Lignocellulosic residues use for energy and materials in ... · Lignocellulosic residues use for...

LignocellulosicLignocellulosic residues use for residues use for energy and materials in the bioenergy and materials in the bio --economy: The Dutch experience economy: The Dutch experience

“Biofuels and their future in the power matrix”University of Chile

by

Jan E.G van DamJan E.G van Dam

Santiago de Chile 2009Santiago de Chile 2009

Product development for Product development for

BioBio --based Materialsbased Materials

04 11 09

Jan E.G van DamJan E.G van Dam

Div Div BiobasedBiobased ProductsProducts

Wageningen URWageningen UR

BioBio --economyeconomy

…….the solution for .the solution for sustainable developments sustainable developments

...?......?...

BioBio economyeconomy

…….the solution for .the solution for financial bubbles and financial bubbles and

crises ...?...crises ...?...

BioBio economyeconomy

…….the solution for .the solution for sustainable green sustainable green

developments ...?...developments ...?...

BioBio--economyeconomy and Sustainable developmentsand Sustainable developments

• KYOTO and CO2 neutral production

• Transition process Copenhagen 2009

• Renewable resources for energy and industries

• Exploitation of biomass from agro-industrial residues

• Value addition in materials, and ‘green’ chemicals

Dutch situation

• Densely populated• Restricted land area for bulk production• Specialized high productivity farming

• Highly industrialized• Logistic organisation• Long trading tradition

Dutch challenges: Milenium development goals

• Reduce oil dependency• Imports of biomass• Collecting and on site pre-processing

systems

• Biorefineries analogue to petrochemical refining

• Exports of value added “green chemicals”

Dutch Government and Industries vsBioeconomy

• Advise for CO2 neutral production• Alternative biomass farming

Energy crops / Marine crops / algae / seaweeds

• Suitable sources for imports for fuel and chemistry and biobased products

• Carbon emission trade• Development aid and CDM

Renewable Resources for energy and industries

• Industrial chemical feedstock– complex route– glucose based chemistry C6– lignin based chemistry C9– C1 / C2 chemical building blocks (syngas)

• Bio-refinery, bio-cascading, whole crop utilisation– opening, refining, extraction, etc

Biobased materials

Biomass for energy returns quickly CO2 in the atmosphere

Carbon sequestration can be achieved in durable goods:

Bioplastics (PLA, PHA/PHB and other), Cellulose and Starch plastics (CDA, cellophane),

CharComposites

Building materials (wood and fibre boards)

Biorefinery

Foo

d

Fee

d

Mat

eria

ls

Che

mic

als

Fue

ls

Pow

er

Hea

t

Bio-Economy

Food/Feed

Bioenergy

Biomaterials

Bio chemicals

Market Volum

eM

arke

t Pric

e

BioenergyFood

Feed

Bio-based Products

Fuels

Power Heat

Materials Chemicals

precipitation Coatings Biopolymersextract

sugars Alcohol / H 2

effluentdryingchoppingpelletising

residue

Feedgassifycombustion

Energy

waste compost

compostingdisposal

silica

fermentation

tar

ash

Protein, lipids

Biomass

fuel

extraction modification

refining fibre pulp Paper / boardadhesives

Biorefinery (cascading) of biomass

Biorefinery is “Green” Chemistry

Products

inter

Sepe

ratio

nun

it

processes

seed

leaf

tuber

mediate

Raw materials Processes

(bio

refin

ery)

PET NYLON

Biodiesel Bioelectricity

Polylactate

Biotechnology

Chemistry

EnzymologyMicrobiology

Logistics and rural economy,

Process technology and food technology–Plant breeding,GMO

Environmental economy Thermodynamics

Renewable Resources for energy and industriesRenewable Resources for energy and industries

•• Speciality crops Speciality crops –– cosmetics and cosmetics and pharmapharma -- small volume / high pricesmall volume / high price

•• NonNon--food cropsfood crops–– oil, fibre (textile, paper pulp), oil, fibre (textile, paper pulp),

–– fermentation feedstockfermentation feedstock

•• Energy cropsEnergy crops–– transport fuel and electricity transport fuel and electricity -- bulk volume/ low bulk volume/ low

priceprice

Biorefinery: raw material cost from Pharma to Fuel

70178.50.080.02--

Loss10% rendementMM € /y

700170850.850.170.0070.003Raw material MM € /y

20.000.0005.000.0002.500.00025.0005.000200100

Kton raw mat. (a 35/ton)

20.000.0004500.0002.000.00010.0001.000101Volume kton/y

0.0350.30.51.541502.500

€/kg

Endproduct

Electricity fuel

Transport fuel

Bulk chemical

Large volume (Glu.)

