copernicus institute research institute for sustainable development and innovation wp 2/3 technical...

Copernicus InstituteResearch Institute for Sustainable Development and Innovation

WP 2/3

Technical and economic characteristics and

environmental assessment of BREW case

study products


Progress track WP 2/3

•Kickoff (Apr 03): Product preselection, data collection methodology, LCA methodology

•Plenary 1 (Sep 03): Product list finalised, data received from companies, generic approach proposed by DSM/Shell

•Plenary 2 (Jan 04): Product trees developed for key platform chemicals, BREWtool developed as tool for standardised LCI and product value calcs

•Plenary 3 (May 04): Preliminary results based on company data. Choice of feedstocks finalised. Background data issues discussed.

•Plenary 4 (Sep 04): LCIs for 3 sugar feedstock types. Uncertainty analysis for dextrose. Environmental and economic comparison of selected petchem and bio-based feedstocks and end products. Sensitivity cases for energy recovery/waste management.

Gen

eric

bac

kgr

oun

d d

ata,

sp

ecif

ic c

omp

any

dat

a fo

r b

iop

roce

ss

Par

alle

l pat

h

Gen

eric

bio

pro

cess

des

ign


- Continuous biotechnological processes

-Waste biomass and water recycling

-Energy integration

-Technologically advanced workup

Emerging bulk, bio-based, biotech industry

PE

TC

HE

M-

BA

SE

D

BIO

-BA

SE

D

CO

NV

EN

TIO

NA

L P

RO

CE

SS

ING

BIO

-BA

SE

D

SP

EC

IALT

Y

CO

NC

EP

T

LAB

PIL

OT

BU

LK

Lactic acid Shell Shell Cargill Dow

1,3-propanediol Shell Shell DuPont

Acetic acid1 BP A&F

Succinic acid (SRI) Others

Fatty acids Uniqema Uniqema

Hydrogen Others A&F

Ethylene Shell Shell

Ethanol Shell Shell

Adipic acid DSM Shell

Acrylamide Degussa

Lysine DSM

Ethyl lactate (solvent) Shell Shell

Fatty acid esters (lubricants, surfactants)

Others UCM Cargill Dow

PLA (plastic) Others Cargill Dow

PTT (plastic)DuPont Shell

DuPont

PHA* (plastic) Biomer A&FMetabolix

P&G

MATRIX OF PRODUCTS SPEARHEADING THE DEVELOPMENT OF BIO-BASED, BIOTECH, BULK ('BBB') CHEMICALS

ESTABLISHED CONVENTIONAL PRODUCTS WITH BBB

POTENTIAL

EMERGING BBBs - stage of development

BIO-BASED

BIOTECH

BULK

PLA

TF

OR

M

CH

EM

ICA

LS

Pro

cess

dat

a av

aila

ble

PLA

TF

OR

M

CH

EM

ICA

LS

Gen

eric

app

roac

h

SE

CO

ND

AR

Y P

RO

DU

CT

S


Scope of presentation

Case ‘TODAY’

Company data

Industry technology reviews (SRI)

Generic process design

Case ‘TOMORROW‘

(2010)

Generic process design


System Boundaries for BREW products

PROCESS BOUNDARY

to processes from processesCo-products4

Land

CO2

SYSTEM BOUNDARY - CRADLE TO GRAVE

Production & delivery of utilities, fuels,

materials

Waste treatment: solids (organic, other); waste water, sludge, exhaust

gases

SYSTEM BOUNDARY - CRADLE TO FACTORY GATE

Biomass production

& conversion

ferment-able

sugars1Biotech.

processing

Raw materials

used product

Post-consumer

waste

treatment3

GHG emissions

Non-renew. energy Exported

energy

product in broth

Product recovery &

purification2

product in bulk form

Product use

Renewable energy


Feedstocks (fermentation substrates)Benchmark for ‘TODAY’

