24-25 june2013 putrajaya biorefinery demo projects in...

BIOREFINERY DEMO PROJECTS

IN EU

Capacity Building Programme

small scale biorefineries24-25 June 2013 Putrajaya

©istockphoto/anna kuzilina

Status of 2nd Generation Biofuels Demonstration Facilities by IEA

Bioenergy Task 39

http://demoplants.bioenergy2020.eu/projects/mapindex

Thermochemical pathways

Source:biofuelstp.eu

Biochemical Pathway

Source EBTP

Generic process scheme for 2G ethanol

Source EBTP

Main cellulosic EtOH running demos

Source EBTP

Start up in July 2012

• Feedstocks

• agricultural residues as feedstock (Phase 1)

• dedicated energy crops (Phase 2)

• The Sunliquid® process involves: a hydrothermal pretreatment at mild

process conditions, a process-integrated production of enzymes, enzymatic

hydrolysis, a specialized fermentation organism that simultaneously converts

C5 and C6 sugars into ethanol in a « one-pot reaction », adsorption-based

CLARIANT FACILITY

C5 and C6 sugars into ethanol in a « one-pot reaction », adsorption-based

separation of ethanol

Source EBTP

ABENGOA

Location: babilafuente Spain

Start up in September 2009

• Feedstocks:

• Wheat straw, barley straw

• The production process involves: preparation of biomass, thermochemical

pretreatment, enzymatic hydrolysis and fermentation with enzymes and yeast,

distillation to produce ethanol and a solid co-product

Source EBTP

Source: biofuelstpeu

DONG Energy

Start up in Dec 2009

Location: Denmark

• Feedstocks

• process developed on wheat straw

• Process: hydrothermal pretreatment (30-40%

Dry Matter), continuous enzymatic liquefaction

and hydrolysis, use of externally-produced

enzymes, production of C5 molasses, Energy

co-productionco-production

Inbicon

Source EBTP

Source: biofuelstp.eu

BETA Renewables

Location: Crescentino Italy

• Start up in December 2012

• Feedstocks: non-food biomass

• developed on Arundo donax (Giant cane) and wheat straw

• Initial capacity 40,000 tons/y then 60,000 tons/y

• Production process : PROESA®

Source EBTP


Main announced EtOH 2Gdemos (>1000t/y) in the EU

Source EBTP

Several demo under construction in U.S.

Source EBTP

Main EtOH 2G demo units outside EU

Source EBTP

Global statistics 2G demo plants

Source EBTPTotal 128

Capacity 2G EtOH by region

Source EBTP

Biobutanol3 relevant projects

Butamax (JV Dupont/BP): Demo 30t/y Hull , UK (Startup 2010)

• Gevo:

• 55,000t/y Luverne, USA (Operating 17 weeks since May 2012 then

switch to EtOH production for flexibility demonstration)

• Cobalt Technologies: 1440t/y Thomaston , USA (Startup 2013)

• Green Biologics

Hybrid processesHybrid processesZeachem : fermentation of C5-C6 sugars to acetic acid, esterification and

hydrogenation to EtOH with hydrogen from gasification of lignin :

● 750t/y : Boardman, USA (Construction completed in October 2012; EtOH production

should have

started since end 2012; conversion of sugar to ester operational)

● 75000t/y : co-located with pilot plant

● Coskata : Gasification then fermentation of syngas to EtOH

● INEOS Bio : Indian River, USA : 24000t/y + 6 MW


Demonstrations based on biological processes

LS9 – fermentation pathway from sugar to

fatty acid /alcohol; 270t/y, Okeechobee,

USA (operating since Sept 2012)

• Amyris - fermentation pathway from sugar

to «Biofene»; 40,000t/y at Paraiso, Brazil

(production since 27/12/2012; full capacity

for 2015)


Demonstrations based on chemical processes

•Virent - Chemical pathway from sugar

(Aqueous Phase Reforming). 38t/y,

Madison, USA (Demo operating since

2010)

• UPM - Chemical pathway from tall oil

(residue of chemical pulp production) to

UPM BioVerno (biodiesel) by

hydrotreatment; 100,000t/y at

Lappeenranta, Finland (plant should be

ready in 2014) Source: biofuelstp.eu

Demonstration projects based on thermochemical pathways


Main products from thermochemical pathways

•Synthetic fuels (oxygenates or hydrocarbons) through gasification.

