The German Lignocellulose Feedstock Biorefinery Project Jochen Michels, Kurt Wagemann, DECHEMA e.v. Frankfurt am Main
Project information Joint Project of 15 Partners Industrial: 4 Partners SME: Res. Inst.*: Universities: 2 Partners 4 Partners 5 Partners Term: 06/2007 08/2009 Financing Total volume Funding 2,6 Mio. 1,8 Mio. Supported by BMELV** Project Executing Organization Fachagentur Nachwachsende Rohstoffe * Large Research Institutions ** German Federal Ministry of Food, Agriculture and Consumer Protection
Objectives of the project Development of a sustainabe wood treatment process for the decomposition of lignocellulosic feedstocks (e.g. beech, poplar) the separation of cellulose, hemicelluloses, lignin, and extracts the subsequent treatment of the raw materials to generate useful platform chemicals from all fractions Development of a Biorefinery pilot plant concept applied (continuous) process for decomposition and separation of the constituents no change of the decomposition medium based on techno-economic and ecologic evaluations
Focusing on hard wood (Beech and Poplar) 30 % of the forestry land in Germany is cultivated with beech The annual potential of beech wood is about 12 Mio t dm (timber use classes: Bark L2) There is no competitive situation to the pulpand wood material industries in Germany Wood from beech and poplar could easily be mobilized on the market Since hardwood has a lower lignin content than softwood its decomposition is easier The complete usage of the constituents Cellulose, Hemicellulose, Lignin und Extrakts seems to be possible using wood from beech and poplar
Project map
Project map WP 1
WP1: Extraction of ingredients Determination of optimal extraction conditions Temperature, time, pressure high pressure solvents, alcohols, ionic liquids Development of a continuous extraction process Analytical characterization of the extractives Applied research studies with extractives Determination of bioactivity Suitability tests of ingredients as basis for pharmaceutics, scents and flavors H H pentacyclic triterpene (Lupan)
WP1: Extraction of ingredients Advanced solvent extraction ASE-extraction of bark (black) and wood (red) of beach Content of triterpenes < 0.1 %
WP1: Extraction of ingredients Results from extraction research Only very low content of triterpenes (< 0.1 %) could be found in extracts either by maceration, percolation or high pressure extraction Extraction was not possible using ionic liquids due to dissolution of wood Accelerated solvent extraction showed a higher content of extractives in bark compared to wood Since extractives content is too low to become economically reasonable, the extraction step was excluded from the biorefinery concept Results from biotransformation of model triterpenes 26 fungal strain and 7 bacterial strains were tested for the biotransformation of model triterpenes (like betuline) Promising transformation products will now be charcterized
Project map WP 2
WP2: Decomposition and separation of wood constituents Optimization of the pulping process and the separation procedure of wood constituents in 1-kg-scale (discontinuous) Treatment using low boiling alcohols (+/- H 2 SO 4 ) Optimization of p, t, T and wood:solvent ratio Treatment using ionic liquids (also in combination with alcohols) Separation of wood constituents Solvent recycling Solubil. of wood in ion. liq. (Photos: SI) Development of an applicable continuous process in 10-kg-scale
WP2: Decomposition and separation of wood constituents Organosolv pulping process Optimal pulping conditions: wood:solvent ratio (1:4) 170 C - 180 C 2-4 h ± Catalysator Ethanol:Water solvent (50:50)
WP2: Decomposition and separation of wood constituents Decomposition using ionic liquids Fine milled wood could be dissolved in different ionic liquids by boiling, ultrasound or microwaves (wood:solvent ratio ~ 1:8) Separation strategy of wood constituents precipitation of cellulose and lignin by pooring in hot water Resolution of lignin in NaOH and filtration of cellulose precipitation of Lignin by addition of HCl Recycling strategy for the ionic liquids Nanofiltration Due to poor recovery results of the ILs, an alternative IL-Pulping step was skipped from the biorefinery concept
