Ghent Belgium September, 19-20-21, 2005 International Biorefinery Systems presented by: Michael Kamm * and Birgit Kamm ** * Managing Director, biorefinery.de GmbH, 14471 Potsdam, Germany, office@biorefinery.de ** Scientific Director, Research Institute biopos e.v., 14513 Teltow-Seehof, Germany, kamm@biopos.de 1
International Biorefinery Systems Content: 1. Introduction 2. Principles 3. Concepts 4. Products 5. Summary 6. Outlook 2
Introduction The retention and the management of the resources are fundamental political areas of a sustainable development of the 21th century. A sustainable economical growth requires safe, sustainable resources for industrial production. It is absolutely necessary to look for solutions to decrease today s rapid consumption of fossil, not renewable resources (petroleum, natural gas, coal, minerals). 3
Bio Economy Product and Energy Market In consequence, it is absolutely necessary to develop solutions in three sustainable and biobased sectors: Biobased Products BioEnergy / BioPower BioFuels Biopower/Bioenergy (electricity and heat) Biofuels (transportation fuels) Biobased Products (chemicals/materials) in context of a biobased economy. Biogenic Raw Materials 3-pillar model of a future biobased economy A key of the development biobased industrial products and fuels are 4
Fuels and Energy Fuels and Energy - Bioethanol, - Biodiesel, Biogas -Hydrogen Petroleum Biomass Chemistry Refinery Material Utilisation, Chemistry -Basic and Fine chemicals, - Biopolymers and Bioplastics Biorefinery Biobased industrial products can only compete with petro-chemically based products if the raw materials are optimally exploited and a variety of value-creating chains are developed and established. development of substance-converting basic product systems and multi product systems, especially biorefineries. 5
Biorefinery A biorefinery is an overall concept of a processing plant where biomass Feedstock s are converted and extracted into a spectrum of valuable products. Based on the petrochemical refinery. U.S. Department of Energy (DEO), Energy, Environmental and Economics (E3) Handbook (2000) 6
combine necessary technologies between biological raw materials and the industrial intermediates and final products. Principles (1) Biorefinery Agriculture Primary Refinery Industry Raw Material Conversion of Raw Material Lignin Carbohydrates Product lines Product lines Special Substances: Pigments, Dyes, Aromatic Essences, Flavours, Enzymes, Hormones, and other Complex Substances Inorganic Substances. Energy Fats Proteins Special Substances Product lines Product lines Product lines After providing code-defined basic substances (via fractionation) it is necessary to develop industrially relevant Product Family Trees. Kamm, B.; Kamm, M.; Principles of. Appl. Microbiol, Biotechnol., (AMB), 64 (2004) 137-145 7
Principles (2) Precursors-contained Biomass Wood / Soft wood Cereals / Maize Sugar-beet /-cane Soya/Rape Alfalfa/ Grass/Clover Biomass- Precursors Lignin Carbohydrates Fats Proteins Straw Bagasse Leaf Lignin Energy Material- Precursors chemical Syngas Levulinic acid Methanol Cellulose Starch Glucose Ethanol Acetic acid Saccharose enzymatic bacterial Lactic acid Oil Enzymes Acrylic acid Dilactide Aminoacids Feed 2,3-Pentanedion Gasoline Ethene Ethyllactate Polymers Plant biomass always consist of the basic products: Carbohydrates, lignin, proteins, and fats Kamm, B.; Kamm, M.; Principles of. Appl. Microbiol, Biotechnol., (AMB), 64 (2004) 137-145 8
