Sustainability and climate protection, the role of bio fuels and

biorefineries in Europe

Biomotion, Hannover, 12 November 2009

Johan SandersProfessor Valorisation of Plant Production ChainsWageningen University and Research center

Energy consumption past and future

Jaartal

A2

A1F1Scenario A1F1: Global economy, fossil fuel intensive

Scenario A2: Regional economy

1900 2000 2050

500

750

1000

250

1250

1500

Yea

rly

ener

gy

pro

duc

tion,

EJ

1950

The New Biomass value chain:

€

€

€

Food

Biomass production

1st Agro logistics Food pretreatment Food productionFoodconversion

Existing

non- food:• Feed

• Paper

• Additives

•Fibres

• Waste

management.

Biomass sourcesAgro2food productionBy products & waste

Logistics&storageNL productionImports

Existing conversion Existing production

Biobased

Products• Biobased

materials

• Bio-based

chemicals

• Bio-fuels

• Bio-energy

New productionPerformance materialsBase&platform chemicalsPerformance chemicalsBio Energy

New Pre2treatment & conversion

physical&chemical conversion

process engineering

bioconversion

Platform Renewable Materials

30% substitution of fossil by Biomass in 2030• 25% chemical resources (140 PJ)

• 60% transportation fuels (324 PJ)

• 17% heat (65 PJ)

• 20% electricity (203 PJ)

By:• Enhancing efficiency present Biomass (400 PJ)

• Development (new) crops (250 PJ)

• Aquatic cultures (250 PJ)

• Import (250 PJ)

30

20

10

30

10

7

3

Production costs (€/GJ endproduct)

heat electricity transport fuel

average bulkchemical

other biomass

2 G€

2 G€

5 G€

6 G€

beet

grass

wood

6 G€

6 G€

15 G€

overall Dutch industry cost price

overall Dutch industry raw material cost

coal

oil

capital

4

23

12

75

How biomass can best compete with fossil derived products

Biomass can bring different contributions to the farmer

(€/ha)Assuming a yield of 10 tonnes dry weight per hectare, being 160 GJ, using whole crop and GAP up to 20 tonnes whole crop yield, 320 GJ/ha

: 640 222

: 1360 222

: 6400 222

: 1800 – 3600

: 2080 3 4160

• All Energy at coal value

• All transportfuel

• All bulkchemical

• 20% bulkchemical, 80% Energy

• 20% bulkchemical, 40% fuel, 40% Energy

€/hectareOn raw materials substitution only

Including capital cost substitution

• 20% bulkchemical, 40% fuel, 40% Energy : 3000 3 6000

Eco2pyramid for biomass utilization

Pharma & Cosmetics

Food & Feed

Bioplastics & Polymers

Bulk chemicals & Fuels

Energy & Heat

high value

low value

Farma

Fun

Food

Feed

Fibre

Fermentation

Fuel

Fertilizer

Fire

Fill

Biomass cascading:

Farma

Fun

Food

Feed

Functional chemical

Fibre

Fermentation

Fuel

Fertilizer

Fire

Flare

fill

You cannot have your cake and eat it: Biorefinery

1,43Butanediamine: polymers e.g. nylon24,6

H2NCH2CH2CH2CH2NH2

NH3

NH3

Naphtha

H2C=CHCH3 + + 1.5 O2 H2C=CHC N

HCN+

CH4 +

1,23Ethanediamine : rubber chemicals, pharma, lubricants,detergents

H2NCH2CH2OHBiomass B

COOH

Naphtha

ClCH2CH2Cl

NH3

Cl2 NH3

NH3

CH2

H2NCH2CH2NH2

H2NCH2CH2NH2

CH2

O2 OH2NCH2CH2OH

Functionalized Savings Potential

Introduction Goal and Scope Inventory/Data Results Final Remarks

� Biomass A: Ethanol

� Biomass B: Serine

� Biomass C: Arginine

C

NH2

NH2

Biomass C

H2NCH2CH2CH2CH2NH2

COOH

H2NCONH2NH3

CO2

Biomass A CH3CH2

OH

Biorefining will give Mitigation under Economic conditions

75 billion €60 €/ton biomassminus 1200 Mton CO2

97 billion €80 €/ton biomassminus 1200 Mton CO2

225 billion €180 €/ton biomass minus 1500 Mton CO2

(125 M (62) hectare = 0,8 % (0.4%) world land area at 10 ton/ha (20 ton/ha))