Small volume (Arg.)

Enzymes

Pharma

Aloe vera glucomannan

Skin care gels health

Linking of markets

F o o d

B io m a s s p r o d u c t io n

1 s t Ag r o lo g is t ic sFo o d p r e t r e a t m e n t

Fo o d p r o d u c t io nC o n ve r s io n

N o n -fo o d :• F e e d

• C o m p o s t

• W a s te m a n a g e m e n t.

Ag r i s o u r c e sAg r o -fo o d p r o d u c t io nB y p r o d u c t s & w a s t e

L o g is t ic s &s t o r a g e

p r o d u c t io nIm p o r t s

C o n ve r s io n Pr o d u c t io n

$

$

$

B io b a s e dP r o d u c t s• B io b a s e dm a te r ia ls• G r e e n

c h e m ic a ls• B io - fu e ls• B io -e n e r g y

Pr o d u c t io nP e r fo r m a n c e m a te r ia lsB a s e & p la t fo r m c he m ic a lsP e r fo r m a n c e c he m ic a lsB io En e r g y

Pr e -t r e a t m e n t & c o n ve r s io n

p h y sic a l& c h e m ic a l c on v e rsio n

p r o c e ss e ng in e e ri n g

b io c o n ve r s io n

F o o d

B io m a s s p r o d u c t io n

1 s t Ag r o lo g is t ic sFo o d p r e t r e a t m e n t

Fo o d p r o d u c t io nC o n ve r s io n

N o n -fo o d :• F e e d

• C o m p o s t

• W a s te m a n a g e m e n t.

Ag r i s o u r c e sAg r o -fo o d p r o d u c t io nB y p r o d u c t s & w a s t e

L o g is t ic s &s t o r a g e

p r o d u c t io nIm p o r t s

C o n ve r s io n Pr o d u c t io n

$

$

$

$$$

$$$

$$$



















Natural Natural fibresfibres end useend use

•• Textiles, yarns and woven fabricsTextiles, yarns and woven fabrics•• Ropes, twines, cordage, netsRopes, twines, cordage, nets•• NonNon--woven fabrics, tissueswoven fabrics, tissues•• CompositesComposites•• Paper and boardPaper and board•• FibreFibre boards and insulationboards and insulation•• BioBio--ethanolethanol value additionvalue addition

•• FuelFuel•• Mulch and compostMulch and compost

€

The Word textile Fibres production

World fibre production 1920-2006 (kton)

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

1915 1925 1935 1945 1955 1965 1975 1985 1995 2005

Cotton

Synthetic (petro-based)

Man-made cellulose fibres *

BambooBamboo growinggrowing RegionsRegions

USA

EU

Cameroon

Nigeria

GhanaEthiopia

Kenia

Viet Nam

India

China

Fujian Province Economic and TradeCommittee

Nicaragua

Colombia

Brazil

Growing demand for Growing demand for biobiomass resourcesmass resources

Agricultural & Forestry crops for energy and materials

Transfer of technology and innovation

Biorefinery / bioconversion

cascading of biomass for value addition

Biomass conversion to energy

• Selection criteria process & products

biomass

pretreatment

Gassify(650 – 1200 ° C)

Combustion(850-1200 °C)

Pyrolysis(500 – 700 °C)

Liquefaction(< 300 °C)

Fermentation

(20 - 70 ° C)

Water % content

<15%

>85 %

CO2 H2 CH

Heat

Gas, oil, tar

Oil

ethanol,

butanol,aceton,

H2

CH4

Temperature / pressure

How to supply the How to supply the biobio --economyeconomy ??

Is there enough biomass available Is there enough biomass available

that can be utilized that can be utilized

without negative effects without negative effects

on food supply and bioon food supply and bio --diversitydiversity

????

