Marine Biorefineries

Transcription

1 Marine Biorefineries Maria Barbosa, René H. Wijffels, Contents Marine Biorefineries Microalgae and Seaweeds Products Current Markets Potential Microalgae Required developments: Feedstock & biorefinery Seaweeds Required developments: Feedstock & biorefinery Conclusions 1

2 The blue revolution? Today we are at sea still in the phase of hunting, sampling, mining and dumping like years ago at the land side! Marine environment: 70% of plant biomass is living in the sea Most of its biodiversity is unknown Promising new compounds, substances in pharmacy, personal health care and chemical industry are extracted from marine organisms The sea belongs to nobody and so everybody; its governance is regulated by international treaties Drivers for marine biomass The limitations of agricultural land and the impacts of global climate change on agricultural productivity are factors of increasing relevance in the decisions that must be taken on land use for food, feed, chemicals and energy. Clearly, this increasing competition for land is driving the current consideration of the potential of the aquatic environment for the production of biofuels and industrial feedstocks. 2

3 Biomass 7 10 TW 1.28 x m 2 50 % of total earth's arable land used for biomass Earth land area 29% Earth water area 71% Time to look at the water!? Microalgae and Seaweeds No competition for arable land High areal productivities Production of a wide range of biobased products + energy 3

4 Algal products Hydrocolloids Colorants Algal production, products and market values Market value in US$ Bio Seaweeds Mio t 10,000 t 6 Micro-algae Seaweeds market values in US$ Bio per category hydrocolloids others nori 0.4 Micro-algae market values in US$ Bio per category others 0.4 carotenoids nutraceuticals aquaculture food 1.5 bio-oils (DHA) 4

5 Applications and world market values Application Genus Whole sale Aquaculture Feed Isochrysis Colorants Heamatococcus US$ 1.2 Bio Pharma, nutraceuticals & cosmetics Vitamins Chlorella, Anthrospira Tocopherols Bio oils (DHA, EPA, ARA) Macrocystis, Lessonia US$ 10 Bio Drugs and toxins Lyngbya, Porphyridium Care Chlorella, Anthrospira, Muriellopsis US$ 150 Mio Carotenoids, xanthins, phycobilins Dunaliella US$ 1.4 Bio Bioremediation Organic pollutants Chlorella, Ankistrodesmus, Scendesmus Heavy metals Sargassum CO 2 sequestration & mitigation Exhaust treatment Chlorococcum, Chlorella Energy Biomass Spirulina, Chlorella, Dunaliella, Nostoc, Aphanizomenon Bio Fuels Botryococcus, Phaeodactylum Bio Gas Bio methane Macrocystis, Gracilaria, Sargassum, Laminaria Bio hydrogen Chlamydomonas Materials Food colorants Dunaliella, Heamotococcus Industrial pigments Silica Research Human food Polymers (hydrocolloids) Euchema, Kappachycus, Laminaria, Ulva US$ 600 Mio Diatoms spp. Nori Porphyra US$ 5 Bio Specialized and others Odontella US$ 5 Bio Microalgae Does not compete for land suitable for agriculture irrigation or consumption by humans or animals > Food security High areal productivity Great variety in species > variety in products! Possibility to steer metabolism to production of specific compounds Ability to accumulate large amount of oils CO 2 mitigation Recycling nutrients 5

6 6/17/2009 Microalgae: Importance of a biorefinery approach Varied and high quality composition of biomass Economic need to optimise valorization of the biomass by extraction of multiple products in addition to e.g fuels Feedstock 9 Economic need: 2007 Delta Feasibility Study Raceway ponds Horizontal tubes Flat panels 6

7 Feedstock Economic need: 2007 Delta Feasibility study 1 ha Labor 28% Power 22% / kg biomass 100 ha Power 42% 4.02 / kg biomass 89% decrease Centrifuge w estfalia separator AG Centrifuge Feed Pump Medium Filter Unit potential Medium Feed pump Medium preparation tank Harvest broth storage tank Seaw ater pump station Automatic Weighing Station w ith Silos Culture circulation pump Installations costs Instrumentation and control Piping Buildings Polyethylene tubes Photobioreactor Culture medium Carbon dioxide Media Filters Air filters Pow er Labor Payroll charges Maintenance General plant overheads 0.4 / kg biomass 15 /GJ Feedstock The economic need: conclusions Sensitivity analysis show that biomass production costs can be further decreased from 4 to 0.4 /kg Power input is the main constrain in photobioreactors Parameters that need improvement Mixing system / efficiency Photosynthetic efficiency reactor design cultivation conditions strain development / screening Integrate processes Harvesting Positive energy balance still needs to be reached 7

8 Bulk chemicals and biofuels in 1,000 kg microalgae 400 kg lipids 100 kg as feedstock chemical industry (2 /kg lipids) 300 kg as transport fuel (0.50 /kg lipids) 500 kg proteins 100 kg for food (5 /kg protein) 400 kg for feed (0.75 /kg protein) 100 kg polysaccharides 1 /kg polysaccharides 70 kg of N removed 2 /kg nitrogen 1,600 kg oxygen produced 0.16 /kg oxygen Production costs: 0.40 /kg biomass Value: 1.65 /kg biomass Food proteins 500 Biofuels 150 Chemicals 200 Feed proteins 300 Oxygen 256 N removal 140 Sugars 100 Present One process for one product 8

