Netherlands) Source: Paping et al /11/2017 8

9 Value pyramid 21/11/2017 9

10 General information - GBR in Europe All GBR but the Biowert GBR are relatively new Viability of new concepts need to be proven first Keypoints: Feedstock availability (amounts, logistics) Instant use vs. Conservation Control of decomposition processes 21/11/

11 NewFoss GBR NewFoss Location: Uden, the Netherlands Founded: 2016 Feedstock: silage grass (grass is provided by Staatsbosbeheer) Capacity: 10,000 t dm /a (40,000 t grass per year) Investment costs: n.a. 21/11/

12 NewFoss the process 21/11/

13 NewFoss the products Huthamaki egg boxes & Co. Egg boxes Grass paper Lactic acid, amino acids, sugars etc. 21/11/

14 NewFoss the products Benefits of NewFoss product (50% grass fibres, 50% recycled paper) 10% less CO 2 emissions (per ton paper produced) 50% less water needed in paper production No feed competition (used grass is made up of 100 different plants > not suitable for feed production) 21/11/

15 Grassa GBR Grassa Location: mobile concept, the Netherlands Founded: 2014 Feedstock: fresh grass or green feedstock (e.g. tomato stems, waterplants) Capacity: kg per hour Investment costs: ca. 600,000 Euro Runtime: 5 months of year (3,000 hours, diversification of feedstocks to lengthen season) 21/11/

16 Grassa mass balance 21/11/

17 Biofabrik GBR Biofabrik Location: Blizevedly, Czech Republic, and Dresden, Germany Founded: 2014 Feedstock: silage grass Capacity: 20 t/day Investment costs: ca. 700,000 Euro Based on Austrian study ( ) 21/11/

18 Biofabrik the process 20 t/d Ion exchanger 5 t/d Product 1 Product t/d Product 3 21/11/

19 Biofabrik the products Fertilizer product Blattwerk (GHX) Amino acids for food supplements 21/11/

20 Biowert GBR Biowert Location: Brensbach, Germany (18,000 m 2 large) Founded: 2007 Feedstock: silage grass (grass is provided by contracted farmers nearby) Capacity: 5,000 t dm /a (20,000 t grass per year) Investment costs: 13 million Euro 21/11/

21 Biowert GBR some facts Cradle-to-Cradle concept all materials are either renewable (i.e. grass) or from recycling processes Source: 21/11/

22 Biowert GBR some facts eldest biorefinery in Germany (2007) initial life cycle assessment was already carried out in 2010 (ISO ) based on the Biowert concept, an industrial directive was elaborated (VDI 6310) Products: grass fibre insulation (AgriCell) natural fibre reinforced plastic (AgriPlast 75% grass fibres, 25% recycled plastic) fertiliser made from digestate (AgriFer) and electricity and heat energy (biogas plant) Source: 21/11/

23 Biowert GBR technical facts annual throughput of 5,000 t dry matter per year integrated biogas plant 2 downstream combined heat and power (CHP) plants - electrical output of 1.4 Mw el electricity is used by the plant to cover its electricity demand surplus heat from biogas plant is used for the plant s heat demand all used water comes from grass and biomass of the biogas plant water is returned to the grass biorefinery in a closed-loop (no fresh water from system needed) no waste water or residues from the processes Source: 21/11/

24 Biowert GBR technical facts Source: grass storage (encircled red) in own bunker silos (to produce silage grass ) waste water (from storage) is fermented directly in the biogas plant Source: 21/11/

25 Biowert the process 21/11/

26 Biowert GBR economic information 2 CHP plants: approx. 10 GWh el per year (assuming 7,000 working hours 9.8 GWh) possible production shift from AgriPlast to AgriCell >flexibility ca. 50% of dry matter can be converted into AgriPlast or AgriCell > 2,500 t per year Assumption: all output into AgriPlast terrace boards: 80 /m mio (ca. 80 /m2, weight m2: 18.6 kg (3,333,300 kg/18.6 kg/m2 = 179,210 m2) (179,210 m2 * 80 /m2= 14.3 mio ) Sources: ; ; own calculation 21/11/

27 GBR in value pyramid Biofabrik Grassa Biowert NewFoss 21/11/

28 GBR possibilities in Mexico Research about green feedstock. Else? 21/11/

29 The SMIBIO project is implemented in the framework of ERANet-LAC, a Network of the European Union (EU), Latin America and the Caribbean Countries (CELAC) co-funded by the European Commission within the 7th Framework Programme for Research and technology Development (FP7). The sole responsibility of this publication lies with the author. The European Union is not responsible for any use that may be made of the information contained therein. Small-scale Integrated BIOrefineries Gracias por su atención Contact: Ingo Ball (ingo.ball@wip-munich.de