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Bio Base Europe Pilot PlantTurning Grams into Tonnes
World Congress on Industrial Biotechnology
July 21, 2015
Montreal
Hendrik WaegemanBusiness Development Manager
Hendrik.Waegeman@bbeu.org
Bio Base Europe Pilot Plant
Mission statement
To enable the transition to a sustainable
bio-based economythrough
Development, scale-up and custom manufacturing
of bio-based product and processes
About BBEU
Multi-purpose pilot- and demonstration facility for bio-based products and processes
Fact and figures
– Founded in 2008 as a joint initiative between Ghent Bio-Economy Valley and Biopark Terneuzen
– Turnover in 2014: 4,2 M€
– Current number of employees: 43
– No industrial shareholders
5 years BBEPP
A one-stop-shop
Pretreatment
Biocatalysis FermentationGreen
Chemistry
Downstream Purification
Examples
Corn stover
Paper pulp
Oils and fats
Husks, bran, straw
Agro Industrial by-products
Bagasse, beet pulp, seed press cakes
Algae
Non-food crops
Syngas
Defined media: glucose, sucrose, etc.
...
Bio-chemicals
Bio-based building blocks
Industrial Enzymes
Solvents
Polymers
Flavors and fragrances
Protein concentrates
Surfactants
Nutraceuticals
Fuels
Specialty carbohydrates
Current infrastructure
Process Hall 2: Fermentations and DSP
Lab Hall 1: fermentation, analysis
Process Hall 1: Pretreatment, DSP and biocatalysis
Process Hall 3: Green chemistry (ATEX)
Maintenance Hall
Biomass Pretreatment
• Steam Injection
• Organosolv
• Acid/Alkaline treatment
• Pressure reactions
• Enzymatic hydrolysis
• Solid/Liquid separation
• Multi tonne scale
Biomass Pretreatment: auxiliaries
Biocatalysis
• Aqueous, Two-phase and Three-phase Systems
• Batch, Fed-batch, Continuous
• High solids contents
• Reactors up to 50 m³
• Immobilization
• Whole cell biocatalysts
• Enzyme production
Fermentation
• Batch, Fed-batch, Chemostat
• Bacteria, Yeast, Fungi
• Aerobic, Anaerobic
• 6*7 L, 2*50 L, 4*150 L, 1*4.5 m³
Fermentation
• Batch, Fed-batch, Chemostat
• Bacteria, Yeast, Fungi
• Aerobic, Anaerobic
• 6*7 L, 2*50 L, 4*150 L, 1*4.5 m³
• Brand new!!!: 2*1.5 m³ and 2*15 m³
Green Chemistry
• Glass lined Reactors up to 5 m³
• Filter Dryer, Conical Dryer
• Liq-Liq extraction column, Sol-Liq extraction
• Crystallisation, filtration
For
Chemical reactions
Solvent based DSP
Corrosive conditions
Downstream Purification• High speed separators
• Membrane filtration
• Ion exchange, activated carbon treatment
• ATEX solvent extraction, precipitation
Downstream Purification
• Evaporation
• Crystallisation
• Drying
Why outsourcing pilot activities?
• For SME’s (and even larger businesses)
– No infrastructure
– No necessary permits
– No skilled personnel
• Better to outsource piloting
– FASTER LEARNING CURVES
– PRODUCTS CAN BE LAUNCHED ON THE MARKET SOONER
ACCELERATING GROWTH OF SME’s
• Scottish technology company
• Aim: convert side-streams from the whisky industry in bio-based products
• Raw materials:– Draff: the residue of husks after fermentation of
the grain
– Pot ale: residue in the pot after distillation
– Mixed and used as animal feed
• Partnership with BBEU for scale up
• Awarded Europe’s most innovative SME
ACCELERATING GROWTH OF SME’s (2)
• Global biotechnology company, HQ in Florida, R&D in The Netherlands
• Aim: discovery, development, manufacture and sale of enzymes and other proteins for the bioenergy, biochemical, industrial enzyme and biopharmaceutical industries.
• Patented and proprietary technology based on C1 fungus exploitation
• Partnership with BBEU for scale up• One of the collaborations we have: 2G-BIOPIC
project: – Aim: build a 24 tpd lignocellulosics to
bioethanol/biolignin demo plant near Toulouse– 35 M€ support– Role BBEU: scale up enzyme production– Other partners: CIMV (Fr), Dyadic (Nl), CRITT (Fr),
Rolkem (Fr), Taurus Energy (Se), TWB (Fr)
Go beyond...
• 8 partners
• 5 countries
Support by Bio Base North West Europe
• € 6,4 Mio• 3 years (2013-2015)
ENABLING INVESTMENTS IN INDUSTRIAL BIOTECH
• Largest Steel manufacturer in the world
• Gigantic contributor to CO2 emissions globally
• Plant in Ghent, Belgium: accounts for 8 % of Belgian CO2 emissions!!!
• Solution: convert steel mill gases (CO/H2) into chemicals using micro-organisms instead of burning
• 2012-2013: BBEU-AM collaboration on technology scouting and TEA
• 2013-…: BBEU-AM research and pilot project on producing other chemicals from steel mill gases
Syngas to ethanol demo plant
50 m€ investment (phase I) + 42 m€ investment (phase II)
16 kta – 47 kta ethanol
36,8 - 108 kta CO2 emissions reduced
50 direct and indirect jobs
Project Steelanol at AM Gent
Take home messages
• Independent development: we do not sell equipment or compete with own production processes
• Faster learning curves and product sooner on market
• Proven track record: dozens of industrial collaborations
• Development and scale up under on roof: we know what works on large scale
• State of the art equipment on different scales
• Flexibility
– Equipment: modular, pilot lines
– Personnel: ‘fast response, excellent organization’ (quote Evonik)
Questions?
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