9 Specific developments required for a microalgae biorefinery Development of mild and efficient cell disruption, extraction and fractionation technologies Effective technologies for separation of carbohydrates, proteins and lipids Lipid /oil refining technologies Improvement of energy consumption and environmental performance, decrease of capital costs Integrate knowledge & facilities for oil, food and fine chemical industry Biomass provision (quantity and quality) Chain Approach: from feedstock to end products 9

10 Initiatives for the future: LG SMART (EU FP7) Let s Get Smart with Micro Algae Refining Technologies Feedstock Producer Processor Different Industry Sectors Hydrocarbons (only for Botryococcus Cracking Fuel distillate Esterification Biodiesel Lipids Lipids Separation Cracking Fuel distillate PUFAs (only for Phaeodactylum) Microalgae production Harvest & Primary Separation Protein Concentrate Separation Functional Protein Fractions Fundamental & applied Research Technology Development or upgrading Remaining Cell components Separation Carbohydrates Cell wall components Fermentation Anaerobic digestion Novel Process Bioethanol Biogas Silica Nanoparticles Biopolymer Not addressed in this project Legend: Initiatives for the future: LG SMART (EU FP7) Let s Get Smart with Micro Algae Refining Technologies Feedstock Producer Processor Different Industry Sectors Hydrocarbons (only for Botryococcus Cracking Fuel distillate Lipids Esterification Energy Biodiesel Lipids Separation Cracking Fuel distillate PUFAs (only for Phaeodactylum) Microalgae production Harvest & Primary Separation Protein Concentrate Functional Food;Feed;Aquaculture Separation Protein Fractions Fundamental & applied Research Technology Development or upgrading Not addressed in this project Remaining Cell components Separation Carbohydrates Cell wall components Energy Fermentation Anaerobic digestion Bioethanol Biogas Silica Nanoparticles Biopolymer Novel Process Nanotechnology Legend: 10

11 Biorefinery: Make value from protein Isolation of pure and native protein from microalgae for food applications Characterization and fractionation of the isolated protein Test techno-functional properties of isolated protein fractions and its possible applications as a food ingredient Challenges High CAPEX and energy consumption for cultivation, harvesting and product separation Current process technology does not allow the production of multiple products Lack of trained personnel Product development to commercial application Regulatory approval for use of algae in feed/food is lacking Broad consumer acceptance of algae and seaweeds in food The full range of potential products, best combinations and their market values is unclear 11

12 Algae Pilot Production and Development Center Development of a process chain Experience with systems Information for design of full scale plants Comparison of systems Comparison of strains Comparison of feeds (nutrients, CO 2, sunlight ) Supply of biomass for further processing Further processing Seaweeds: Present and Future Biomass Present Chemicals Future Direct consumption Polysaccharides (alginate, agar carrageenan) Chemical buillding blocks replace oil derivatives Bio based economy Fertilizer (maerl) CO 2 fixation High value compounds (nutraceuticals, cosmetic, personal care) Fermentation (ethanol, butanol, citric acid, butyraldeyde, glycerol, lactic acid 12

13 Seaweeds: Importance of a biorefinery approach High quality composition of biomass Economic need to optimise valorization of the biomass by extraction of multiple products in addition to e.g fuels Economic need Biomass Production Costs Cultivation System Multilayer system Strains Local strains e.g. North Sea strains Palmaria (red), Ulva (green), Laminaria (brown) Productivity Substrate availability Light Intensity Feeding System Operating, Harvesting Transport, processing Automatic harvesting Dewatering at sea Processing 13

14 Economic need: Biomass Production Costs Break even seaweed production cost or Seaweed production cost ( / ton DW) Combination of products / functions is comandatory! Methane Electricity Bioethanol + Electricity HTU Tidal flat farm Gracillaria / Ulva 30 ton / ha/ yr Super Critical Gasification Gracillaria / Laminaria Cultivation on line offshore 59 ton DW / ha / yr Floating Cultivation Sargassum 66 ton /ha/ yr Macrocystis cultivation neashore 57 ton DW / ha / yr Seaweed production in Europe In several European countries (Ireland, Norway, France, Spain) production processes are based on harvesting natural populations. There is currently no seaweed production in the North sea 14

15 Challenges Dewatering without loss of valuable ingredients (offshore) Pre treatment extraction of secondary high value metabolites without losing much energy and biomass Improvement of existing technologies for extraction of hydrocolloids, with respect to costs, energy use and environmental performance Development of technology for new applications (e.g ethanol fermentation) Selection, up scaling and process integration Ecological impact Public acceptance Development of new innovative markets Process, Products and Energy Whole Biomass Consumption Fertilizer Seaweed Extraction Chemicals Residue dried Fermentation HTU Hydro Thermal Upgrading Food Feed Personal health care Pharmacy Gasification Energy carriers Electricity and heat 15

16 Product valorisation Carrageen, alginates, agar Purification of waste water from the refinery process recovery of minerals Methane purified to gas grid quality Ethanol dewatering Bio crude further upgrading (existing commercial plants) Conclusions Marine biomass has the potential to offer a wide range of biobased products and energy. Economic feasibility requires a biorefinery approach Technology still needs to be developed or further upgraded to produce a wide variety of products in the same process (both for feedstock cultivation and processing) Market development and public acceptance are important issues that need to be dealt with 16

17 Thank you for your attention! Wageningen UR 17