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RE(DE)FINERY – for Green Chemicals, Fuels & Energy
Quimica Verde Conference | CTBE 19 oct 2015
Erick Fernandes (Worldbank), Jan van Breugel (BBI/Corbion), Adrie Straathof (TUD) and Luuk van der Wielen (TUD/BE‐Basic)
http://www.be‐basic.org/downloads
contents
• urgency: scale & scope
• priorities & options
• feedstocks – crude oil & biobased
• feasibility & ‘role’ of advanced biofuels
• (public-private) open innovation model -examples
GHG balance & climate
33.4 bn T/yr
3.4 bn T/yr
fossil, cem
ent, steel
land use
change
oceans8.8 bn T/yr
land9.5 bn T/yr
atmosphere18.4 bn T/yr
Projected sea‐level rise and northern‐hemisphere summer heat events in a 2°C world and a 4°C world
• Increased sea‐level rise from 70 cm to more than a meter
• Increased frequency of extreme and unprecedented heat events
• … and 75% of the poor in dev (agro) countries are hit first
Atmospheric CO2 is now higher than it’s been for 650,000 years and increasing rapidly
This graph, based on the comparison of atmospheric samples contained in ice cores and more recent direct measurements, provides evidence that atmospheric CO2 has increased since the Industrial Revolution. (Source: NOAA)
CO2 level as of February 28, 2015
400.26 ppm
Doubling in 50 yrs
Doubling in 50 yrs
‘decades’ : process / agro / logistics are slow industries
0,1
1
10
100
1000
10000
0 5 10 15 20 25
agro & logistic systems
commercialdemo
pilot
new product, new application
existing product, new applicationinve
stm
ent
(mio
euro
’s)
years
Example: Brazilian ethanol learning curve:4x cost reduction in 30 yrs /20 x volume increase
vd Wall Bake et al. Biomass & Bioenergy 33, 644-658, 2009
2
High rate of change
1. So we have a time window of a few decades !
2. Linked climate and economic impacts
3. 80% of GHG emissions already locked in existing capital stock
4. 2oC goal: less then 1/3 of proven fossil reserves can be consumed before
2050 (significant capital loss)
5. 70‐95 bn US$ in global annual adaptation costs
6. Impact investment ‐ required: $ 1…2 trillion in next decade (@10‐30%
profit).
7. Pension funds : US $ 20 trillion, NL (EUR) 1 trillion
• SCOPE / UNEP / UNESCO• 137 authors from 24 countries of 82
institutes, peer reviewed• BE-Basic 9 of 21 chapters• Launches: Sao Paulo (FAPESP), Nairobi
(UN), W’ton DC (Worldbank), Brussels (EU),
contents
• urgency: scale & scope
• priorities & options
• feedstocks – crude oil & biobased
• feasibility & ‘role’ of advanced biofuels
• (public-private) open innovation model -examples
drop-outs ?
mass yield: energy poor (O-rich) in materials*
C H
O
substitutes
fuels (energy dense) &polymers (PE,PP, PS, PVC)
natural gas
crude oil
biomass CH2O0.5
ethanol
sugars, lactic
CO2
drop-ins
mass composition biobased and fossil feedstocks and products
energy density increases
global production (MT/year) fuels 2000 (jet 300)cement 3000 (600 MT CO2)food 4000 (50% waste)glass 120plastics 280 (big 5: 200)steel 120 (200 MT CO2)
Biobased technology is/gets there“any” chemical can be produced from biobasedfeedstocks – by chemo / bio / thermo catalysis
but not all make sense
cost (benefit)emission (reduction)resource efficiency
yield is central parameter in both
12Werpy & Peterson, 2004
3
“Drop-in Greenification” of Chemical Industry
BIOMASS
protein / sugar / lignocellulose
