ETHANOL FROM RECYCLED FEEDSTOCKS 27 November 2012 TEKES Biorefine Final Seminar, Marina Congress Center Esa Sipilä Pöyry Management Consulting
CONTENTS What is FibreEtOH? Status of technology Competitiveness of waste based ethanol Future vision of Urban Biorefineries Paper machine Power plant Waste treatment Pulping Ethanol production Biogas production and waste water treatment ETHANOL FROM RECYCLED FEEDSTOCKS 2
FIBREETOH CONCEPT IS BASED ON UTILISING INDUSTRIAL SIDE STREAMS AND WASTE FIBRES Picture source: UPM ETHANOL FROM RECYCLED FEEDSTOCKS 3
DEVELOMENT PATH FOR FIBREETOH -CONCEPT Concept idea has been developed since 2006 where the role Tekes was highest in the beginning. Now the development is going towards first demonstration plant supported by European Commission. Piloting and Demonstration First Commercial Unit at Paper Mill Dissemination of Commercial Units in Europe Concept Identification Proof of Concept and Feasibility Consortium members Kemiinformation Ab 2006 2008 2010 2020 ETHANOL FROM RECYCLED FEEDSTOCKS 4
FIBREETOH EU DEMONSTRATION PROJECT UPM has been leading a project consortium called FibreEtOH to demonstrate waste-to-ethanol technology Current project called FibreEtOH demo is EC funded project aiming at commercial scale demonstration of the technology. FibreEtOH process consists of four main process steps Commercial & Industrial waste pulping and pulp preparation for ethanol production Fibre hydrolysis and fermentation to produce ethanol (yield 200 litres/dry tonne of fibre) Biogas production from distillation stillage Sludge drying after biogas production to prepare solid biofuel for CHP Main products of FibreEtOH plant are fuel grade ethanol and biogas to green electricity and steam production Main figures of the ethanol plant Input : Waste 170 000 tsrf/a Output: Ethanol 15 000 m 3 /a Biogas green electricity 60 GWh/a Sludge for fuel 100 000 t/a ETHANOL FROM RECYCLED FEEDSTOCKS 5
CURRENT STATUS OF FIBREETOH TECHNOLOGY FibreEtOH-process has been technically proven by over 1000 hours of continuous piloting in multiple campaigns All process steps from waste pulping to fermentation have been tested and designed together with selected technology partners The key steps in the process are continuous high viscosity hydrolysis and continuous fermentation of cellulose without pre-treatment Next steps for the technology are: Final feasibility of the first industrial demonstration plant Improvement and optimisation of the full scale unit Dissemination of the technology A constant R&D is carried out parallel to the demonstration to improve the process design ETHANOL FROM RECYCLED FEEDSTOCKS 6
RENEWABLE FUEL PRODUCTION TECHNOLOGIES CELLULOSIC ETHANOL, EXAMPLES OF DEVELOPERS Corn and cobs Straw & grass Wood MSW or Waste Abengoa Abengoa KL Energy INEOS Bio DuPont Chempolis BlueFire BlueFire Pasific Ethanol Dong Energy Lignol Fiberight POET Iogen Mascoma UPM/FibreEtOH Mascoma SEKAB St1 ETHANOL FROM RECYCLED FEEDSTOCKS 7
COST COMPARISON OF FIBREETOH AND OTHER CELLULOSIC ETHANOL CONCEPTS With the apparently very low to negative cost of the industrial waste feedstock, the FibreEtOH produces ethanol at a very cost competitive level. FibreEtOH production cost below <50 cent/litre seem to be feasible at suitable production sites, whereas typical straw and wood ethanol costs are around 70-120 cent/litre. The integration to an existing paper mill infrastructure helps to make a small and medium scale ethanol production competitive even when compared against large scale 100 000 m3/a stand alone investments around 300 MEUR. ETHANOL FROM RECYCLED FEEDSTOCKS 8
URBAN BIOREFINERY Recycled fibre represents today over 50% of European fibre consumption in paper and board production. There are lot of R&D resources allocated to wood based biorefineries while suitable waste streams may easily be made available at existing paper mills in the urban value chain. Separated RCP grades Paper / re-use CIW 1/3 Paper & board Paper mill Fuel ethanol 1/3 1/3 Waste wood Plastics Power plant Bio-oil Power and heat Wood for growing green power market Currently: solid fuels and gas New technologies ETHANOL FROM RECYCLED FEEDSTOCKS 9
CONCLUSIONS FibreEtOH development has been remarkably business not technology driven FibreEtOH concept development has been a business driven and supported by targeted research, which has resulted in new business model around cellulosic ethanol production. EU demonstration funding is an effective way to commercialise new technologies due to limited share of funding eligible for research and development and clear goal towards flagship investments. Novel concepts do not always easily fit into a companies existing portfolios. Therefore strong individual and visionary management commitment is needed to develop new approaches to the point that they pass basic feasibility hurdles. The final success of the technology development will be seen in the success of the actual proceeding investments. This development process has been a joint effort between research focused and industry application focused consortium partners. ETHANOL FROM RECYCLED FEEDSTOCKS 10
THANK YOU! CONTACT: ESA SIPILÄ SENIOR CONSULTANT ESA.SIPILA@POYRY.COM WWW.POYRY.COM ETHANOL FROM RECYCLED FEEDSTOCKS 11