NR energy use

R energy use

Total energy use

NR GHG emissions

R GHG emissions

Total GHG emissions Land use

Product value Price

GJHHV/t GJHHV/t GJHHV/t(t CO2 eq./t) (t CO2/t)

(t CO2 eq./t) (ha/t) (EUR/t) (EUR/t)

Sucrose (59%ds) from sugar cane. 1st fig: AVERAGE (medium sucrose); 2nd fig: ADVANCED

(high sucrose) 1)

-10.5 -14.9

33.9 48.0

23.4 33.1

-0.26 -0.36

0.11 0.15

705)

(Brazil)3307)

Dextrose (32%ds) from

corn wet milling2)6.3 17.3 23.6 0.47 -1.54 -1.07 0.13 805)

(US)2006)

C5/C6 sugars (13%ds) from lignocellulosics

(corn stover) 3)

5.6 29.2 34.8 0.28 -1.46 -1.18 0.051503)

125-

1604)

-

NR: non-renewable-sourced

R: renewables-sourced

FE

ED

ST

OC

KS

(S

UG

AR

S)


Sensitivity analysis on feedstock:dextrose from corn

Energy use (GJ/t)Cradle to factory gate

02468

101214161820

1 2 3 4 5

Non-renewable energyuse (GJ/t)

Renewable energy use(GJ/t)


Sensitivity: dextrose from corn

Greenhouse gas emissions (kg CO2eq/t)

-2.0

-1.5

-1.0

-0.5

0.0

0.5

1.0

1 2 3 4 5

NR-GHG(processing)emissions (tCO2eq./t)

R-GHG (CO2sequestered) (tCO2/t)

TGHG emissions(cradle to factorygate) (t CO2eq./t)


Assumptions for dextrose from corn

-Corn production in US

- Industry current best practice corn wet milling

- Dextrose 32% dry solids. For higher % ds there will be

additional energy inputs to evaporate water

Integrated facility for dextrose production and biorefinery

(allows delivery of fairly dilute sugar solution)

- Allocation by mass (small difference for price-basis

allocation)


Commercialised today: lactic acid & PLASRI Conventional HLa Process BFD (pH = 6)

FermentationBiomassFiltration

SeedPre-Seed

CSL

CaCO3Tank

CaCO3

H2O

GlucoseNutrients

L. delbrueckii

CO2

Biomass

Acidification

H2SO4

GypsumFiltration

H2O

Evaporation

Recycle H2O

Polishing Extractor

To WWT

H2O

Solvent

ref: Cargill Dow (SRI process)


Lactic acid and PLA via dextrose from corn

Energy use (GJ/t)Cradle to factory gate

0102030405060708090

LA1

LA2

LA3

LA4

PLA1

PLA2

LDPE

PET

Non-renewableenergy use(GJ/t)

Renewableenergy use(GJ/t)



Breakdown of non-renewable energy use (GJ/t)Cradle to factory gate

0

10

20

30

40

50

60

LA1

LA2

LA3

LA4

PLA1

PLA2

LDPE

PET

Otherprocesses

Bioprocess &workup

Substrateproduction



NREU (GJ/t) cradle to grave with different post-consumer energy recovery options

0102030405060708090

LA1

LA2

LA3

LA4

PLA1

PLA2

LDPE

PET

No energyrecovery

Digestion withenergyrecovery

Incinerationwith energyrecovery



Greenhouse gas emissions (kg CO2eq/t)

-2.0

-1.0

0.0

1.0

2.0

3.0

4.0

5.0

6.0

LA1

LA2

LA3

LA4

PLA1

PLA2

LDPE

PET

NR-GHGemissions (=cradle to grave*)(t CO2eq./t)

Renew. C storedin product (CO2eq.) (t CO2/t)

GHG emissions(=cradle tofactory gate) (tCO2eq./t)



Land use (ha/t)