Principles (3) In the first step, the precursor containing biomass is separated mostly by physical methods. The M1-Mn- and B1-Bn-products will subsequently be subjected to microbiological and/ or chemical methods. In the following, the F1-Fn-products can be further converted or enter the conventional refinery. The goal principle of a biorefinery is defined in the following: (Biomass) Feedstock-Mix + Process-Mix Product Mix Kamm, B.; Kamm, M.; Principles of. Appl. Microbiol, Biotechnol., (AMB), 64 (2004) 137-145 9
Principles (4) Feedstock(s) biological raw material various, mixed Food and Feed Grains, Ligno-cellulosic Biomass, (e.g. late grass, reed, bush, harvest rest) Forest Biomass, (e.g. wood, underwood, waste wood-processing) Municipal Solid Waste (MSW), (e.g. paper/cardboard, town-cleaning, hospitals) Processing-Technologies various, combined Bioprocesses ( bacterial, enzymatic a.o.), Chemical Processes, Thermo-chemical Processes, Thermal Processes, Physical Processes, Products Substances and Energy various, multi product systems Fuels, Chemicals, Materials ( e.g. Polymers ) Specialities, Commodities, Goods Basic principles of a biorefinery [phase III or type III biorefinery] 10
Currently four Biorefinery Systems are forced within research, development and practice: The Whole Crop Biorefinery (WC-BR) raw material: cereals, maize etc.. The Green Biorefinery (G-BR) raw material: nature-wet biomasses, green grass, lucerne, clover, immature cereals a.o.. The Lignocellulose Feedstock Biorefinery (LCF-BR) raw material: nature-dry biomasses, wood, straw, corn stover, cellulose-containing biomasses and waste. The Two-Platform Concept production of syngas and/or sugar as platforms for biobased products and fuels. 11 Kamm, B.; Gruber, P.R.; Kamm, M.; (eds.) Industrial Processes and Products, Wiley-VCH, 2005
Lignocellulosic Feedstock Biorefinery Raw materials: nature-dry lignocellulosic biomass straw, reed, grass, wood, paper-waste A general equation of conversion at the LCF-Biorefinery: Lignocellulose + H 2 O Lignin + Cellulose + Hemicellulose Hemicellulose + H 2 O Xylose Xylose (C 5 H 10 O 5 ) + acid Catalyst Furfural (C 5 H 4 O 2 ) + 3 H 2 O Cellulose (C 6 H 10 O 5 ) + H 2 O Glucose (C 6 H 12 O 6 ) 12
Lignocellulosic Feedstock Biorefinery Cellulose biotech./chemical Sugar Raw material Residues Lignocellulosic Feedstock (LCF) Hemicellulose biotech./chemical Cogeneration ( CHP ) Heat and Power Fuels, Chemicals, Polymers and Materials Lignin chemical Lignin Raw material General Scheme of a Lignocellulosic Feedstock Biorefinery Kamm, B.; Gruber, P.R.; Kamm, M.; (eds.) Industrial Processes and Products, Wiley-VCH, 2005 13
Lignocellulosic Feedstock Biorefinery Ligno-Cellulosic Feedstock Biorefinery [LCF-Biorefinery] LC-Feedstock (LCF) e.g. Cereals (Straw, Chaff); Ligno-Cellulosic Biomass (e.g. Reed, Reed Grass ); Forest Biomass (Underwood, Wood); Paper- and Cellulosic Municipal Solid Waste Lignocellulose (LC) Lignin Phenol-polymer Natural Binder and Adhesives Sub-bituminous Coal Sulphur-free Solid Fuel Hydrolysis Xylose (Pentose) Xylite Sugar-Substitute Furfural Furan Resins Hemicellulose Pentoses, Hexoses Chemical Products Nylon 6 ; Nylon 6,6 Plant Gum Thickeners, Adhesives, Protective Colloids, Emulsifiers, Stabilizers HMF (5-Hydroxymethyl-furfural), Levulinic Acid Softener + Solvents Lubricants Chemicals and Polymers Cellulose Glucose-polymer Hydrolysis (E/C) Glucose (Hexose) Celluloseapplicants Fermentation- Products Fuels e.g. Ethanol Organic Acids e.g. Lactic Acid Solvents Acetone, Butanol Optimal size plant: Lignocellulosic raw material-mix, optimum: 4.360 to/day Main products: 47,5 Mio gallons Ethanol ($1.25) and 323tt Furfural ($ 0,32/pound) Annually; Jobs: 6.095 (without construction); Invest. In plant+ equipm.: $ 455 Mio Van Dyne et al., Perspectives of new crops and uses. ASHS Press, 1999, USA 14
