Biorefinery, the bridge between Agriculture and Chemistry Gent 19 September 2005 Johan Sanders Professor Valorisation of Plant Production Chains Wageningen University and Researchcenter
Energy consumption in 2050 three times larger than today 300 Mean energy use per head of the population (GJ/j) Dutch 2000 American 2000 200 100 59 2050 prosperity level Chinese 2000 world population 2000 world population 2050 2000 Total 350 EJ 0 Total 1000 EJ 0 6 billion world population 10 billion
Biomass can have different applications and contributions.. Integral cost prices ( /GJ end product) Raw material cost fossile ( /GJ) Netherlands energy is 3000PJ Heat 4 3 (coal) +/- 20% Electricity 22 6 (coal) +/- 20% Transport fuel 10 8 (oil) +/- 20% Average bulk chemicals Rest 75 30 (oil) +/- 20% +/- 20%
Biomass can bring different contributions to the farmer ( /ha) Assuming a yield of 10 tonnes dry weight per hectare, being 160 GJ, (or 20 tonnes whole crop yield, 320 GJ/ha) /hectare All Energy at coal value : 640 --- All transportfuel :1360 --- All bulkchemical :6400 --- 20% bulkchemical, 80% Energy :1800-3600 20% bulkchemical, 20% fuel, 60% Energy :1940-3880 Using all crop and good agricultural practices up to double values could be obtained
The separated components of grass value 700-800 /ton as compared to 50 70 /ton raw materials Fresh grass Fresh grass % water 85 Dry substance 15 water 80-90 % dry substance 10-20% Fiber 30 Protein/amino acids 20 Polysaccharides 15 Minerals 10 Mono/di-saccharides Oligo- 9 Organic acids 5 Lipids 3 Oligosaccharides 3 saccharides 3% 1500 Lipids 3 % 120 100 2000 80 Organic 60 40 acids 5% 2000 0 1 Mono/di- water Dry substance saccharides 9 % 150 Fibers 30 % 100 Protein / Amino acids 20 % 1000 Minerals 10 % 500-1000 Polysaccharides 15 % 1500
Pilot biorefinery line Foxhol (Groningen) (Prograss Consortium) Grass protein (products) white grass protein Protein compound feed Green grass protein Grass juice concentrate Grass juice Fibers Fibers compound feed Ethanol +... Potting soil Construction material + paper Polymer extrusion products
New routes to industrially important diamines 1,2-Ethanediamine : rubber chemicals, pharma, lubricants,detergents Biomassa H 2 NCH 2 CH 2 OH COOH Nafta O 2 O NH 3 H 2 NCH 2 CH 2 OH NH 3 H 2 NCH 2 CH 2 NH 2 CH 2 CH 2 Cl 2 ClCH 2 CH 2 Cl NH 3 H 2 NCH 2 CH 2 NH 2 1,4-Butanediamine: polymers e.g. nylon-4,6 H 2 NCH 2 CH 2 CH 2 CH 2 NH 2 C NH 2 NH 2 Nafta H 2 C=CHCH 3 + NH 3 + 1.5 O 2 H 2 C=CHC N + CH 4 + NH 3 HCN H 2 NCH 2 CH 2 CH 2 CH 2 NH 2 Urea COOH Biomassa
Costs breakdown of Bulkchemicals ( /ton) at 40$/bbl non-functionalised functionalised Raw materials 200 650 Capital 300-500 400-650 Operational 50 50 Recovery 50-100 50-100 Total 1300 725
Functionalised chemicals can be made from Biomass without major enthalpy differences, but not from naphtha C x H y naphtha C x H z N C x H y C x H z N amine C x H z O y (OCH z ) v lignin C x H y O z oil / fat Enthalpy Oil / gas Petrochemical way one raw material C x H z O chemicals many products C x H z O y NS v protein C x H z O y Biomass carbohydrate Biorefinary way many raw materials
Biorefining will give Mitigation under Economic conditions (125 M hectare = 0,8 % world land area) electricity (750000M W) (10%) electricity (750000MW) (10%) electricity (3 x 10 6 MW) (40%) fuels (375 Mton) (15%) platformche micals (250 Mton)(100%) fuels (250 Mton) (10%) 75 billion 97 billion 180 billion 60 /ton biomass 80 /ton biomass 140 /ton biomass minus 1200 Mton CO 2 minus 1200 Mton CO 2 minus 1500 Mton CO 2
Developments that will improve the biomass route Lower raw material prize better refinery technologies GMO to tailor make products new material-properties small scale technology and integrations that can give more income to the farmer
Using the potential components of Potato
Lysine (%) in mature transgenic potato tubers
Project: BIOFOAM (EU KP5, QLK-1999-01298) Goal: Development of new polymers (poly(ester)amide) based on renewable feedstocks for industrial foam applications Results Successful integrated synthetic route(s) from a biobased origin: 1,2-ethanediamine, 1,4-butanediamine, 1,2- ethanediol, 1,4-butanediol, adipic acid, ε-caprolactone. Monomer quality (purity) acceptable for polymer applications Successful polymer formation for foam applications.
Small scale (pre) processing technology Advantages less transport short recycle streams new integrations (energy, organisation, labour,..) product and chain innovations Disadvantages: Economy of scale? Examples: cassave grass multifold application of energy?
Forward integration reduces tranport cost and seasonality and will give more income to the farmer Fields Farm Processing Present 100% 100% Return flow 10% Concept 100% Small scale processing 30% Return flow 70%
Small scale offers innovative heat generation Today 1 60 TJ Gas 30 TJ electricity heat 4000 ton concentrated alcohol (often much bigger) 60 TJ Today 2 30 TJ electricity food & flowers 60 TJ 60 TJ Gas heat 2 ha & 30 TJ heat loss Small scale integration 60 TJ Gas or biomass 30 TJ electricity heat heat 4000 ton concentrated alcohol 60 TJ (or 4000 tonnes of biomass waste) food & flowers & 2 ha 30 TJ heat loss
Mobile Cassava starch refinery in Africa Source: Duteso
Conclusions Biorefinery increases the value of the individual biomass components (cf Pigs are not converted all to meatballs!) (platform) chemicals can be derived from biomass under economic conditions. For the moment functionalized chemicals offer the best chances to compete with petrochemical processes New materials derived from biomass will always be attractive if their properties are unprecedented Small scale (pre)processing offers economic advantages and potential forward integration to the farmer
Afsluiting Wageningen UR
Benutting van bulkchemicaliënwaarde verhoogt grondstofwaarde van biomassa van 60 naar 140 /ton Eindwaarde (G ) (fossiel) grondstof waarde Fossiel J/y input Mtonnen biomassa input /ton biomassa Bulkchemicaliën 375 90-120 15-20 250 360-480 Ethanol 75 45 7.5 500 90 Elektriciteit 80 30 7.5 500 60 Totaal 525 65-195 30-35 1250 130-150 6 /GJ = 50 $/bbl 4 /GJ = kolen
There will be enough Biomass for 15% energy substitution (2050) % landarea WW EJ/year Non collected Straw (50 %) 12* 75 Collected waste processing (50 %) 12* 45 Invisible losses (50 %) 15* 75 Forest / pastures (10 %) 2* 150 Dedicated Crops land (sea) (3 %) 3 (1 %) 300 (300) Total 12-20 * 645 (945) * More or less the same area Total energy required (2050) 1000 EJ