0.00

0.05

0.10

0.15

0.20

0.25

LA1

LA2

LA3

LA4

PLA1

PLA2

LDPE

PET


Near future commercialisation (<2010):Succinic acid (SRI design)

Design capacity: 75 k t.p.a.>> First medium-scale plant being built. Market

for products still under development.

ref: SRI

CO2 SuccinicGlucose acid

UltrafiltrationSolvent

extractionDistillationFermentation


Longer-term commercialisation (<2020):bio-Hydrogen

Photofermentation (A&F)Design capacity: 0.45 k t.p.a

>>Factor 100 + higher for bulk commodity status

ref: A&F

Biomass Hydrogen

CO2

Protein slurry

hydrolysis

Fermentation with

(hyper)thermo-philic bacteria

(Photo)fermentation with

purple, non-S bacteria

Gas separation

Gas separation


Longer-term commercialisation (<2020): Splitting of fats/oils using enzymes

Fatty acidFat/oil

Glycerol waterConv: 10 - 15% glycerolEnzym: 50% glycerol

(1) Conventional, 250 °C, 70 bar(2) Enzymatic, 60 °C

Continuous splitting (1) or

(2)

2010?


-20% 0% 20% 40% 60% 80% 100%

Lactic acid-CD

Succinic acid-SRI

Bio-H2-A&F

Feedstocks

Auxil/Cat

By-product cred/deb

Utilities

Waste mgmt

Supplies

Labour

Tax + insur

Overhead

Marketing, admin, R&D

Capital charge (20%)

Product value breakdown for BBBs with commercialisation (1) today, (2) in near future (<2010)

and (3) longer term (<2020)


Thought exercise – common scaling for case ‘TODAY’

- Plant size scaleup: I2/I1 = (C2/C1)2/3, C2 = 200 k t.p.a.

BUT

- ISBL in this case LINEAR since scale-up will be just a matter

of replication

- OSBL: power 2/3 rule? Ensure: Offsites include CHP plant or

other energy recovery/waste management options for biomass

waste from process (basis NREL investment figs)

- Fixed + variable direct: linear


Lactic acid-CD

Lactic acid-Shell s

Lactic acid-Shell e

Ethyl lactate from lactic acid-Shell

PLA from lactic acid-CD

1,3-propanediol Aer-SRI

1,3-propanediol Anaer-SRI

PTT-SRI from 1,3-propanediol Aer-SRI

PTT-SRI from 1,3-propanediol Anaer-SRI

Succinic acid-SRI

Hydrogen

mcl-PHA latex from fatty acids

Fatty acids enzymatic splitting

mcl-PHA latex from dextrose:fatty acids 5:1 wt/wt

Succinic acid from methanol-TNO

mcl-PHA by fermentation with p. putida on fatty acid substrate. DSP acc. to A&FI (2003)

Splitting of fats using Candida Rujosa lipase

mcl-PHA by fermentation with unspecified microorganism using dextrose supplemented with 20% wt/wt fatty acid as substrate. DSP acc. to A&FI (2003)

Succinic acid by methanol fermentation according to TNO study

Polycondensation of PDO and PTA to PTT (SRI 1999) using PDO from SRI anerobic bioprocess on dextrose, PTA from APME report (Boustead 2002).

Fermentation of glucose to succinic acid (A. succinogenes 130Z) according to SRI, purification by solvent extraction and distillation.

Hydrogen from potato waste by hydrolysis followed by dark fermentation and photo fermentation, A&F process.

1,3-propanediol (PDO) from SRI anaerobic bioprocess on dextrose

Low pH fermentation of glucose to lactic acid followed by pervaporation assisted esterification (one step process; lactic acid is not isolated). Shell design.Fermentation of dextrose to lactic acid, purification by repeated neutralisation & acidification steps. Condensation polymerisation to poly(lactic acid). Cargill Dow data, supplemented by SRI process design. EU data for utilities (electr, steam).