Whole Crop Biorefinery Raw materials: Whole crops Cereals, e.g. Rye, Wheat, Barley, Maize 15
Whole Crop Biorefinery Grain biotechn./chemical physical/chemical Starch line, Sugar Raw material Whole Crop Cereals - Dry Mill - Flour (Meal) physical/chemical Residues Cogeneration ( CHP ) Heat and Power Fuels, Chemicals, Polymers and Materials Straw biotechn./chemical Lignocellulosic Raw material Kamm, B.; Gruber, P.R.; Kamm, M.; (eds.) Industrial Processes and Products, Wiley-VCH, 2005 16
Whole Crop Biorefinery Products from whole crop biorefinery Combustion Electricity Energy Grain [ Cereals, Corn, Maize ] Fields Straw Seed Grinding Meal Decomposition Elevatedpressure Gasification Biotechnological Conversion Glucose Starch Chemical Conversion / Modification Extrusion Co-Extrusion Plasticization Directly Use Decomposition to paste/ pasting Lignin Hemicellulose Cellulose Fermentation Ethanol Hydrogenation Red. Amination Esterification Ether formation Syngas Methanol PHB Sorbitol Glucosamine Co- and Mixpolymerisate Acetate- Starch Carboxymethyl Starch Bio-Plastic Binder Adhesive Cement Kamm, B.; Kamm, M.; Principles of. Appl. Microbiol, Biotechnol., (AMB), 64 (2004) 137-145 17
Whole Crop Biorefinery Grain Steep (Steep Tank) biotechn./chemical physical./chemical Endosperm Starch line, Sugar Raw material, Amino acids Whole Crop Cereals - Wet Mill - Grain Germs physical/chemical Residues Oils Cogeneration Heat and Power, Extractives Fuels, Feed, Fats and Oils, Chemicals, Pharmaceutics, Materials Straw biotechn./chemical Lignocellulosic Raw material Kamm, B.; Gruber, P.R.; Kamm, M.; (eds.) Industrial Processes and Products, Wiley-VCH, 2005 18
Whole Crop Biorefinery Products from whole crop wet mill based biorefinery Cultivation Harvest, Storage, mechanical Pre-Treatment Corn Grain Straw ( Blades, Nodes) Foliage, Chaff etc. Steep Tank Straw Chipping Straw Meal Corn Steep Liquor Degermination Cellulose and Paper Endosperm Germ Industry Grind and Wash Expel and Extract Feed, Fuels, Chemical Industry Hydrolyzate [ Sugar, Levulinic Acid ] Fermentation Products Hull (animal feed, chemicals) Centrifuge Edible Oil Germ Meal (Feed) Gluten Meal (amino acids) Starch Fatty Acids Dextrose (Industry) Syrups Industry, Pharmacia, Food Corn Starch (Industry & Cosmetics, Food) Dextrins (Industry) Fermentation Products Ethanol Organic Acids, Biochemicals 19 Kamm, B.; Gruber, P.R.; Kamm, M.; (eds.) Industrial Processes and Products, Wiley-VCH, 2005
Green Biorefinery Raw materials: nature-wet biomass, Green grass, alfalfa, clover, immature cereal 20
Green Biorefinery Press Juice biochemical biotechnol./physical Proteins, Soluble Sugars Residues Green Biomass Techn. Press Biogas, Cogeneration ( CHP ) Heat and Power Residues Press Cake hydrothermal enzymatic thermal chemical Feed, Fuels, Chemicals, Polymers and Materials Cellulose Lignocellulose By primary production of photosynthesis in green crops more than 20 tons of dry matter as well as 3 tons of proteins per hectare in temperate climates can be obtained per year. 21
