Biorefinery enables cost effective feedstocksGroene chemie, Rotterdam, 1 November 2011

Johan SandersProfessor Valorisation of Plant Production ChainsWageningen University and Research center

Qualitative example of Biorefinery Rotterdam (700PJ)

cornwheatcornwheat

cassava chipscassava chips

diesel fueldiesel fuel

DDGSDDGS

soybeansrapeseedjatropha seed

soybeansrapeseedjatropha seed

Medium protein 1st residues- DDGSMedium protein 1st residues- DDGS

starchstarch C6 sugarsC6 sugars

oiloil

glycerolglycerol

biodieselbiodiesel

press cake(high protein)press cake(high protein)

proteinprotein

lignocellulose(LC)lignocellulose(LC)

C6 sugarsC6 sugars

C5 sugarsC5 sugars

O-chemicalsO-chemicals

fermentationproductsfermentationproducts

ligninlignin

animal feedanimal feed

N-chemicalsN-chemicals

fuel ethanolfuel ethanol

lactic acidlactic acid

49.6 Mt raw materials converted to:- fuels 5.5 + 6 + 1 = 12.5 Mt- chemicals 2 + 2 + 2.5 + 0.5 + 1 + 1.5 = 9.5 Mt- animal feed 2 Mt- syngas 3 Mt- electricity 3800 MW

electr.electr.

plant oilsplant oils

ethanolethanol

ethyleneethylene

propylenepropylene

fuel ethanolfuel ethanol

ethanolethanol

15

8

4

3

9

6

5

18

3

6

1.2

6

glycerolglycerol 0.6

0.6

0.6 methanol

6

18

11

torrefied LCpyrolysis oiltorrefied LCpyrolysis oil

7

2

0.5

0.5

2

2

5.5

2.5

0.5

10 syngassyngas

5

6

2

13.5

5

1.5

2

1.5

1.5

1

3

3800 MW

3000 MW

800 MW

3

1.5

2

2

O

D

D

D

O

R

R

O

O

O’

O’

O

O: operation D: development R: research

From side stream to bulk product

Text: 28 pt Arial Unicode MS, not bold this is 24 pt, sizes have been tested

Accentuation colours test and surfaces: Main colours: petroleum blue and green Supporting colours: orange-yellow and orange

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Different options for optimisation of agricultural waste streams

Protein content 0 5 % 15 % 35 % 50 %

ExamplesWheat straw

Cocoa husks

Corn stover

Sugarcane leaves

Coffee pulp

Rape straw

Beet leaves

Rape meal Soy meal

Costs(€/ton) 50-80 50-110 100-140 150-180 300-350

Value (€/ton) as raw material:

electricity 85 80 80 75 75

ethanol 25-50 25-50 25-50 15-30 10-20

ethanol + protein 25-50 45-70 105-130 175-190 250-260

idem + hemicell.+ lignin 70 100 145 195 260

idem + hemicell.+ minerals 75 110 155 205 265

The route to NMP, new vs conventionalNew route

Conventional route

Glutamic acid NMP

N O

CH3

Biomass NH2 COOH

COOH

NH2 COOH+ CH3OH- CO2

hydrolysis,separation

enzyme,

30 oC

cat,

250 oC

O O

CH3NH2

OHHO

- H2OHHO

+ H2

CH2

OCH3OH

+

200-350 oC

100 bar

cat,

180-240 oC

Gascat,

90-150 oC

N2 + 3 H2 NH3

+ CH3OHcat

300-550 oC

150-250 bar

cat

400 oC

N O

CH3

cat,

80 oC

Amino acids contain N and O.

Less steps (= factories) & energy for the same product!

step 1 step 2

N-ergy Wasteaspartic + arginin

Chemicals

Food

Multiproduct second generation biorefinaryIncome per tonne rape meal (€/ton)

Product Mass Income €

Protein 300 240

Amino acids 100 30

Animal feed 200 100

Ethanol (200) (20)

Fibres 100 20

PO4 20 10

Lignocellulose 200 10

Total 920 330-410

Costs rape meal = 180 €/tonne

Integrated production of chemicals & powerRape meal

Protein + K

Agricultural residues

NaOH

Ca(OH)2

95 °C

1 day

Fibres

Amino acids

Lignocellulose

Amino acids +

phosphate

Recalc.lignocellulose

Ca(lactate)2

heat

Ferm

Ca(lactate) 2

Recalcitrant Lignocellulose

CaO

Heat

Cellulase

Ferm

Ethanol

CHP

Prec

ElectricityWaste paper/CaCO3

BBE parc Cuijk & Renkum

36 kton glutamic acid H2N

OH

COOH

O 23 kton NMP

(~2500 € / ton)

=58 M€/y

500 Million liters bioethanol

(~ 400 kton) =200M€

360 kton DDGS (~130 € / ton) =46M€

Biobased NMP, an example

Our daily food needs a twenty fold higher energy input

NL fossil 3.300 PJ

EU fossil 85.000 PJ

Dutch Agriculture 475

Net Import160

Greenhouses/Food 100

Transportion Food

Other Agriculture 60

Household 165

Food Industry150

2500 kcal/day = 55 PJ

100

Biomass

NL 635 PJ

EU 20.000 PJ

Fossil

NL 575 PJ

EU 20.000 PJ

EU 1.800 PJ

Development of Dutch BbE can be build on Dutch pilars: Agriculture, Chemistry, Ports.

1980/1995 6 Mton soy

cake

2007/2015 5 Mton wheat

compound feed

compound feed

compound feed

chemicals (100.000 ton/aa)

lys, trp, thr, met

glu, asp, ser

accessable lignocellulose

electricity 50 PJ

ethanol

2007/2015 3 Mton rape

seed

lignocellulose

1 Mton protein

lignocellulose

2 Mton protein

manure

50 PJ ethanol

50 PJ biodiesel

N, P, K

N, P, K

fertilizer

From side stream to bulk product

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Glutamic acid – industrial raw material

Diaminobutane

Acrylonitrile

N-Methylpyrrolidone

N-Vinylpyrrolidone

Glutamic acid

H2N COOH

COOH

NWO-ACTS (ASPECT)

Glutamic acid in byproduct streamsAmino acids in residual proteins

0%

20%

40%

60%

80%

100%

Maiz

e DDGS

Whe

at D

DGS

Sugar

beet

vina

sse

Sugar

cane

vina

sse

Rapes

eed

mea

l

Soybe

an m

eal

Jatro

pha

mea

l

Palmoil

mea

l

Chlore

lla m

icroa

lgae

Ala

Pro

Glu

Asp

Tyr

Phe

Ser

Gly

Arg

His

Val

Leu

Ile

Trp

Thr

Cys

Met

Lys

Output(kton/y)

Investment(M€)

Turnover(M€/y)

Investment/ton(€)

Turnover/investment(€/€)

Neste Oil 800 760 480 950 0.63

2nd generation ethanol

175 300 87 1700 0.30

2nd generation multi product

30 15 12 500 0.8

Small scale can be competitive