Polycondensation of PDO and PTA to PTT (SRI 1999) using PDO from SRI aerobic bioprocess on dextrose, PTA from APME report (Boustead 2002).

1,3-propanediol (PDO) from SRI aerobic bioprocess on dextrose

Fermentation of dextrose to lactic acid, purification by repeated neutralisation & acidification steps. Cargill Dow data, supplemented by SRI process design. EU data for utilities (electr, steam).

Fermentation of glucose to lactic acid, purification by solvent extraction and distillation. Shell analysis based on SRI process design.

Fermentation of glucose to lactic acid, purification by electrodialysis. Shell analysis based on SRI process design.

BREWtool results - key


NREUCradle to

factory gate

NREU REU TEU

NREU Incineration

without energy

recovery (1)

NREU Digestion

with energy

recovery (2)

NREU Incineration

with energy

recovery (3)

NREU (4)

NREU Incineration

without energy

recovery

NREU Digestion

with energy

recovery

NREU Incineration

with energy

recovery

P

Aero

bic

AN Lactic acid-CD 25.1 19.8 44.9 25.1 21.3 18.7 - - - -

P AN Lactic acid-Shell s 33.3 29.3 62.6 33.3 29.5 26.9 - - - -

P AN Lactic acid-Shell e 33.9 29.3 63.3 33.9 30.1 27.5 - - - -

P


52.7 21.8 74.5 52.7 46.1 41.6

P PLA from lactic acid-CD 44.9 25.3 70.2 44.9 39.6 36.1

G AE 1,3-propanediol Aer-SRI 57.4 29.6 87.0 57.4 50.3 45.5

G AN 1,3-propanediol Anaer-SRI 65.7 37.1 102.8 65.7 58.6 53.8

G


69.1 11.0 80.1 69.1 62.3 57.6

G


72.2 13.8 86.0 72.2 65.3 60.6

G AN Succinic acid-SRI 45.8 21.2 67.0 45.8 42.0 39.5 96.8 96.8 93.0 90.4

P AN Hydrogen -0.9 (190.3) (189.4) - - - 180.0 - - -

G AN


80.0 78.2 158.2 0.0 -10.1 -17.0

P BT Fatty acids enzymatic

splitting0.0 68.1 68.1 72.4 62.2 55.1 4.1 4.1 -6.0 -12.9

P AN mcl-PHA latex from fatty

acids72.4 171.1 243.5 80.0 69.7 62.7

P AN Succinic acid from methanol-

TNO40.2 74.6 114.8 40.2 36.5 33.9 96.8 96.8 93.0 90.4

Energy Use (GJHHV/t)Cradle to factory gate Cradle to grave

Biotechnological process Petrochemical (reference) process

Cradle to grave

Sugar

feedsto

ck

Pro

prieta

ry p

rocess: P

; G

eneric p

rocess: G

Oth

er

feedsto

ck

NREU = Non-renewable energy use; REU = Renewable energy use; TEU = Total energy use = NREU + REU


GHGCradle to

factory gate

NRGHG RGHG TGHG

TGHG Incineration

without energy

recovery (1)

NRGHG Digestion

with energy

recovery (2)

NRGHG Incineration

with energy

recovery (3)

TGHG (4)