= 4% agricultural land (excl. grassland)

fuels (375 Mton) (15%)

electricity (750000 MW) (10%)

electricity (3 x 106 MW) (40%)

platformchemicals (250 Mton) (100%)

fuels (250 Mton) (10%)

electricity (750000 MW) (10%)

20% 40%

40%

DuPont /Tate & Lyle BioProducts :1,3 Propanediol

factory, Loudon, USA

Biomass GlycerolPropylene

glycol Isopropanol

Chemical

Physical / Chemical

Chemical

Acetone

Ethylene glycol

Scheme. Chemical production in Rotterdam 2 a bio2based alternative for butadiene and ethylene.

Current production by Shell Chemical and Lyondell

Many ‘Rotterdam’ chemicals can be produced from BiomassExample of short term substitution potential

epichlorhydrin

methanol

Acetic acid

MTBEDimethyl Ether

formaldehyde

PLA in different applications (Synbra/PURAC)

Biofoam

Developments that should improve the biomass route

� Lower raw material price

� better refinery/ separation technologies/downstream processes

� More efficient fermentations

� Plant GMO to tailor make products

� new material2properties

� small scale technology and integrations that can give more income to the farmer

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

2012? 2009? 2006

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

2010 2014

Upscaling230L lime pretreatment of straw + cellulase

Reactor during enzymatic hydrolysis at t = 0 and t=24 h after adding enzymes

EET project with consortium of 3 R&D institutes, 3 companies, 1 university

Other co2products as a consequence of biofuel production

� if 10% of the WW transportation fuels are produced from corn, wheat, rape, palm, sunflower, cane this will supply 100 million tonnes of proteins

� Several bulkchemicals might be produced from different amino acids: 1,4 butandiol, 2,3 butandiol, 1,2 propanediol, Succinic acid, Acrylonitril, Acrylate, Metacrylate, (hydroxy) Styrene, (hydroxy) Phenethylamine, Caprolactam, Butandiamine, urea

Jatropha as a source for biodiesel

� Energy:� The seed contains about 30340% oil ���� potential

source of biodiesel and bio3oil

� Food:� Contains toxic compounds ���� not suitable for food

� Can be grown in extremely dry soil—not suitable for most food plantations

� Increasing productivity of unused/barren land

Components of J. curcas seeds

Components Seed (%)

Crude Protein 15

Lignin 20

Fiber 15

Carbohydrate 10

Oil 35

Ash 5

Jatropha protein functional properties

Economics biobased chain (Sugar beet)

Forward integration reduces tranport cost and seasonality and

will give more income to the farmer

Fields Processing

Present

100%

100%

Return flow 10%

Farm

Concept Small scale processing100%

Return flow 70%

30%

concentration fermentation

Zeafuels

biogas

heat

Less investment costs/liter ethanol than large scale US ethanol production from corn

Electricity

/minerals

Stem

Corn

Grain

60%

ethanol

Biogas

fermentationCHP

Ethanol

fermentationDistillation

Biogas

Filtration

Zein

ZEA FUELS bv

ZEA FUELS bv

Mobile Cassava starch refinery in Africa

Source: Duteso

Total Crop YieldsWet Weight and Dry Weight Yields

0

10

20

30

40

50

60

70

80

90

100

Cas

sava

Grass

Luce

rne

Maize

Oil pa

lm

Potato

Rap

esee

d

Sorgh

um

Soy

a be

an

Sug

ar bee

t

Sug

ar can

e

Sun

flower

Switc

hgrass

Toba

cco

Whe

at

Willo

w tree

ton/ha

Wet Weight

Dry Weight

143 140 240

Total Biomass Production

Best Practice Yields

Above 10ton/ha/a dry weight = Good

Above 20ton/ha/a dry weight = Great

Above 30ton/ha/a dry weight = Fantastic

Constituents Proportions

0%

20%

40%

60%

80%

100%

Cas

sava

Grass

Luce

rne

Maize

Oil Pa

lm

Potato

Sorghu

mSo

ya B

eans

Sug

ar Bee

tSu

gar C

ane

Sun

flower

Switc

hgrass

Toba

cco

Whe

atW

illow

Tree

kg/kg

Fat

Protein

Lignin

Complex Carbohydrates (C.C.)