Iso-butanol ethanol methane SNG
Iso-butylene Ethylene
Gasification
B substitute A drop-in
FermentationAerobic
An-aerobic
othersuccinic acid
acetic-acid
Lactic acid
Funct. molecules
Preservatives, plastics
synthet. polymers
glue
plastics, thickeners
Paraxylene
PET-bottles
Propylene
fertilizer methanol
=80% chemical industry
Plastics, surfactants, detergents
Plastics, carpet
Biorefinery
Reforming
Fermentation and other processes
glycerol
From: Ton Runneboom Bio Based Chemicals March 22 2011, Rotterdam
Biopower
BioPVC
BioHydrocarbons
2020 2030
2nd gen. advanced biofuels (hydro carbon-like)
Synthetic biology: novel pathways, robustness,
rate and yield
1st gen. EtOHfrom sugar cane
2010
photosynthetic micro organisms
to excrete solar biofuels
Low cost photo bioreactor technology
C5 & C6 cofermentation ; biomassN –recycle HTE, -array bioreactors
Genomics & (Directed) evolution
CO2 + solar light
based (3rd gen) biofuels
Low-cost lignocellulosic pretreatmenttechnology for efficient fail-proof intermediate:
low cost sugar (C5/6) platform
1st gen. advanced liquid biofuels
(hydro carbon-like)
2nd gen lignocellulosic EtOHpilot and demonstration plants
2nd gen lignocellulosic EtOHcommercial plants
System
Process Engineering
Develop
Basic Hardware
Enabling Technology
Basic Science
deploy
discovery
discovery
demonstrate
Solution
(piloting)
Low-cost lignocellulosic, thermostable enzymes
Abengoa Bioenergy: “1.3 million gallon/year
capacity demo plant”.’09
“the advances made by Joule Unlimited to achieve direct,
continuous conversion of solar energy to renewable diesel at 15,000
gallons/acre/year ”2010
“Shell and Cosan Form $12bn Ethanol Joint Venture
Raizen 21/11/2011
Amyris: “is scheduled to be in full production of Amyris
renewable products by Q2 2012.
DSM-TUD-B-Basic: “all you can eat
yeast”.2011
Genencor / Novozymes / DSM: “commercial
hydrolytic enzymes”.’10
Sime Darby-Mitsui: “convert oil palm empty fruit bunches, or EFB, into bioethanol”.2010
GranBio 147 M$ = 464 mRM (160 ktpasugars > 82 mio m3 ethanol)
ChemTex + Novozymes + DSM
DuPont 235 M$ = 744 mRM (200 ktpa hydrolysate sugars > 100 mio m3 ethanol)
POET/DSM 250 M$ = 790 mRM (300 biomass > 160 ktpa sugars > 100 mio m3 ethanol)
Roadmap for tech innovations in the Chemical and Energy sectors : Energy | liquid biofuels
NRW and NL are #1 and # 2 in Europe
CO2/ha/yr
#1#1
#2#2
… in GHG emissions !
(so we have carbon to be recycled)
… this enables the largest industry cluster worldwideRegional priorities: chemical sector and transport w/o alternatives (aviation etc)
Aviation sector needs to green
0
5000
10000
15000
20000
25000
30000
35000
40000
201
420
16
201
820
20
202
220
24
202
620
28
203
020
32
203
420
36
203
820
40
204
220
44
204
620
48
205
0
biofuels 1G
biofuels 2G
biofuels tot
fossil
total bio+fossil
reference
reference
CO2 emissions (kton/year) in NL at 3% net growth of aviation fuels
consumption
proposed path
fossil fuels
biofuels (1G+2G)
Aviation: GHG-reduction via TOI and jet biofuels
improved technology, operations, infrastructure
aviationbiofuels
From “Visie Duurzame Luchtvaart”. SER Report Van der Wielen et al.June 2014. adopting NL to ATAG ambitions
Carbon neutral growth
50% GHG emission wrt ‘05
KLM 1% biofuels in ‘15
4
0
1000
2000
3000
4000
5000
6000
7000
8000
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35
fossil