TGHG Incineration

without energy

recovery

NRGHG Digestion

with energy

recovery

NRGHG Incineration

with energy

recovery

P

Aero

bic

AN Lactic acid-CD 1.9 -1.3 0.6 1.9 1.7 1.6 - - - -

P AN Lactic acid-Shell s 2.3 -1.3 1.0 2.3 2.1 2.0 - - - -

P AN Lactic acid-Shell e 2.1 -1.3 0.8 2.1 1.9 1.7 - - - -

P


3.3 -1.9 1.4 3.3 3.0 2.7

P PLA from lactic acid-CD 3.1 -1.8 1.3 3.1 2.9 2.7

P AE 1,3-propanediol Aer-SRI 57.4 -1.7 55.6 3.6 3.3 3.0

P AE 1,3-propanediol Anaer-SRI 65.7 -1.7 63.9 4.1 3.8 3.5

P


69.1 -0.6 68.5 5.0 4.7 4.4

P


72.2 -0.6 71.6 5.2 4.9 4.6

G AN Succinic acid-SRI 2.9 -1.5 1.4 2.9 2.7 2.5 7.2 8.7 8.5 8.3

P AN Hydrogen 0.0 (11.0) (11.0) - - - 10.1 - - -

G AN


4.0 -2.6 1.4 0.0 -0.4 -0.8


splitting0.0 -2.5 -2.4 3.3 2.8 2.4 0.2 0.2 -0.2 -0.6


acids3.3 -2.6 0.7 4.0 3.5 3.1


TNO3.2 -1.5 1.8 3.2 3.1 2.9 7.2 8.7 8.5 8.3

GHG emissions (t CO2 eq./t)

NRGHG = emissions from non-renewable energy use; RGHG = emissions from renewable energy use, TGHG = Total GHG = NRGHG + RGHG

Pro

prieta

ry p

rocess: P

; G

eneric p

rocess: G

Sugar

feedsto

ck

Oth

er

feedsto

ck

Cradle to graveCradle to graveCradle to factory gate

Petrochemical (reference) processBiotechnological process


Land useBiotech process

Cradle to factory gate

Land use

PA

ero

bic

m

eta

AN Lactic acid-CD 0.146

P AN Lactic acid-Shell s 0.216

P AN Lactic acid-Shell e 0.216

PEthyl lactate from lactic acid-Shell

0.161P PLA from lactic acid-CD 0.187

P AE 1,3-propanediol Aer-SRI 0.217

P AE 1,3-propanediol Anaer-SRI 0.271

P


0.081

P


0.101

G AN Succinic acid-SRI 0.155

P AN Hydrogen 0.003

G AN mcl-PHA latex from

dextrose:fatty acids 5:1 wt/wt0.319 + NA


splittingN/A


acidsNA


TNO0.001

Su

ga

r fe

ed

sto

ck

Land use (ha/t)

Land use

Pro

prie

tary

pro

cess

: P;

Ge

ne

ric p

roce

ss: G

Oth

er

fee

dst

ock


Product valuePetrochemical

(reference)

process1)

Product Value Price Price

P AN Lactic acid-CD

P AN Lactic acid-Shell s

P AN Lactic acid-Shell e

P


P PLA from lactic acid-CD LDPE, Amorphous PET

P AE 1,3-propanediol Aer-SRI PDO EO, PDO Acrolein

P AE 1,3-propanediol Anaer-SRI PDO EO, PDO Acrolein

P


PTT via PDO EO, PDO Acrolein

P


PTT via PDO EO, PDO Acrolein

G AN Succinic acid-SRI

P AN Hydrogen Hydrogen from natural gas

G AN mcl-PHA latex from

dextrose:fatty acids 5:1 wt/wtPP


splittingFatty acids conventional splitting


acidsPP


TNO

Biotechnolgical process

Oth

er

fee

dst

ock

Product value and price (EUR/t) (1 USD = 1.1 EUR/t)

Product value = production cost + 20% of total fixed P

rop

rie

tary

pro

cess

: P

; G

en

eri

c p

roce

ss:

G

Ae

rob

ic m

eta

bo

lism

: AE

; An

ae

rob

ic m

eta

bo

lism

(fe

rme

nta

tion

): A

N; B

iotr

an

sfo

rma

tion

: B

T

Su

ga

r fe

ed

sto

ck


END


Additional slides (methodology)


Environmental indicatorsNREU, REU, GHG, LAND USE

Economic indicatorPRODUCT VALUE

input process-Sensitivity analysis specific dataNREU, GHG, PRODUCT VALUE

background datavia lookup

via cellreferences

BACKGROUNDDATA

FF(feedstocks and fuels)