Simple Carbohydrate (S.C.)

Nominalised Results: Optimal Biorefinery

Introduction Goal and Scope Inventory/Data Results Final Remarks

125GJ/ha22.2GJ/ton

721GJ/ha50.8GJ/ton

Afsluiting

© Wageningen UR

1e Generatie transportbrandstoffen leidt mogelijk tot verlaging van honger; 2e generatie wellicht niet

Schatting werkgelegenheid 4% 0.1% van gehele bevolking

CO2 reductie % matig matig matig

Incl. verbranden stro goed goed goed goed goed goed

0

2

4

6

8

10

12

Waarde

Transport

Brandstof

Raapzaad

diesel

Mais

Ethanol

Suikerriet Biet

Ethanol

2e

generatie

ethanol

FT diesel

€/GJKapitaalkosten

1e Generatie transportbrandstoffen leidt mogelijk tot verlaging van honger; 2e generatie wellicht niet

Schatting werkgelegenheid 4% 0.1% van gehele bevolking

CO2 reductie % matig matig matig

Incl. verbranden stro goed goed goed goed goed goed

0

2

4

6

8

10

12

14

Waarde

Transport

Brandstof

Raapzaad

diesel

Mais

Ethanol

Suikerriet Biet

Ethanol

2e

generatie

ethanol

FT diesel

€/GJKapitaalkosten Transportkosten Grondstofkosten + Winst

Amino acid reactive separation

Figure 1: Comparison of the traditional and proposed, energy efficient method for the production of

building blocks for (bulk) chemicals.

Feedstock Building

Block

Product

Traditional

method Fossil Fuel

Ethylene

amine

Electro

dialysis

Functionalized

Specialty

Bulk

Chemicals

Specific

modification

Oxidation Amination

Protein

Source

Proposed

method

Ethylene

Amino acids

Focus of

proposed project

Feedstock Building

Block

Product

Traditional

method Fossil Fuel

Ethylene

amine

Ethylene

amine

Electro

dialysis

Functionalized

Specialty

Bulk

Chemicals

Functionalized

Specialty

Functionalized

Specialty

Bulk

Chemicals

Bulk

Chemicals

Specific

modification

Oxidation Amination

Protein

Source

Proposed

method

Ethylene

Amino acids

Focus of

proposed project

STW: 1 AIO + ¼PD + ¼TA

General scheme Biorefinery Rotterdam

corn

wheat

corn

wheat

cassava chipscassava chips

fuelfuel

DDGSDDGS

soybeans

rapeseed

jatropha seed

soybeans

rapeseed

jatropha seed

Medium protein 1st residues

- DDGS - rape pods

- sunflower pods

Medium protein 1st residues

- DDGS - rape pods

- sunflower pods

Low protein 1st residues

- soybean straw

- cane leaf - corn stover

Low protein 1st residues

- soybean straw

- cane leaf - corn stover

Zero protein 1st residues

- wheat straw

- residual wood

- primary LC

- miscanthus

Zero protein 1st residues

- wheat straw

- residual wood

- primary LC

- miscanthus

Wet crops

- grass

- luzerne

Wet crops

- grass

- luzerne

starchstarch C6 sugarsC6 sugars

oiloilglycerolglycerol

biodieselbiodiesel

press cake

(high protein)

press cake

(high protein)

proteinprotein

lignocellulose

(LC)

lignocellulose

(LC)

C6 sugarsC6 sugars

C5 sugarsC5 sugars

ethanol + other

fermentation

ethanol + other

fermentation

O-chemicalsO-chemicals

fermentation

products

fermentation

products

ligninlignin

animal feedanimal feed

N-chemicalsN-chemicals

ethanol + other

fermentation

ethanol + other

fermentation

lactic acidlactic acid

protein

(= animal feed)

protein

(= animal feed)

juice com-

ponents

juice com-

ponents

Underlined: available for Rotterdam (2009)

Italics: partly available for R’dam – future

———> : existing process / application

---------> : still to be developed

electricityelectricity

Bulk chemicals from Biomass: lysine

Biomass raw materials

Capital (fermentation)

Capital (recovery)

Fossil raw materials (fermentation)

