9105z-wa-wa-TEC IEA42 SugarBiorefinery · 2013-10-18 · ZAFES Offstein, Dr. Wolfgang Wach 2009/09...
Transcript of 9105z-wa-wa-TEC IEA42 SugarBiorefinery · 2013-10-18 · ZAFES Offstein, Dr. Wolfgang Wach 2009/09...
Sugar Biorefinery
Wolfgang Wach, Südzucker AG Mannheim/OchsenfurtIEA-Bioenergy Task 42 Biorefineries – German Workshop on Biorefineries15th September 2009, Worms
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 2
Content
Südzucker Group
Sugar factory and logistic aspects
Sugar as raw material for biobased economy
Bioenergy
Palatinose™ Isomalt
Gluconic acid
Summary
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 3
The Südzucker Group: Overview
Global operating German food group Segments sugar, special products, CropEnergies and fruit 18.000 employees € 5.9 billion annual revenues Sugar production: 4.2 million tonnes Leader in the European sugar market Member of the German MDAX
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 4
Core Competence of the Südzucker Group
“From Farm to Fork”
Transformation of agricultural raw materials into food/feed ingredients and agrochemicals
The Südzucker Group relies on its close cooperation with theagricultural industry, the basis of its commodities, the group's in-house research expertise, its extensive manufacturing knowledge in connection with processing renewable raw materials and itsmarketing experience, particularly in the B2B area.
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Südzucker Group – Segment Overview
30 sugar factories and 3 refineries in
Germany, Austria,Belgium,
Bosnia-Herzegovina, The Czech Republic,
France, Hungary,Moldova, Poland,
Romania, Slovakia
Sugarsegment
BENEO-Group(Orafti/Palatinit/
Remy)Freiberger
PortionPack EuropeStarch
Special productssegment
Fruitsegment
Fruit preparationsFruit juice concentrates
37 production sitesworldwide
CropEnergiessegment
Bioethanol4 sites in Germany, Belgium and France
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 6
Sites of the sugar factories/refineries today
Südzucker Raffinerie Tirlemontoise Saint Louis Sucre AGRANA
France
Austria
Germany
Czech.Republic
Belgium
Slovakia
Hungary
Romanie
Moldova
Marseille
Eppeville
Roye
Etrépagny
Kaposvár
Tulln
Leopoldsdorf
HrusovanyOpava
Sered
Roman
Buzau
Drochia
Falesti
Alexandreni
Tienen
Wanze
Poland
Ropczyce
Strzyzów
Otmuchów
Swidnica
Cerekiew
Cagny
Warburg
WabernBrottewitzZeitz
Ochsenfurt
PlattlingRain
Status at: Mai 2009
Bosnia-Herzegovina
OffsteinOffenau
Strzelin
^
Brcko
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 7
““FromFromagricultural rawagricultural rawmaterials to materials to food ingredients and
agrochemicals””
Fruit juiceconcentratesFruit preparations
Fruit
EthanolSugar beet
Maize
Wheat
OligofructoseInulin derivatives
InulinChicory
Modified starchesInulin derivatives
StarchMaize, Potatoes
FlourStarchProteinsRice Bran
Rice
Invert sugar syrup, Fructose syrup, PalatinoseTM, Isomalt, Caramel sugar
SucroseSugar beet
ProductsAgricultural rawmaterial
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 8
Sugar beets – a powerful sugar producing crop
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 9
Südzuckers core competence‚From Agrocrops to Agrochemicals‘
Best available technology
biomass logistics processing conversion product market
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 10
Content
Südzucker Group
Sugar factory and logistic aspects
Sugar as raw material for biobased economy
Bioenergy
Palatinose™ Isomalt
Gluconic acid
Summary
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 11
Sugar plant data
Grown under contract campaign: mid September to begin January Typical sugar factory:
15.000 t beets/day, beet storage on site for max. 3 days 800 trucks/day, 24-h-delivery, 30 bis 40 trucks/h 1,5 … 2 million t beets/campaign 200.000 bis 300.000 t sugar/campaign 130.000 bis 180.000 t dry feed pulp/campaign or 330.000 bis 440.000 t pressed pulp/campaign
Costs for Logistics Transportation approx. 40 km Costs for loading, cleaning and transport approx. 6 €/t beets
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 12
Sugar Yield [t sugar/ha grown] - the last 26 Years
4
5
6
7
8
9
10
11
12
13
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
SZ
[t Sugar/ha]
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Amounts of nitrogen- phosphor- and potassium-commercialfertilizer used in sugar beet cultivation 1980 - 2005(Trials within „Verband Süddeutscher Zuckerrübenanbauer e.V., Würzburg“)
0
5
10
15
20
25
30
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
NP2O5K2O
kg fertilizer / t sugar yield
NP2O5K2O
0
50
100
150
200
250
300
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
kg h
a-1
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 14
Sugar beet harvest with topping of beets
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 15