ERE(energy requirements for energy) UTIL

(utilities conversion)

PRODUCTCALCSHEET

BREWtool: data structure


Production cost and Product value calculations (~ SRI methodology)

Investment costs (EUR/t.p.a)Inside battery limits (ISBL)Outside battery limits (OSBL)

Total fixed capital (TFC)

Production costs (EUR/t)FeedstocksAuxil/cat FROMBy-product credits/debits CALCUtilities SHEET DIRECTWaste treatment OPERATINGOperating supplies (10% of operating labour) COSTSMaintenance supplies (1.5 % of ISBL)Operating labour (given or estimated)Maintenance labour (2.5 % of ISBL) PLANTLaboratory labour (13 % of operating labour) GATE

COSTSTaxes + insurance (2% of TFC)Plant overhead (80% of labour costs) PRODUCTION

COSTSMarketing, admin, R&D (6% of plant gate costs) Compare

PRODUCT BULKCapital Charge (20% of TFC) VALUE PRICE


Energy recovery from post-consumer waste (1) incineration

Post-consumer waste Calorific value,

100 GJHHV

MSW incinerator with energy

recovery

Electricity to grid 12 GJ

Heat export 12 GJ

Primary energy avoided

η=38.0%1 31.6 GJ

η=76.9% 15.6 GJ

47.2 GJ

1Weighted according to EU electricity mix; assume same mix for avoided electricity.

Final Energy produced

~ 50 GJ


Post-consumer waste Calorific value,

100 GJHHV

Anaerobic digester

Electricity to grid 8.8 GJ

Heat export 4.1 GJ

Primary energy avoided

η=38.0%1 23.2 GJ

η=76.9% 5.3 GJ

28.5 GJ

1Weighted according to EU electricity mix; assume same mix for avoided electricity.

Final Energy produced

~ 30 GJ

Biogas-fueled

CHP plant

Biogas, 37 GJ

Energy recovery from post-consumer waste (2) digestion


Energy recovery from post-consumer waste (2) digestion REFERENCES

Calc composition of organic waste from digestion + CHP process for a plant in Germany described in De Mes et al. 2003, p.77:

fruit + veg: 26 kt/y; of which organics: 35%

park wastes: 4 kt/y; of which organics: 70%

Avg organics 30%, Total organics: 11.9 kt/y

Composition organics: assume avg. carbohydrate CnH2nOn: 17 GJ HHV/t

For the Vagron plant described in De Mes et al. 2003, p.100 (process shown on this slide),

Assume same composition for OWF as above, i.e. 30% of total mass waste.

Ref organic fractions:

Provincie Antwerpen, 1999: Onderzoek naar de mogelijke toepassing van nieuwe afvalverwerkingsteknieken in de provincie Antwerpen. Eindrapport. http://www.gomesanet.be/nederlands/publicaties/afvalsverwerking/19mei99.pdf

Refs Vagron process:

De Mes, T.Z.D., Stams, A.J.M., Reith, J.H. and Zeeman, G (2003): Methane production by anaerobic digestion of wastewater and solid wastes, in: Reith, J.H., Wijffels, R.H., Barten, H. (eds): Bio-methane and Bio-hydrogen - Status and Perspectives of biological methane and hydrogen production. Dutch Biological Hydrogen Foundation 200, c/o ECN, Petten, the Netherlands. pp. 58-102.

Vagron plant in Groningen: http://www.vagron.nl/html/uk/vagron4.htm

Clarifies that Vagron is also treating GFT. The biowaste above refers to the organic wet fraction (OWF). Assume same composition of OWF as for the German plant. Calc. organic dm = 303 kg/1000 kg biowaste

copernicus institute research institute for sustainable development and innovation wp 2/3 technical...

Documents