Welcome to the World’s most
advanced biorefinery!
Jerry Gargulak
Gudbrand Rødsrud
Martin Lersch
Rolf Andreas Lauten
Anders Sjøde
A Practical Discussion
•Borregaard Business Model and
History
•The Technology and Value of
Lignosulfonates
•BALI Pretreatment: Viable
Economic Business Model
Borregaard products in daily life
Bio fuel
Dust control
Construction
products
Paint
Food
Flavour Pharmaceuticals
Car batteries,
gaskets, care
products
Animal feed
Soil
conditioner,
fertilizers
Textiles, spectacle
frames
Gypsum Board
Copper pipe
Global presence
Borregaard 2010 Turnover: € 660 mill.
Employees: 1300 in
20 countries
Main office
Sales office
Production
LignoTech USA Inc.
• Part of LignoTech group since 1991
• Specialty Lignosufonate products
• Capacity: 75,000 MT dry solid/yr
• Powder and liquid products
• Proprietary process technologies
• Formulation capabilities
• 75 Employees
• North American Legal entity
– Multiple sales locations
– Administration and customer service
– R&D, Tech support and BD Functions
• Leading supplier of specialty cellulose
• Global leader in lignin performance chemicals, 50%+ market share
• Only producer of vanillin from lignocellulosics
• Production of lignocellulosic bioethanol since 1938 (20.000 m3/y)
• 100% renewable energy expected by 2013
True Biorefinery
From Paper Mill to Biorefinery
Oil or biomass – green or black carbon?
Sustainable
chemicals,
materials,
ingredients,
biofuel
GREEN CARBON BLACK CARBON
Borregaard site in Sarpsborg, Norway
Head office - R&D - Production
800 employees, 2.5 bn NOK turnover
From spruce: specialty cellulose, lignin
products, biovanillin, 2G bioethanol
Other raw materials: basic chemicals,
energy, fine chemicals
The Team
Further development of the biorefinery concept
BioMaterials - Polymers - Composites
BioChemicals - Flavours - Monomers - Proteins - Fine chemicals - Speciality chemicals
BioFuel - Bioethanol - Biodiesel - Biogas
BioEnergy - Electricity/Heat - Liquid Fuels - Pellets
Co
st/
pric
e
Low
High
Creati
ng
valu
es
Low
High
BIOREFINERY
When you have choices you can optimize.
BIOETHANOL
A Practical Discussion
•Borregaard Business Model and
History
•The Technology and Value of
Lignosulfonates
•BALI Pretreatment: Viable
Economic Business Model
Pulping
• Pulping is the separation of cellulose from lignin and other components
• Lignin is rendered soluble
• Insoluble cellulose is filtered off
12-Dec-11
Production of lignosulfonate Production of Lignosulfonate
Fermentation
ethanol
Worlds first sulfite ethanol plant
started in Sweden in 1909
• First sulfite ethanol plant ever opened 1909
in Sweden, Skutskär, Uppland
• 33 plants in operation in Sweden, only one in
operation after 1983: Domsjø, capacity of 15
000 m3/y
Source: Persson, Bertil. Sulfitsprit. Förhoppningar och
besvikelser under 100 år. Bjästa : DAUS Tryck & Media,
2007. ISBN: 91 7542 258-1.
0
10000
20000
30000
40000
50000
60000
70000
80000
1909 1914 1919 1924 1929 1934 1939 1944 1949 1954 1959 1964 1969 1972 1977 1982 1987 1992 1997 2002
tom 100% sprit
år
Den svenska sulfitspritproduktionen
17 Sulfite ethanol plants in Finland 1927 -
1977
Sources:
1. Biorefining in the pulp and paper industry.
Niemelä, Klaus. Flensburg : s.n., 2008. 5th
European Biorefinery Symposium.
2. Kaukoranta, Antti. Sulfittispiriteollisuus
Suomessa vuosina 1918-1978 (Eng:"Sulphite
alcohol industry in Finland in 1918-1978"). s.l. :
Paino Polar Oy, 1981. ISBN 951-9479-25-2.
