Biorefinery Concepts Berlin

30.05.2007 1

Universität für Bodenkultur Wien

Dept. für Nachhaltige Agrarsysteme l Institut für Landtechnik l Ao.Univ.Prof. Dr. Thomas Amon

Potential of Biogas Production from Sustainable Biorefinery Concepts

Ao.Univ.Prof. Dr. Thomas Amon

30.05.2007 2



Biofuels in the EU:Development & Technology Roadmap

0

50

100

150

200

250

300

350

2000 2010 2020 2030 2040 2050

Mto

e B

iom

ass

1st generation: EtOH, ETBE, FAME, FAEE

2nd generation: EtOH, Syn Diesel, DMEfrom lignocellulosic biomass, SNG

Integrated biorefiningcomplexes

Source: Final report of the Biofuels Research Advisory Council; EUR 22066

30.05.2007 3



Biorefinery of Biomasses(Source: modified after Kamm et al. 2006)

Technology

• Enzymatic fermentation• Biogas production• Mechanical pressing• Gasification• Polygeneration• Combustion• Co-combustion

Biorefinery usage

• Fuels:- Bioethanol E85- Biodiesel- Bio-CNG- Synfuel (Bio-CNG, Diesel)

• Energy:- Electricity- Heat

• Chemicals:- synthetic polymers- solvents - adhesives- Fetty acids- Drugs dyestuffs- Tenside, etc.

• Food and Feed

Biomasses

• Biomass of maize, sudan-und meadow grass etc.;

• Sec. Agric. biomasses and by products: straw, sugar beet leaves, pulp; glycerin, raps seed cake, etc.

• Wood for energy, wood waste-products

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Objectives/challenges :

To increase substantially the production of biofuels that are commercially viable, CO2- efficient and compatible with vehicle engines.

To promote the transition towards “second generation biofuels” which will be produced from a wider range of feedstock (including waste biomass and bio based products from industry).

To promote the transition towards “fully integrated biorefinery concepts”.

To reduce competition for land and food. To produce biofuels in the most efficient way.

30.05.2007 5



European biogas initiative to improve the yield of Agricultural biogas plants (EU-Agro Biogas)

Aim

Demonstrate and optimize innovative approaches to improve biogasyield and energy output and economic efficiency at selected biogas plants in Europe.

Partners

BOKU, RTD Sevices, GE Jenbacher, Thoeni Industriebetriebe (Austria), Research Institute of agricultural engineering (Czech Republic), Danish Institute of Agricultural Sciences (Denmark), Institute of Agricultural Engineering, Federal Agricultural Research Centre, KTBL, Vogelsang GmbH (Germany), Universita degliStudi di Torino (Italy), EC Baltic Renewable Energy Center (Poland), Agrotechnology & Food Innovations (The Netherlands), Institute of Grassland & Environmental Research (UK)

30.05.2007 6



Virtual Biogas

WP1: Raw materials &

Biogas production

WP2: Gas purification & grid interface WP3:

Accounting, certification of

Biogas content, economy of operations

WP4: Fuel station /

increased pressure WP5: Vehicle /

increased pressure

WP6: Fleet test

BOKUDNAS

TU WienVerfahrenst.

Axiom

OMV Gas

EVN

WienEnergieGasnetz

TU WienIVK.

OpelMagna

C&K Taxi

OMV R&M

EnergieparkBruck

Biogas Bruck

WP Leaders

WP7: Power train efficiency

AVL

30.05.2007 7



Platform “Bio-CNG-Traffic”

Bio-CNG = 80 % Natural Gas + 20 % Biogas

Chamber of Agriculture

Austria

30.05.2007 8



Geographic allocation of field experiments in Austria Loimersdorf

wheatHaidershofenmaize

Lenzing, Schörfling a. AS,Schwanenstadt

wheat, rye, triticale

Irdning (Gumpenstein),Admont (Buchau) grass

Ludersdorfmaize, sorghum

Groß-Enzersdorfmaize, sunflower,

sorghum

Hundsheim

Rudenmaize

St.Margareten am Moos

F.Sch Tullnsorghum, maize, sunflower

Experiments 2004 - 2005

New experiments 2006

30.05.2007 9



Biogas-laboratory University of NaturalResources and Applied Life Sciences

120 Batch-Fermenters (1000 ml)For 27 different Substrates, Standardsand Inoculum with 3 replicates

30.05.2007 10



Setup of new trial in the biogas laboratory

30.05.2007 11



R&D Exampel: Biogas from residues and by-products

30.05.2007 12



Is the glycerine a possible additive for biogas production?