Directly on the truck or beet clamp after harvest
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 16
Coverage of beet clampsoil cleaningfreeze protectionreducing sugar losses
Only short term storage – notfor months
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 17
Loading of the beets to trucks (no tractors)
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Soil separation during loading
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Unloading of the beets in the plant
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 20
Unloading – here: dry
in many plants as well wet unloading
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Storage and ventilation of beets in the plant
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Sugar logistic – mainly on road
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Feed material from sugar beet – wet or dry beet pulp (pellets)
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Isomalt Syrups / Fructose
Burnt SugarsR&D
Offstein site (located 15 km from Worms) – biorefinery ‚nucleus‘
thick juice storage
Sugar factory campaigndaily beet capacity 15.800 tabout 19.000 ha beet areaSugar production 1.500 … 1700 t/dThick juice storage 2 x 50.000 m³
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 25
Content
Südzucker Group
Sugar factory and logistic aspects
Sugar as raw material for biobased economy
Bioenergy
Palatinose™ Isomalt
Gluconic acid
Summary
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 26
From classical beet process to sugar biorefinery
Unloading
Beet Storage Beet WasherCosette /
Juice MixtureTower Extractor
Raw Juice ExhaustedCossettes
Carbonation
Press-water
EvaporatingCrystallizers
Minglers
Centrifugals
Cooling and drying drums
SugarSilo
Screening
Packaging Dispatch
Steam Boiler
To Juice Heat Exchangers and Crystallization
Multiple Effect Evaporator
Melted LiquiorFilter
Dissolving
Steam turbine
Run off syrup
SlicingMachine
Liming
ThickeningFilter
White sugar Refinade sugarMolasses
Fuel
Exhauststeam
Run off syrup
Refinadesugar
Whitesugar
Raw-sugar
After product
Steam
Thick Juice
Thin Juice
Thin Juice toJuice Evaporation
fermentationto
bioethanol
Raw Juice
Thin Juice
Thick Juice
green syrup
MolassesBiomethan from
beet pulpBioethanol
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 27
CropEnergies sugar based bioethanol plant in Zeitz, Germany
Raw material: 150,000 t of thick juice/a
Ethanol 100,000 m3/a
Side product: 35,000 t/a vinasse
Fermentation: Batch wise
Start of production: June 2008
Distillation
Fermentation
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 28
Principle of ethanol production from thick juice (Zeitz)
1. Thick juice (65-70 % dry matter)
2. Diluted thick juice
3. Pasteurisation at about 80 °C
4. Batch fermentation
5. Distillation, rectification Ethanol
6. Evaporation of vinasse Feed, fertiliser
fresh water
backset vinasse
N-source, yeast, trace elements
Partial yeast separation
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 29
AGRANA opens first-of-its-kind biogas plant in Kaposvár, Hungary
In 2007 at the site of the Kaposvár sugar factory in Hungary, AGRANA installed a large-scale biogas facility that to date is unique in the European sugar industry.
The feedstock consists of the spent beet pulp produced during sugar beetprocessing, as well as of beet syrup. These organic by-products nowsupply a large portion of the energy needs of the sugar plant.
About 860 tonnes of beet pulp per day is fed into the plant’s fermentationprocess, corresponding to roughly one-half of the factory’s daily output of beet pulp. This results in the production of 110,000 cubic metres of biogasper day.
Quelle: press release 15.11.2007; www.agrana.com
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 30
71. IIR-Kongress am 13./14. Februar 2008 in BrüsselEugen Gaschler
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 31
71. IIR-Kongress am 13./14. Februar 2008 in BrüsselEugen Gaschler
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 32
Product Groups with high Potential
Product categories with revenue potential >> 1€
Food ingredients with special features / properties (functional food)
Renewable feedstocks, e. g. products with additional properties to
petro chemicals
Maximum utilization of intrinsic molecular structure, i. e.
Pursuing these targets beyond the present utilisation means:
„R & D in new technologies"
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 33
Sugar based Biorefinery
Sucrose
Fru/Glu mixturechrom. Glucose
Fructose
new technoloy
Specific catalysts
Gluconic acid
catalysis Mannitol-solution
Isomaltulose (solution)cryst.
Isomaltulosecat.catalysis
Isomalt50 GPM : 50GPS
Isomalt GS40GPM : 60 GPS
Isomalt LM
Isomalt DC
Isomalt HCcat.
new catalyst
new drying
new agglo.