3. Niemelä, Klaus. Private communication. s.l. :
VTT TECHNICAL RESEARCH CENTRE OF
FINLAND , 2010.
1977 last sulfite ethanol production Early 1990’ies Last sulfite mill in Finland stopped production
Composition of crude LS solids
% RANGE
SOFTWOOD HARDWOOD
LignosulfonateHexose SugarsPentose SugarsMiscellaneous Hemicellulose, Sugar Acids Resins and Extractives
65146
123
52520
203
12-Dec-11 Page 19
Sulfite Pulping
Three dimensional structure
20 nm
Typical size exclusion curve
1000 nm 20 nm
Particle Size of Lignosulonates
30.04.03 -
Page21
Dispersing Agricultural formulations Concrete Ceramics, refractories Dyestuffs Gypsum board Oil drilling muds Pigments Carbon black Water treatment & industrial cleaning
Some Applications
Binding Briquetting bricks Dust control Paper & board Particle board Pelleted feeds
Other Emulsion Stabilization Batteries Cement Retarders (oil well) Soil conditioner Protein Bypass Flotation aid
Interfacial Agent
• Common denominater in these applications is that lignosulfonate is
used as an interfacial substance.
• This means that an application specific system (emulsion, suspension,
formulation) is manipulated or processed to concentrate lignosulfonate
at the interfaces between solid particles or oil droplets and suspending
medium (usually water)
• Once located at the interface, lignosulfonates performs.
• Lignosulfonates are present and used at interfaces, i.e. liquid-solid,
liquid-liquid, liquid-gas, solid-gas
• Lignosulfonate may or may not adsorb onto an interface. There has to
be an affinity between lignosulfonate and the interface in question. A
low affinity can be overcome by processing techniques.
Lignosulfonate
Lignosulfonate - emulsifier and dispersing agent
Flow table test
stabilize emulsions
disperse color pigments
disperse pesticides
Lignosulfonate
Concrete Additives
• Additives for concrete admixture formulations
• Water reducer for concrete
– Stronger, lower cost concrete
• Borresperse®, Norlig®, Wanin®, Wafex®, Ultrazine®
Essential Component for Lead Acid Batteries
• Modified Lignosulfonate –Vanisperse A
• Maintains charge capacity
• Improves cold cranking
• Longer lifetime
Improve life
0
3,200
0.0 0.3 0.6Vanisperse A Dosage:
% on weight of leady oxide
Lif
e @
41 C
Increase cold crank ability
20
33
0 0.3 0.6Vanisperse A Dosage:
% on weight of leady oxide
Co
ld C
ran
k @
-18 C
III BLT Latin
America March 8th-10th,
2007
Page 27
Organic Expanders
Increase the surface area of negative active material yielding
sponge lead
Preserve fine, porous lead crystal structure on cycling
Promote formation of small lead sulfate crystals on discharge
Promotes formation of a porous lead sulfate layer
No Organic 0.5% Vanisperse A
Images from D. Boden
A Practical Discussion
•Borregaard Business Model and
History
•The Technology and Value of
Lignosulfonates
•BALI Pretreatment: Viable
Economic Business Model
Sugar platform pathways – how to choose?