Vandaag (1G)
Morgen (2G)
Biofuels (1G+2G)
Fuel-pool composition in (kton/year) at 3% net growth of
fuels consumption
2030 20502015
7 mio ton/yr2G: - 80% GHG
0.7 mio ton/yr
4 mio ton/yr
Introducing aviation biofuels (NL- numbers)
150 kton/yr1G: - 35% GHG
8 (16)
6 (12)
4 (8)
2 (4)
investment estimates [bn $]
doubling jet fuel towards 90% biojet
Carbon neutral growth
fossil
Brazilian roadmap to aviation biofuels (2013)
Implementing the Bioport concept
NL (bio)Fuelsmix 2050
Aviation 50%Marine 33%Road+rail 17%
International setting is critical for globally operating industries (transport & chemical)
contents
• urgency: scale & scope
• priorities & options
• feedstocks – crude oil & biobased
• feasibility & ‘role’ of advanced biofuels
• (public-private) open innovation model -examples
Platforms from biomass
Xylose
Plantation image from: biofuel.webgarden.com
Glucose
24
0.00
0.20
0.40
0.60
0.80
0.00 0.20 0.40 0.60 0.80
London Sugar price (euro/kg)
Brent oil price (euro/kg)0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
Jan‐10 Jan‐11 Jan‐12 Jan‐13 Jan‐14
Price (euro/kg)
oil
sugar
Oil price vs. sugar price (Europe)
2010-2011
2012-2014
5
palmitic acid
glycerolsugars
methane
butanol
propionic acid
ethanol
succinic acid
citric acid
lactic acid
p‐xylene
crude oil
syngas
0.25
adipic/acrylic
ethylene
propylene
jetfuel/diesel
1,4 BDO
0.5
1.0
0.3
1.1
0.4
0.34
CO2
biomass
ligninemethanol
Hcomb
105 J/kg
600
0
biomass yield
Cost contribution of feedstocks
$400/ton
$50..130*/ton
$660/ton
$6/ton
$1600/ton
$1200/ton
$400/ton
$800/ton
$402/ton
feedstocks products
Only established market: APEX ENDEX Woodpellets ~ $130*/ton 26
Chemicals price model so far
€/kgproduct = €/kgfeedstock kgfeedstock/kgproduct 1.5
Cheaper product when lessconversion steps from oil
Feedstock costs Rest
At 100% conversion 100% molar yield
0
0,5
1
1,5
2
2,5
3
3,5
4
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0
Pre
dic
ted p
rice
($/k
g)
Literature price ($/kg)
27
Other fermentation products than ethanol
Price
Price
product
product sugar product
ethanolethanol ethanol
sugar
MassMass Factor
Mass FactorMass
Ratio 1Yield ratio
Best-case assumptions • 1-step conversion from sugars• Microorganism engineered to convert available sugars feed• Sugars are dominating cost factor• Multiplication by factor (ca. 1.5) for other costs
28
Competitiveness compared to ethanol fermentation
ethanol
1‐butanolisopropanol
adipic acid
ethylene
butanone
phenolpropylene glycol
acrylic acid
isobutanol
ethylene glycol
1,4‐BDO
propylene
0
0.5
1
1.5
2
2.5
0 0.2 0.4 0.6 0.8 1
Relative price (kg basis)
Reported fermentation yield of product on glucose (g/g)
ethanol
1‐butanolisopropanol
adipic acid
ethylene
butanone
phenolpropylene glycol
acrylic acid
isobutanol
ethylene glycol
1,4‐BDO
propylene
0
0.5
1
1.5
2
2.5
0 0.2 0.4 0.6 0.8 1
Relative price (kg basis)
Stoichiometrically maximum yield of product on glucose (g/g)
competitive
not competitive
29
Calculation results
1. Poor: naphtha products (ethene, propene, butenes, BTX)
2. OK: mono alcohols (1-propanol, 2-propanol, butanols, acetone)
3. Good: diols (ethylene glycol, 1,2-propylene glycol, 1,4-butanediol)
4. Very good: adipic acid, acrylic acid, methyl methacrylate
But is a 1-step conversion by fermentation (or chemocatalysis) achievable ? And how sensitive is outcome for sugars/lignin pricing ?