Glycerine

Glycerine from biodiesel production

Volume (actual): 64,000 t a-1

outlook: 180,000 t a-1 to 2010

30.05.2007 13



Effect of glycerine addition on the specific methane yield of agricultural raw materials

30.05.2007 14



0

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Days from start of anaerobic digestion

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3 % glycerine0 % glycerine Basic mixMethane content in the biogas [%]

Effect of glycerine on the methane yield of a mixture from maize, CCM and swine manure

30.05.2007 15



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h


30.05.2007 16



0

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15 % glycerine8 % glycerine6 % glycerine3 % glycerine0 % glycerine Basic mixMethane content in the biogas [%]


30.05.2007 17



R&D Exampel: Biogas with raw materials fromsustainable crop rotation systems

30.05.2007 18



Co-Fermentation of energy crops, organic manures and industrial based by products

Content of used mixtures (% of FM).

Raw materials

Block Mix

Sun flower silage

grass silage

Rye silage

Maize silage

CCM Pig manure

Sugar beet silage

--- M11 0 0 0 31 15 54 0

M2 20 0 0 30 10 20 20

M3 15 0 0 25 20 10 30

M4 30 0 0 20 0 20 30

Block 1 (energy

rich)

M5 20 0 0 40 0 30 10

M6 5 30 10 10 5 40 0

M7 5 40 20 0 0 35 0

M8 5 30 30 5 0 20 10

Block 2 (protein

rich)

M9 0 40 20 5 0 30 5

M10 20 10 10 20 0 20 20

M11 30 5 5 10 10 20 20

M12 35 7,5 7,5 35 5 0 10

Block 3 (balanced)

M13 15 0 10 45 0 15 15 1Der Mischung M1 wurde 4% Rohglyzerin zugelegt.

30.05.2007 19



Effects of co-fermentation

Spec. Methane yield Additional methane yield

Block Mix Measured (lN/kg VS)

Expected (lN/kg VS)

Absolut (lN/kg VS)

Relative (% of expected)

--- M1 383 258 +125a +49

M2 367 287 +79ab +28

M3 349 295 +54abc +18

M4 302 274 +28bc +10

Block 1 (energy

rich)

M5 347 281 +66abc +23

M6 371 267 +104ab +39

M7 363 267 +96ab +36

M8 395 283 +111ab +39

Block 2 (protein

rich)

M9 386 271 +115a +42

M10 369 281 +89ab +32

M11 378 279 +99ab +36

M12 303 311 -7c -2

Block 3 (balanced)

M13 427 298 +129a +43 a,b Signifikant differences (P<0.05; Scheffé-Prozedur).

30.05.2007 20



Using energy crop mixtures

Y = 0,8337 X + 60,826R2 = 0,8337

275

300

325

350

375

400

425

450

275 300 325 350 375 400 425 450

Measured specific methane yield (LN/kg VS)

Est

imat

ed s

peci

fic m

etha

ne y

ield

(LN/k

g V

S)

Relationship between measured and estimatedspecific methane yield (Model 4)