Technology for material conversion
Chemical catalytic processes• Hydrolysis• Hydrogenation• Oxidation
Biochemical catalytic processes• Hydrolysis• Isomerisation• Transferases
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 34
O
HO
HOOH
OHO
O
OH
HOOH
OH
HydrolyseInvertase, H+
HO O
HO
OH
OHOH
O
OHHOHO
OH
OHHO
OH
OH
OH
OH
OH
HO
HO
OH
OH
OH
OH
Sucrose
Glucose
Fructose
H2
catalyst
Sorbitol
Sorbitol + Mannitol
Applied by Südzucker: H+ -fixed-bed ion exchanger (about 200kt/a)
Large-scale production of fructose by Südzucker
Mannitol (sorbitol)-production of SZ-products by customers
H2
catalyst
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 35
Sucrose
PalatinoseTM Fructooligosaccharide NeoamyloseIsomaltTM
HOO
HOOH
OH
O
O
HO
OHOH
OH
HOO
HOOH
OH
OHO
OH
OH
OH
O
HOO
HOOH
OH
OOH
OH
OH
OH
OH
HOO
HOOH
OH
OHO
OH
OHO
OHO
OH
O
OHO
OHOH
O
n
HOO
HOOH
OH
OO
HOOH
OH
OO
HOOH
OH
OHn
- sweet- crystalline- water-soluble
- delayed digestible glucosesource
- caloric energy 4 kcal/g- very low GI- very low I I
- toothfriendly
- sweet- crystalline- water-soluble- little digestible- caloric energy
regulatory EU: 2,4 kcal/gphysiological USA: ~2 kcal/g
- very low GI- very low I I- fiber- bifidogenic- toothfriendly
- less sweet- crystalline- very well water-soluble- indigestible- caloric energy ~ 1,5 kcal/g- very low GI- very low I I- fiber- bifidogenic- higher mineral resorption
(long-chain inulin)
- not sweet- crystalline- insoluble in water- indigestible- caloric energy 1 kcal/g- very low GI- very low I I- fiber
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 36
Production of PalatinoseTM
2
1
3
Palatinose™ Protaminobacter rubrum
Trehalulose Pseudomonas mesoacidophila
Leucrose Leuconostoc ssp.
Palatinose™Saccharide
O
HO
HO
OHO
O
OH
HOOH
OH
OH
Protaminobacter rubrum1,2 1,6
Technical production
O
HO
HO
OHO
O
OH
HOOH
OH
OH
2
1
3
HO O
HO
OH
OHO
OH
OHO
OH
OH
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 37
What is Palatinose™?
Palatinose™: The ONLY fully digestible, low GI carbohydrate providing prolonged energy release in the form of glucose
Like sucrose composed of glucose and fructose
A natural constituent of honey
Produced via non-GMO enzymatic rearrangement of sucrose
Sugar
Origin and molecular structure of Palatinose™
• Generic name: Isomaltulose• (6-0-α-D-glucopyranosyl-D-fructofuranose)• CAS Reg. No. 13718-94-0• Total molecular formula: C12H22O11 x H2O• Molecular weight: 360.32
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 38
Chemical catalytic process with Ni-catalyst
in fixed bed
Hydrogenation of Palatinose™ to Isomalt
OH
O
HO
HOOH
OHO
OH
OHOH
OH
1,1 GPM1-O--D-glucopyranosyl-
D-mannitol
O
HO
HOOH
OHO
OH
OH
OHOH
OH
1,6 GPS6-O--D-glucopyranosyl-
D-sorbitol
Palatinose™
H2
O
HO
HOOH
OHO
O
OH
HOOH
OH
Isomalt is the only bulk sweetener made from sucrose which can replace sugar in a 1:1 ratio
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 39
Palatinose™/Isomalt - Production plant
Offstein, Deutschland
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 40
Sugar Beet
Glucose
Gluconic Acid
Oxidation on Au / Al2O3
Oxidation of Carbohydrates
COOH
H
H
H
H
OH
OH
OH
C
C
C
C
CH OH2
HO
Lactobionic Acid
Milk
Starch
Lactose
COOH
OH
H
OH
OH
H
H
CH2OH
O O
HH
OH
OH
H
OH
H
CH2OH
T = 40-60°CpH = 7-9
High activityExtreme high selectivity > 98%High long term performanceSimple synthesisNo leaching
or
or
Complexing agent, acid regulatoringredient for cosmetics,
pharmaceuticals & cleaners
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 41
Oxidation of Carbohydrates using supported gold catalystAdvantages vs. fermentative process
Simple synthesis Applicable for diverse feed (Glucose /- syrups, Maltose, Lactose) Outstanding properties (high activity, selectivity, long-term
stability) High productivity
130 gGluc l-1 h-1 vs. 15 gGluc l-1 h-1 fermentative
63 gglucon acid g-1Kat h-1 vs. 5 gglucon acid g-1
BioM h-1 fermentative
Economically and environmentally friendly process
+ ½ O2
Glucose Sodium gluconate
+ H2ONaOH
Au/Al2O3
HO O
HO
OH
OHOH
HO
OH
OH
OH
OH
O
ONa
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 42
Summary
Sugar biorefinery needs strong agricultural industry
research expertise (along the value chain)
extensive manufacturing knowledge in connection with processingrenewable raw materials
crossfunctional teams
ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 43
Thank you for your attention!
Contact:
Dr. Wolfgang WachSüdzucker AG Mannheim/Ochsenfurt
Wormser Straße 1167283 Obrigheim/Pfalz