•Bio-methane through gasification

•High efficiency heat & power generation through gasification•High efficiency heat & power generation through gasification

•Intermediate bio-energy carriers through techniques such as pyrolysis and

torrefaction


Synthetic fuels from gasification

The Forest BtL Project, FI

480 MWt / FT products / 2016-17

Gasification technology: Carbo-V

88 million € NER300 grant

FEED contract for Gasification & gas

cleaning signed Jan 2013

Forest BtL flowsheet

Bioliq® Project, DE

2 MWt / Synthetic Gasoline / 2013

Pyrolysis started 2008

Fast pyrolysis of straw+Gasification

(5MWt) + DME/gasoline synthesis


Chemrec Projects, SE

a. BioDME project

~3 MWt / DME / 2011

b. Domsjö and Vallvik mills

~200 MWt / Methanol and DME / On hold

(Currently

awaiting new national regulation on biofuels)


UPM Project

Pilot testing at GTI, Chicago, USA

~5 MWt / syngas production / Ongoing

Commercial Demonstration, FR

~300MWt / FT products(100 000 t/a) /

Investment decision 2014;


Gasification Module

Full sized plant

Source: UPM, Andritz,

Carbona Source: biofuelstp.eu

The Woodspirit Project, NL

Forest resid / Methanol / Dec 2016

200 000 tpa Biometnanol

Torrefied biomass into entrained flow gasif.


Consortiun of BioMCN, Siemens, Linde and VS

Hanab Site for the Woodspirit Plant

FICFB techn.


FICFB techn.

Güssing Plant, AT

8 MWt / Heat and Power / 2002

H&P plant but also test site for

FT, SNG, higher alcohols and H2


BioTfueL Project, FR

~ 12 MWt / FT products / 2014

Fuel mix of fossil and renewable

Including torrefied biomass


Värmlandsmetanol, SE~ 111 MWt / Methanol / 2017

CFB Gasification


Biomethane from gasification

ECN / HVC Project, NL

12 MWt / Fuel Gas + SNG(10%) / 2014

MILENA and OLGA technology

FICFB techn. – Güssing, AT

8 MWt / Heat & Power / 20028 MWt / Heat & Power / 2002

Test (=>2009): Side stream converted to SNG

SNG (1 MWt ) now restarted

Three other plants (AT, DE) producing H&P in

operation. One planned also for SNG

GAYA Project, FR

Decentralized SNG for

transportation application

1 MWt / SNG / 2013


GobiGas – Gothenburg Energy, SE

Phase 1

Wood pellets / 20 MWtof SNG / 2013

FICFB techn. (Fast Internally Circulating Fluidized Bed

type Güssing)

Phase 2

Biomass / 80 – 100 MWt of SNG / 2016


Biomethane from gasification


E.On Bio2G Project, SE

Biomass for~200 MWSNG / SNG / On Hold

4 years to plant completion after decision;

Currently awaiting new national regulation on

biofuels


High efficiency CHP through

gasification

FICFB techn. Güssing Plant, AT

8 MWt / Heat & Power / 2002

(3 more plant in operation and

2 in EPC phase, 10-25 MWt)

Atmospheric indirect gasification and gas

Engines

Skive Plant, DK

19.5 MWt / 11.5 MW Heat & 6 MW Power /

2011

Max input: 28 MWt

Atmospheric direct gasification and gas

engines


Intermediate energy carriers

PYROLYSIS

Fortum Joensuu Plant, FI

Forrest residue / 50 000 t/y pyrolysis oil /

end 2013 VTT/Metso integrated technology

KIT (former FZK), DE Joensuu, Finland

Part of Bioliq project (see Value Chain 1)Part of Bioliq project (see Value Chain 1)

Pyrogrot Project, SE Forrest residue / large PO

plant / end 2015


PYROLYSIS

Btg, NL

b. Demonstration, NL

~25 MWt / Pyrolysis oil / 2014


TORREFACTION

ECN Project, NL

Runs a pilot (50 kg/h)

1t/h demo started up 2012, DK

BioTfueL, FR

3 t/h / energy carrier / 2014

Other ProjectsOther Projects

There are a great number of actors in the field of torrefaction technology utilizing

different technologies.