Hydrolysis processes
• Dissolving cellulose and hemicellulose leaving hydrolysis lignins undissolved
– Strong acid
– Weak acid
– Enzymatic
– Microbial
– Supercritical water
Pulping processes
• Dissolving lignin and (hemicellulose) leaving cellulose undissolved
– Kraft
– Soda
– Sulfite
– Solvent
– Extrusion
Lignin quality depends strongly on process and biomass source
Hemicellulose/xylan form and quality depending on process
Hydrolysis Lignin (S)
Hemi- Cellulose (L)
Cellulose (L)
Lignin (L)
Hemi- Cellulose (L)
Cellulose (S)
SOLID
SOLID
LIQUID
LIQUID
Pretreatment challenges
• Lignins bind to enzymes
– high enzyme dosage required for acceptable yield/reaction time
– prevents recycling
• Lignins are often impure and often strongly condensed
– unattractive feedstock for chemicals
• Unfavorable mass balance
– low yield of valuable product
– large fraction of feedstock used for energy production
Inspired by today’s existing biorefinery Borregaard has
developed a modified chemical pretreatment that
addresses these issues
BALI™ process in a nutshell
Feedstock handling
Pretreatment
Lignin processing/ marketing
Hydrolysis
Product purification
Fermentation
BALI – a significant simplification and spin-off opportunity
Lignin Cellulose Energy Lignosulfonate Sugars for fuel or chemicals
BALI vs Woodpulp biorefinery:
- Significantly reduced raw material cost - Reduced complexity and capital requirement - Value creation from lignin compared to other processes - Generates growth opportunities Change in business model for Lignosulfonate
Improved competitiveness through value creation
Traditional woodpulp Biorefinery
BALI
Biorefinery
Low cost raw material
High cost raw material
Dose-response curves with Novozymes
Cellic® CTec2
0 %
20 %
40 %
60 %
80 %
100 %
120 %
140 %
0 2 4 6 8 10 12
Glu
can
co
nve
rsio
n
Enzyme dosage % v/w (Cellic® CTec2 from Novozymes)
BALI acid pretreated bagasse
24 hours
48 hours
72 hours
0 %
20 %
40 %
60 %
80 %
100 %
120 %
140 %
0 2 4 6 8 10 12
Glu
can
co
nve
rsio
n
Enzyme dosage % v/w (Cellic® CTec2 from Novozymes)
BALI alkaline pretreated bagasse
24 hours
48 hours
72 hours
6.3% glucan loading
DS: 9.2% DS (acid) and 11.3% (alkaline)
50 °C, 200 rpm in shaking incubator
50 mM sodium citrate buffer at pH 5
50 g total reaction mass in 100 mL flasks
0.01% NaN3 for microbial control
Sugar analysis by HPLC
(> quantitative yield due to underestimation of
glucan in raw material analysis)
Novozymes comment:
”This is probably among the best
10-15% of all results we have seen”
Cost and complexity
Time to market
R&D Lab and miniplant
Pilot plant Full scale plant (green – or brownfield)
BALI project: Next steps
• Development and test of concept • Choice of technology • Analytical methods • Initial product tests
• Scale up • Adapt and improve technology • Process optimalization (reduce VC) • Test products to external customers • Base case for dimensioning full scale plant
• Commercial production
• Several plants
2007-2011 2011-2013 2014 -
Pilot : • Necessary for further technology development
Feedstock handling
Pretreatment
Product purification
Hydrolysis Fermentation
Lignin processing
Pilot demonstration plant
• Location: Sarpsborg, Norway
• Flexible feedstock
• Flexible process conditions
• 1 metric ton dry matter/day (50 kg/h)
• Commissioning expected May 2012
• 800 m2 total area
• Total cost approx 24 mill USD
• Continous operation
BALI Pilot – Status construction
Concrete work ready:
22 September
Steel structure ready:
25 October
Sealed building:
15 November
Building finished:
January 2012
Funding
BALI • PILOT
Biomass2Products Borregaard receives 19 mill NOK from the Norwegian Research Council (2009 – 2012) EuroBioRef Borregaard receives 3.0 M € from FP7 through the EuroBioRef consortium (2010 – 2013) Pilot plant 58 mill grant from Innovation Norway. BIL Board approval 72 mill NOK Technoport award for innovative environmental technology
BALI SUMMARY
• BALI pretreatment process, enables good economy in a biorefinery
• A good solution for a limited number of biorefineries
– market for lignin performance chemicals is not unlimited
• Borregaards strategy is to produce biochemicals, not biofuels
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