Fossil raw materials (recovery)

400

150

70

500

350

300

215

19

6

3

110

400

200

85 300

250

60

GJ/ton GJ/ton GJ/ton GJ/ton€/ton €/ton€/ton€/ton

fermentation direct plant productsState of the art ADM, Degussa, Ajinomoto

TWIN (under development Wageningen UR)

GMO (under development Wageningen UR)

Plant residues (in progress Wageningen UR)

1345

28

795

28 62033

610

37

21

7

65

18 GJ 18

15

18

10

Fossil chemical reference

Import large scale bio2commodities

� Pyrolysis oil� Torrefaction pellets� HTU biocrude� Non purified syngas� (hydrous) ethanol� Biodiesel� Pure plant oil� Rape seed� Soy beans� Cereal grains� Crude protein (hydrolysates)

Biobased Economy ChainsCultivation/harvest pretreatment Transport/Storag

e export harbour

as:

Processing

Rotterdam

Application

Lignocellulose densification Pyrolysis oil

Torrefaction pellets

HTU biocrude

FT diesel Transportation fuels

Electricity

heat

Oil crops - Seed, beans Refinery/conversion Transportation fuels

Animal feed

Fertilizer

Chemical Industry

Sugar/Starch Refinery/conversion (hydrous) ethanol Transportation fuels

fermentation

Seeds - Cereal grains Refinery/conversion Transportation fuels

Animal feed

fertilizer

Chemical industry

Leaf Refinery/conversion (hydrous) ethanol

protein (hydrolysates)

Transportation fuels

Chemical industry

Algae Refinery/conversion Biocrude HTU

protein (hydrolysates)

HTU upgrading Transportation fuels

Manure Refinery/conversion protein (hydrolysates) Transportation fuels

Chemical industry

Costs breakdown of Bulkchemicals (€/ton) at 60$/bbl

Raw materials

Capital

Operational

Recovery

Total

non3functionalised functionalised

300

3002500

50

502100

975

4002650

50

502100

825 1525

Derived from J.P. Lange (Shell)

Our daily food needs a twenty fold higher energy input

Biomass 635PJ

Dutch Agriculture 475

Net Import160

Fossil575PJ

Greenhouses/Food 100

Transportion Food

Other Agriculture 60

Household 165

Food Industry150

2500 kcal/day = 55 PJ

100

BEET chain can deliver renewable energy and sugar as well!

leaf

decentral

pretreatment

feed

agricultural

lime nutrients

protein

electricity &

heatsugar

feed

CHP

ethanol

biogas

press

field

(central) processing

fermentor

beet & beettops

pulp

-2

-3-3.6

Gross (PJ)

+19+26+29.6

-4

-3.3-3.3

0

04

leaf

0

+3+3

0

+8+8

+4

00

Nett

(PJ/85000 ha)

A: Actual 13

B2: No diffusion + ethanol + biogas 20

D2: B2 + leaf 23

GMO Bulkchemicals would save another 10 PJ

Many different drivers for one Biobased Economy

� Shortage of cheap oil� High energy prices� Security of energy supply� Climate change by green house gasses� Rural development� Developing countries� Geo2political conditionsDifferent countries/groups are confident however that

a BbE can contribute to their goals.

Different Economies of Scale

72 $ / barrel

108 $ / barrel

36 $ / barrel

0

5

10

15

20

25

30

0.1 1 10 100 PJ

€/G

J

Ethanol Fischer Tropsch

1000 MWNedalco

Investments Other costs, including transportcosts Raw materials

0

30€/ton 50360% conversion100€/ton 95% conversion

Pilot biorefinery line Foxhol (Groningen)(Prograss Consortium), nu Grassa (Oenkerk)

Green grass proteincompound feed

white grass proteinGrass protein (products)

+ .....

compound feed

Grass juice concentrate

Ethanol

HTU3Biofuel

Construction material+ paper

Polymer extrusion products

Grass juice

Protein

Fibers

cyanophycin granule peptide, mainly in cyano2bacteria as nitrogen and energy reserve material

= Asp + Arg

Granule35% (wt/wt) and slow growth

Ethanol production and Cyanophycin accumulation (collab. Univ. Münster/Steinbuchel, AVEBE, Cosun, Energy Valley)

EOS2 project (Economic Affairs)