Competing claimsCompeting claims for biomass resourcesfor biomass resources

Sustainable production

food supply security FAO / UNEP / UNIDO / IEA

land use

deforestation NGO

rural development

Rapid expansion of demand for energy purposes

DEVELOPMENT OF BIOREFINERY

For human consumption For human consumption

6 6 GtGt is harvested each year is harvested each year

for food, feed and nonfor food, feed and non --food food

((or 3.5% of total plant production)or 3.5% of total plant production)

Transition to the Transition to the biobio --economyeconomy

Current world wide land use: Current world wide land use:

1010--12% cultivated terrestrial surface12% cultivated terrestrial surfaceor 50% of the suitable arable land areaor 50% of the suitable arable land area

and 25% forest area and 25% forest area (including plantations)(including plantations)


What are the What are the biobio mass resources mass resources

where are those available where are those available

at what costs at what costs

????


What are the What are the biobio mass resources mass resources

where are those available where are those available

And for which sustainable application?And for which sustainable application?


How much biomass is needed How much biomass is needed

to supply industries to supply industries

at viable economical scale at viable economical scale

and of what quality and of what quality

?? ??


Unused biomass resourcesUnused biomass resources

Agricultural crops Agricultural residues

Food industry wastes

Forestry crops Forestry residues

Black liquorWaste paper

Animal waste ManureMunicipal solid waste SewageMarine crops Algae,

Fishery residues

VariousVarious CropsCrops and and RegionsRegions

Cotton

CottonCorn

Sugarcane Soya

Sugar beet

Palm oil CoconutCoconut

Cassava

Algae

Soft WoodSoft Wood Soft Wood

Cotton

Hard Wood

Hard Wood

Wheat Soya

Rice

Wheat

EucalyptEucalypt

Cacao

Soya

Bamboo

BambooBamboo

• Agroresidues of food and non-food crops– cotton stalks – rice straw / hull– sugar cane bagasse– corn cobs– coconut husk– jute fibre and other fibre crops – palm oil residues– eucalypt bark– verge grasses / bamboo

Renewable raw materials and sustainable development

R&D activities for sustainable developments (1)R&D activities for sustainable developments (1)

•• Supply managementSupply management

•• Upgrading of existing and innovative Upgrading of existing and innovative technologies to ecologically improved technologies to ecologically improved productionproduction

•• Novel innovative markets for renewable Novel innovative markets for renewable products products

•• Valorisation of residuesValorisation of residues

R&D activities for sustainable developments (2)R&D activities for sustainable developments (2)

•• AgroAgro--logistics, storage, transport and packaginglogistics, storage, transport and packaging

•• ‘‘WhiteWhite’’ biotechnology, biotechnology, biorefinerybiorefinery

•• Product developmentProduct development–– Renewable energy from biomass residuesRenewable energy from biomass residues

–– Building and construction materials Building and construction materials

–– ‘‘Green chemicalsGreen chemicals’’ and bioand bio--polymers, adhesives, additives polymers, adhesives, additives and coatingsand coatings

Biomass from agroBiomass from agro--industrial residuesindustrial residues

World production capacity coconut husk 15-20 million tons /year

Husk preparation (CFC/ FAO project)Husk preparation (CFC/ FAO project)

Coconut husk

Opening Milling

Coconut

coconut based boards

• High quality wood substitute products – High strength – Moisture – Good workability– Fire resistance– Resistance to biodegradation

• Added value for wasted resource– abundantly available– Highly competitive cheap resource

• Non need for expensive chemical additives– Ecologically save material– CO2 neutral

• Fits in policies for sustainable development

Building and construction materialsBuilding and construction materials

Economical evaluation

• Production: – 10,000 tonnes board/year– 400,000 boards 4 ft*8 ft* 0.25 inch

� 1,333 boards/day

• Raw material– 77,650,000 husks/year

� 260,000 husks/day

• Investment estimate– 650,000 US$

Eucalypt bark Eucalypt bark INNOVA INNOVA EsquerrEsquerréé LtDLtD

Eucalypt bark applicationsEucalypt bark applications

• Binderless fibre board / particle board

• Pyrolysis oil for ‘green’ chemicals (resins)

• Non-woven erosion mats (geotextiles)

• Charcoal and micro-powder

• Pellets for fuel

• guaranteed supplies

– sufficient quantities of raw material– whole year availability– constant quality – competing price

Biomass requirement for industrial board production

Jute based geotextiles with prolonged lifetime

Dunes replanting with jute fabric

Demands functional lifetime geotextile

Experimental plot Regge & Dinkel, March 1999

Durability increase by acetylation

Conclusions:

• 3-5 x life time extension of jute, flax and cocos

• Very well rooting of plants

• After 5 yrs only cocos can be retraced

Technology for natural fibre reinforced plastics

Compression (one-shot) moulding

Injection moulding

Raw materials agrofibrePP

Granules

Extrusion

Production of high yield pulps from green jute

• Newsprint quality• High yields• Low chemical input• Low COD and BOD demandsOptions considered:

– Extrusion pulping– Refiner mechanical pulping– Enzyme pretreatment

Pilot scale biopulping experiments (USA)

Oil Palm (Oil Palm (MalaysiaMalaysia, , IndonesiaIndonesia))

27 millions of tons a year, 23% of the World’s vegetable oil production (2003)

Extensive global expansion (from 2 to 7 million ha in last 20 years)

80% of the World production on account of Malaysia and Indonesia

Palm oil and palm kernel oil are the only “products” (9% of the produced biomass), the rest is “waste”

Exploitation of biomass from agro-industrial residues

• palm oil residues

• low utilisation rate

UtilisationUtilisation of Palm of Palm oiloil residuesresidues

Lignocellulosic fibres at estate– fronts (10.5 tons /ha/yr)

– trunks (70 tons / ha / 25 yr)

Residues at palm oil mill– empty fruit bunch (1 ton / ton palm oil)

– mesocarp fibre (0.6 ton / ton)– shells (0.4 ton / ton)

– effluent (0.4-1.0 ton/ton)

partly used as boiler fuel

OptionsOptions forfor sustainablesustainable residueresidue utilisationutilisation

Bio-diesel (residual oil / pressing cakes)Bio-gas, H2 / ABE and ethanol fermentationBio-polymers (PLA, PHA)Bio-oil pyrolysis (BTG) / CharcoalFibres for paper, building boards and

compositesDissolving cellulose“green” chemicals (lignin and furfural

adhesives)

Sustainable building

• Renewable materials• High performance

• Competing for quality• for comfort• for safety

Bamboo fast growing Bamboo fast growing biobiomass resourcemass resource

Industrial application in

textile fibre

paper & pulp

cellulose materials

particle boards and laminated structures

China: shortage of wood resources

non-polluting bamboo innovation

Innovations for bamboo fibre

cellulose processing cellulose modification (acylation)xylan product developmentlignin conversionsilica & waxbamboo carbon fibre

recycling and chemical recovery

Bamboo structures Simon Velez

Bamboo plywood construction

Sustainability criteria

• Ecological .. Wood substitute products to prevent deforestation

• Carbon credits / CDM• Socio-economic – labour, income and housing• Addressing poverty by supporting the incomes

and livelihoods of commodity producers• Fair trade and quality certification

ConclusionsConclusions

By-products utilisation for added value is beneficial to the sustainability of crop production

Essential for certifying the sustainability of biomass energy and products.

Multi-stakeholder involvement needed.

Include outsider (food vs non-food) industries involved in energy and fibre products

Developmental strategyDevelopmental strategy

Demonstration of • technical feasibility laboratory and pilot scale• socio-economic potential field study• marketing potential• business plan

Identification of partners • in primary production and industry • investors and stakeholders

Industrial implementation of R&D

• difficult and slow• remain at the level of laboratory or pilot scale

• lack of investors• small size of the industries involved in innovation (SME)

•not capable of organising •raw materials supplies•maintenance of quality standards•marketing tools to penetrate market niche fast enough

Dutch Government new initiatives Nov 2009

• Ministries of Economic Affairs and Agriculture join efforts to boost investments in bio-economic developments:– Support for Pilot and demonstration plants for biorefinery

to make food medicines, feed, chemicals biofuels and materials 10 M€

– Subsidies for gassification of biomass 13.5 M€– Financial injection in R&D for aquatic biomass (algae

and seaweeds) 1.3 M€

Innovation agenda energy: “clean & efficient”

Alginate polyuronic acids from Sea weeds

print paste

dental modeling gel

wound dressing

Outlook markets for biobased materials

Many innovative industrial projects possible…

but

Not without industrial investment and government commitment

Bio-based economy is investment in the future

companies TO GET INVOLVED:

• Primary processors / biorefineries• Fibre pulping industries• Cellulose manufacturing • Cellulose textiles • Bio resin producers• Fibre board producers• Fibre composites producers• Activated carbon • Bio plastics • Building industries .. And many more.. And many more

Conclusion

There is no need for waste There is no need for waste

when itwhen it ’’s bios bio --basedbased

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