There are still no plants in commercial operation but some demonstrations are in

commercial scale such as: Topell, NL: 60 kton/y in operation

Stramproy Group, NL: 90 kton/y in operation


Advanced biofuels project database updated to 2012

Available at www.biofuelsdigest.com

BETA RENEWABLES PLANT - ITALY

Area 15 Ha

Located in Crescentino

To date world’s largest

EtOH demo plant

Located in Crescentino

Ethanol Capacity: 40’000 (60’000 design) Mt

per year

Biomass used: 270’000 Mt (at 60Mtpy)

Biomass storage capacity: 27’000 Mt

13MW green electricity from lignin

100% water recycle

100 operators on staff

Ligno-cellulosic feedstocks

• Energy crops, e.g. Giant Reed (Arundo Donax)

• Agricultural residues

• Wheat straw

• Rice straw

Source: biolyfe.eu

M&G Group building the world’s largets lignocellulosic

ethanol plant in Italy

Source:biolyfe.eu

M&G Group building the world’s largest lignocellulosic ethanol plant in Italy

Source:biolyfe.eu

DONG INBICON PLANT - DENMARK

The current technology version converts

biomass into

three products:

� 2nd generation bio-ethanol

� C5 molasses for bio-gas production, and

� Lignin for wood pellet substitution in

power production

A new technology version which converts

C5 to ethanol C5 to ethanol

is under development and is expected

ready in 2013

Input: 30,000 t wheat straw

Output:5.4/8,1 mill. liters ethanol

13,100 t lignin pellets

11,250 t C5-molasses/vinasse


INBICON PROCESS

Hydro-thermal and

enzymatic pre-treatment

INBICON PROCESS

The first full scale integrated biorefinery in 2017 in

Denmark

Output:

• 70 million L 2G

ethanol/year

• 100 million m3

biogas/year

• Electricity for 25.000

households

• District heating for 20.000

households

www.maibjergenergyconcept.eu

PARTNERSHIP AMONG DONG ENERGY + NOVOZYMES + 3 MUNICIPALITIES

Integration of

•DH CHP plant 'Maabjergværket’

•biogas plant, Maabjerg BioEnergy,

using manure and industrial waste as

feedstock

•New 2G bio-ethanol plant with

mixed fermentation of both the C6

and C5 (molasses).

The by-product vinasse will be used in

the biogas production and the lignin

will be used as fuel in the heat and

power production, while the district

heating plant partly will work as a

cooling medium for the bio-ethanol

production steam.

Expected energy efficiency 96% for

the whole biorefinery.

The three plants will be interlinked so they can

take advantage of each other’s production

and side streams.

MEC BIOREFINERY SCHEME

UPM Biorefinery under construction at Kaukas mill site in

Lappeenranta

Source:upm.com

UPM Biorefinery under construction at Kaukas mill site in

Lappeenranta Commercial scale industrial investment

•Total investment of appr. 150 MEUR

•Production 100.000 tonnes/a of

advanced biodiesel

•Construction started in June 2012

•Employes 200 persons directly and •Employes 200 persons directly and

indirectly

•Production starts in 2014

Source:upm.com

Raw material - Crude Tall Oil (CTO) 10

•Tall oil is a residue of pulping process

•Contains extractive components of wood

•Distillation derivatives

–Tall Oil Fatty Acid TOFA

–Tall Oil Rosin Acid TOR

–Tall Oil Pitch TOP

•Manufactured by acidulating raw sulphate soap separated from black liquor

•Yield 20−50 kg CTO/ t pulp

•Global production now > 1 500 000 t CTO/a

•Additional soap potential remarkable

•Utilization of low grade CTO

Source:upm.com

24-25 june2013 putrajaya biorefinery demo projects in...

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