Model Regression equation adj. R2 R2 Significance

1 CH4 = –1410,48 VS*** – 1876,97 XL*** – 451,46 XF*** + 937,16 C*** + 8309,46 GE*** + 139,38 CN*** – 59293***

0,5418 0,6003 ***

2 CH4 = 7399,91 XP*** + 2405,65 ADL*** – 193,76 Cell*** + 1721,50 GE*** – 442,94 Sug*** + 3076,48 CN*** – 197204***

0,5416 0,6001 ***

3 CH4 = 2811,98 DM*** + 4400,48 XA*** – 3872,16 XP*** + 3532,00 XF*** + 1983,89 H-Cell*** + 1476,69 Zuc*** – 192070***

0,5412 0,5998 ***

4 CH4 = 3911,18 XP* + 4515,25 XL* + 4864,12 ADL* + 1665,29 Cell* + 3840,62 H-Cell* + 936,88 Sta* + 1955,44 Sug* – 213356

0,5307 0,6006 ***

5 CH4 = –7,19 XP – 23,22 XL** + 1,96 XF + 527,80*** 0,2385 0,2871 **

6 CH4 = 13,15 H-Cell*** + 172,82*** 0,2498 0,2658 ***

7 CH4 = –2,01 VS + 533,12*** 0,0230 0,0438 n.s.

8 CH4 = 1,92 XF + 327,07*** 0,0044 0,0256 n.s. ADL = lignin (% DM); C = carbon (% DM); Cell = cellulose (% DM); CH4 = specific methane yield (LN/kg VS); CN = C/N quotient; DM = dry matter (% FM); FM = fresh matter; GE = gross energy (MJ/kg DM); H-Cell = hemicellulose (% DM); Sta = starch (% DM); Sug = sugar (% DM); VS = volatile solids (% DM); XF = crude fiber (% DM); XL = crude lipids (% DM); XP = crude protein (% DM); adj. R2 = adjusted coefficient of determination; R2 = coefficient of determination Level of significance for the models and the regression coefficients: * < 0,05; ** < 0,01; *** < 0,001; n.s. = not significant

Regression equations to estimate the specific methane yield of the energy crop mixtures (n = 48)

30.05.2007 21



Using residues from food industryFermenter 1 (F1)Diet composition

Fermenter 2 (F2)Diet composition

Average values for F1:Methane concentration = 61,9 Vol.%Specific methane yield = 581 LN/kg VS

Sugar beet silageVegetable litterOld foodLecithinGreaseCanteen litterSoya residues

Average values for F2:Methane concentration = 63,6 Vol.%Specific methane yield = 574 LN/kg VS

30.05.2007 22



EthanolEthanolproductionproduction

MaizeMaize,,cerealscereals

MaizeMaizecorncorn

StrawStrawStrawStraw

11,6 t ha11,6 t ha--11 aa--1

Maize corn Maize corn 8,9 t ha8,9 t ha--11 aa--11 1

Ethanol Ethanol 22.560 kWh ha22.560 kWh ha--11 aa--11

StillageStillage(DDGS)ΣΣ 22.56022.560 kWh hakWh ha--11 aa--1 1 100%100% (DDGS)

30.05.2007 23





MaizeMaizecorncorn

Biogas Biogas plantplant


11,6 t ha11,6 t ha--11 aa--1

Maize corn Maize corn 8,9 t ha8,9 t ha--11 aa--11


Biogas Biogas StillageStillage

9.080 kWh ha9.080 kWh ha--11 aa--11 StillageStillage

ResidueResidue

1

ΣΣ 31.64031.640 kWh hakWh ha--11 aa--1 1 140%140%

30.05.2007 24





MaizeMaizecorncorn



11,6 t ha11,6 t ha--11 aa--1




9.080 kWh ha9.080 kWh ha--11 aa--11

StrawStraw26.510 kWh ha26.510 kWh ha--1 1 aa--1

StillageStillage1

ΣΣ 58.15058.150 kWh hakWh ha--11 aa--1 1 258%258%ResidueResidue

30.05.2007 25





MaizeMaizecorncorn



11,6 t ha11,6 t ha--11 aa--1


Steam explosionSteam explosion



9.080 kWh ha9.080 kWh ha--11 aa--11

StrawStraw(Steam explosion)(Steam explosion)35.980 kWh ha35.980 kWh ha--1 1 aa--1

StillageStillage

1

ΣΣ 67.62067.620 kWh hakWh ha--11 aa--1 1 300%300%ResidueResidue

30.05.2007 26



Hydrolyse via steam explosiontechnical development

30.05.2007 27



Methane yield from untreated and steam exploded wheat straw

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Days from start of anarobic digestion

Sp

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ield

[l

N kg

-1 V

S -1]

steam exploded strawuntreted straw

30.05.2007 28



Energy potentials of bioethanol production from maize

Energy output Energy input utilisation level*

[MJ/kg DM] [MJ/kg DM]

Ethanol 3,96 3,00 1:1,3 22%

Ethanol and stillage 5,56 1,96 1:2,8 31%

Ethanol, stillage and straw 10,21 2,19 1:4,7 57%

Ethanol, stillage and straw (Steam explosion) 11,87 ? ? 66%

* 1 kg DM contained 18 MJ Energy (corn and residues)