Juice Green Biorefinery Products Grass, Lucerne, Beets a.o. Green crop drying plant (wet-fractionation) Green pellets Beet pellets Solid fuel Raw material for chemical industry Heat, Electricity High value products Separation Enzymes Carbohydrates Straw, Wood, Biogas Block calorific power station Energy Flavourings Coulorings (dyes) Fibres, Cellulose Whole crop Straw Seeds a./o. Straw Potatoes a./o. Juice Molasse Pretreatment Biogas Fermentation Lactic acid, Lactates, Esters Amino acids Proteins Enzymes Organic acids Fertilizer Ethanol Construction of a prototyp Primary Biorefinery Selbelang Tier 1: 8.000 t DM (8 mo/y); Primary products: pellet, chlorophyll, Prenacell fibre, Lactic acid, Proteins, biogas-energy; Construction cost: 5 Mio EURO 22
Two Platform Concept Sugar Platform biochemical Sugar Raw material Residues Biomass Cogeneration ( CHP) Heat and Power Clean Gas Fuels, Chemicals, Polymers and Materials SynGas Platform gasification thermal chemical conditioning Gas National Renewable Energy Laboratory (NREL), www.nrel.gov/biomass/biorefinery.html 23
Two Platform Concept Products from Syngas Aldehydes, Acids, Alcohols Surfactants O Lancaster, M.; The Syngas Economy, Green Chemistry, Royal Society of Chemistry, 2002 R-OH Alcohols Plastics NH 2 CONH 2 Urea CO 2 CH 3 Cl Methyl chloride CO, H 2 HCHO Formaldehyde NH 3 Ammonia H 2 O HCl N 2 Polymers, Adhesives, Paints H 2 C CH COOH Acrylic acid CH 3 OH Methanol CO + H 2 Syngas H 2 O Polymers CH 3 COOH Acetic acid H-ZSM-5 Alkanes Fischer-Tropsch Oligomers Syngas H 2 C CH 2 Ethylene (Ethene) H 2 O/Rh/Se/TiO 2 Pt/Alumina Ethylene oxide (Oxiran) - H 2 O C 2 H 5 OH Ethanol Gasoline and Waxes O 2 /Ag Esters, Ethers Aromatics Biogas: CH 4 fermentation Biomass 24
Summary present : Complex and integrated systems of sustainable technologies based on biological raw materials. Economically self-consisting enterprises and economic entities. Bearing pillars of the future biobased economics. Motors of research and development in the 21th century. One fundamental task in the biorefinery topic is the development of biorefinery demonstration plants, close to industry and agro-industry. 25
Outlook Several requirements to enter the phase of development of Industrial Biorefinery Technologies and Biobased Products: To increase the production of substances on the base of biogenic raw materials in the ordinary plants of production of cellulose, starch, protein, sugar and oil. To get the commitment of the chemistry, particularly the organic chemistry, for the concept of biobased products and biorefinery systems. To force the combination of biological and chemical conversion of substances. To introduce and establish biorefinery demonstration plants. 26
2005. ISBN 3-527-31027-4 27
Contact Michael Kamm Managing Director biorefinery.de company (GmbH) Main Seat: Stiftstraße 2, D-14471 Potsdam, Germany Email: office@biorefinery.de Laboratories Teltow-Seehof : Kantstraße 55, D-14513 Teltow Fon: +49 (0)3328-3322-0 or -20, Fax: +49 (0)3328-3322-22 Web: www.biorefinery.de, www.biorefinica.de Dr. Birgit Kamm Member of the board of biopos e.v. and director of the institute, Research Centre Teltow-Seehof, Kantstraße 55, D-14513 Teltow Email: kamm@biopos.de Fon: +49 (0)3328-3322-10, Fax: +49 (0)3328-3322-11 Web: www.biopos.de Potsdam and Teltow in the Greater Berlin, Germany 28
City of Potsdam - Market Square State of Brandenburg, Greater Berlin, Germany Thank you for the invitation and your attention 29