Project map WP 3
WP3: Processing of the achieved fractions Enzymatic hydrolysis of cellulose Optimization of hydrolysis conditions Recovery of enzymes Fermentation capability of achieved glucose Hydrolysis of hemicelluloses Enzymatic hydrolysis of (oligo-)hemicelluloses Fermentation capability of achieved xylose Research on the lignin fraktion Thermoplastic applications Manufacturing in duroplastic systems Catalytical hydrogenation in ionic liquids Anaerobic degrad. of Cellulose in 4 d (Photos: TUM)
WP3: Processing of the achieved fractions (Cellulose) Hydrolysis of cellulosefibres Repeated fed batch hydrolysis of cellulosefibres (yield: 80 %)
WP3: Processing of the achieved fractions (Cellulose) Simultaneous saccharification and fermentation SSF of cellulosic fibres from organosolv pulping
WP3: Processing of the achieved fractions (Lignin) Thermoplastic Application of Organosolv-Lignin 15 cm Compounding of polylactic acid (PLA) with a lignin content (20 % wt)
The German Lignocellulose Feedstock Biorefinery Project WP3: Processing of the achieved fractions (Lignin) Duroplastic Applications Phenol based resins with partial substitution of phenol by lignin can be used for wood construction boards (up to 30 %)
WP 4 Project map
WP4: Techno-economical und ecological assessment Definition of system boundaries and of sub-processes of concern Provision, delivery and costs of feedstocks (logistics) Feasibility study: balancing as well as economical und ecological assessment of the process chain
WP4: Economical und ecological assessment Economic assessment: Structure of costs and credits for lignin production Production costs of Lignin: about 395 per ton
WP4: Economical und ecological assessment Sensitivity analysis Prices for wood chips and lignin mainly affect glucose production costs
Project map WP 5
WP5: Conceptual design of a pilot plant Planning and assessment of the conceptual design of the lignocellulose feedstock biorefinery pilot plant Frisches EtOH/H 2 O Holzhackschnitzel (50 % Feuchte) EtOH/H 2 O Vorratsbehlter: EtOH/H 2 O fr Holzaufschluss Reaktion bei 18 bar Entspannung auf 1 bar Holzaufschluss Kondensator LM- Erhitzer Auffangbehlter: Mutterlauge Ligninfllung H 2 O Ligninreinigung M Lignintrocknung Abluft Lignin Aufschlusslsung H 2 O Vorratsbehlter: H 2 O M Auffangbehlter: Ligninslurry Cellulose C5/C6- Zuckerlsung rec. EtOH/H 2 O zum Vorratsbehlter Capacity 1,300 kg wood per week (2 x 150 kg batch reactors) Faserfraktion fr Reinigung Faserfraktionreinigung Auffangbehlter: Reinigungsfl. Solventrckgewinnung rec. H 2 O zum Vorratsbehlter Products 80 kg lignin 280 kg cellulose fibres 110 kg hemicelluloses
Main Results and Summary The carbohydrate fractions of the organosolv-pretreatment of beech and poplar are suitable for enzymatic hydrolysis and fermentative applications The sulphur-free lignin fraction can replace fossil aromatics in (high added value) products An initial wood extraction step is not necessary for pretreatment and so far not economic for beech and poplar. Bark does also not interfere Ionic liquids seems to be not applicable in wood treatment due to high costs and therefore a necessary expensive recovery strategy Ionic liquids can be used as solvent to prepare fibres for easier enzymatic attack and to depolymerize lignin (data not shown) The results of the economical an ecological assessment shows that it is possible to build up a sustainable LCF-Biorefinery (400,000 t/a) The main subjects of project phase II are to build up and to run the pilot plant and to supply its fractions for added value products.
Thank you for your attention Further Information Dr. Jochen Michels DECHEMA e.v. Tel.: + 49 69 7564-157 Mail: michels@dechema.de