Input/outputRation

30.05.2007 29



Biogas production from integrated biorefineryConcepts and sustainable crop rotations

MeadowMeadow grasgras7 t/ha

FeedingFeeding barleybarley30 %30 %

Brewer‘sBrewer‘sbarleybarley70 %70 %

StrawStraw1,9 t/ha

CCMCCM

MaizeMaize strawstraw 4,3 t/ha

CornCorn

100%100%

WheatWheat strawstraw

5,3 t/ha

SeedsSeeds

StrawStraw RapeRape oeloelmealmeal

RMERME

PressPress

5 t/ha

1,9 t/ha

3 t/ha

2,7 t/ha

IntercropIntercropcloverclover

RapsRaps

WheatWheat


MaizeMaize70% GPS, 30 % CCM70% GPS, 30 % CCM


RapeRape

∅ MHY

of crop rotation∑3.231m3CH4/ha*a

2,7 t/ha

2,7 t/ha

Spring Spring barleybarley

30.05.2007 30



Methane energy potential of agricultural residuesCalculation basis EU25

Cereals: Rapeseed:Sun flowers:Sugar beets:Fallow land:Manure:Grassland:Cropping system:

Straw and grain depending on degree of self-sufficiency (DSS)Straw and rape oil mealStraw and sun flower oil mealLeaves and sugar production residues100% use for biogas production100% use for biogas productionGrassland depending on DSS milkPreceding or succeeding crop, 15% of arable area

Not yet included:- Residues of bioethanol production (DDGS, distilled dry grain solubles)- Residues of biodiesel production (crude glycerin and oil seed cake)- Residues of starch production

30.05.2007 31



36%

6%

2%

3%

26%

7%

6%

14%

CerealRapeseedSun flowersSugar beetsFallow landManureGrasslandCropping system

Methane energy potential of agricultural residues

EU252005(Source: Eurostat)

207 Mio. tons of oil equivalent (toe)

Energy consumption by transport of EU25 (2004)

= 350 Mio. toe(Source: Eurostat)

30.05.2007 32



KapitalkostenSubstratkostenTransportkostenArbeitskostenSonstiges*

* repairs,electricity, management, insurance,analyses etc.

42%

9%

7%

7%

39%

Kosts and shares of biogas production from biomasses. Total power: 1,5 MW ≈ 250 m3/h

Costs of electricity production:14,0 – 15,0 €cent/kWhel.

Cost of bio-methane production for feeding into the gas distribution system:4,5 – 5,6 €cent/kWhBiomethanenergieQuelle: D. Hornbachner et a. 2005

Sourse: Walla 2006

30.05.2007 33



Fuel-oriented, fully-integrated biorefinery system

BiomassEnergy

production

Crops

Manure

Industrial-based

byproducts

Energy

Residues

Bioethanol

Other fuels

Biodiesel

Biohydrogen

Biogas

Food andfeed

30.05.2007 34



Conclusion / Outlook

Biogas is the key technology within integrated biofuels based biorefinery systems. It enables:

high land productivity, whole crop utilisation and reduce competition for land and food.

Further developments are required to fully maximise the potentials of already existing conversion technologies.

Ways must be found that make it possible:to combined the production of food, feed, chemicals and energywitch are based on already existing conversion technologieswithin sustainable, regional adapted crop rotation systems

In the longer term the implementation of full-scale integrated biorefineries using new energy crops, crop residues and Industrial based by-Products will be necessary.

30.05.2007 35



Universität für Bodenkultur Wien Department für Nachhaltige Agrarsysteme

ao.Univ.Prof. Dr. Thomas AmonDr. Katharina Hopfner-SixtDI. Alexander BauerDr. Vitaliy Kryvoruchko Dr. Barbara Amon DI Vitomir BodirozaDr. Dejan Milovanovic Dr. Andrea MachmüllerMag. Violetta SimicDI Regina HrbekDI Debora Fistarol LysonMag. Markus LysonDI Andreas MoserDr. Helmut Wagentristl

Peter-Jordan-Strasse 82A-1190 WienTel. +43-1-47654-3502Fax. +43-1-47654-3527E-mail: [email protected]

http://www.forum-biogas.net

founded June 2006

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