contents
• urgency: scale & scope
• priorities & options
• feedstocks – crude oil & biobased
• feasibility & ‘role’ of advanced biofuels
• (public-private) open innovation model -examples
6
Biorefinery structure - biomass to integral value
• tune portfolio value renewable energy/fuels/chemicals
• counter-acting scale effects of logistics (5-10% for bagasse,
30% for palm oil biomass) and conversion costs
• energy/heat, water, and nutrient integration
• need for cross-industry sector collab’s (JVs, trade, co-op’s,…)
conversion to fuels fuel
conversion to chemicals
conversion to power/heat
pretreatment / hydrolysis
harvest / logistics
chemicals/materials
renewablepower/heat
nutrients/water
‘switch’
food/feed(I) Bioenergy Only: sugars to ethanol (100%) , power (heat)
(II) Chem’s : sugars to organic acids (25%) + ethanol (75%), lignin to power (+ less excess heat), CO2
(III) Chem’s & Materials : sugars to organic acids (25%) + ethanol (75%), lignin to power (+ less excess heat), CO2 to bioconstruction
150
900 910
1743
3 tons of raw biomass at gate(2/3 cellulosics + 1/3 lignin)
biomass biorefined to sugars and lignin
revenue in US$
CO2
heat
CO2 in mat’s
(II) (III)(I)
power
ethanolsugars
chem’s
biorenewables’ scenarios
pos. and neg. economic value
lignin
(IV) Chem’s & Materials & LignoFuels : as III, lignin to liquid biofuels
CO2 in mat’s
(IV)
Winning Team
2013 LST MSc
Design Competition
woodpellets + … power/heat + ethanol + biochemical + €€ (instead of –SDE)
2013: 5 fairly different designs
35
WoodChips4000ktpa
Ethanol
Ethene
EtOx
EC
PEC
50
100
50
100
100
920
CO
2
O2
CO
2
H2O
50
490
CO
2
60 50
H2O
i-Butene
Lacticacid
PLA
H2O H2O
240
100
100
Acrylicacid
400
Succinic acid
1,4 BDO 100
100
100
H2O
H2O
H2
CO
2
380
Methanol
686L914L
100700
CO
2
3HP100
GTBE
PEPP
1,2 PDO
1,3 PDO
225
Aceticacid
250
CO
Syngas
CO H230400
MEG
100
H2O
MCA
i-Butanol
PX
H2
DMC
THF
Biosene
250opt
CO
2
SHC
CO
2 opt
36
WoodChips4000ktpa
Ethanol
Ethene
EtOx
EC
PEC
i-Butene
Lacticacid
PLA Acrylicacid
Succinic acid
1,4 BDO
Methanol
3HP
GTBE
PEPP
1,2 PDO
1,3 PDO
Aceticacid
Syngas
MEG
MCA
i-Butanol
PX
DMC
THF
Biosene
SHC
Authors: Kim Meulenbroeks/Jan van Breugel
36
7
wood chips at ‘mid price’
cost of /return on capital at market conform pricing included
Equal to woodBunker oil
0
100
200
300
400
500
0 200 400 600 800
€/t sugars
€/t lignin
4 Mt/a
1.5 Mt/a
London #5 Sugar Price(26/06/2015)
New York #11 Sugar Price(03/07/2015)
o
o – transfer price for lignin priced as wood at target NPV
Presentation based on public data
NPV>0
NPV<0
REDEFINERY to produce sugars and fuels
& Kerosine
Coal value
NPV= 0 at various scales
various scales
wood chips at ‘mid price’
cost of /return on capital at market conform pricing included
Equal to woodBunker oil
0
100
200
300
400
500
0 200 400 600 800
€/t sugars
€/t lignin
4 Mt/a
1.5 Mt/a
London #5 Sugar Price(26/06/2015)
New York #11 Sugar Price(03/07/2015)
o
o – transfer price for lignin priced as wood at target NPV
Presentation based on public data
NPV>0
NPV<0
REDEFINERY to produce sugars and fuels
& Kerosine
Coal value
NPV= 0 at various scales
various scales
contents
• urgency: scale & scope
• priorities & options
• feedstocks – crude oil & biobased
• feasibility & ‘role’ of advanced biofuels
• (public-private) open innovation model -examples
About us: www.BE-Basic.org/downloads RD & Innovation strategy
Focus: (1) start-ups , (2) training bio-engineers, (3) pilot facilities
DISCOVER DEVELOP DEMO DEPLOY
B-Basic &Ecogenomics2004-2009
front end
high risk
unbound
failure is an option
early spin-outs
new processes and products
new companies
new monitoring methods
new approaches(e.g. Smart Soilfor CO2 capture)
in via partners
DISCOVER DEVELOP DEMO DEPLOY
B-Basic &Ecogenomics2004-2009
B-Basic2004-2010
fuzzy
wild ideas
high risk
unbound
failure is an option
early spin-outs
new processes and products
new companies
new monitoring methods
new approaches(e.g. Smart Soilfor CO2 capture)
spin-spin-
unbound
pilot plant
demo plant
full plant
lab R&D
BE-Basic2010-2015
8
Synthetic Biology in the real world?
glucose
xylose
arabinose
acetate
glycerol
furanics
commercial product based patent portfolio
Successful SME’s in BE-Basic (Q1 2013)
• TUD-spin-out discovered FDCA-technology for sustainable PET-
replacement (’09), developed in BE-Basic (’10-’11) for further
commercialisation in Purac (mar’13)
• WUR-starter pioneer in chemicals from
waste streams, closes series A investment
with Horizon3 and DGF* (5 apr 2013)
• TUD starter (oct’12) with BPF, TUD, VC
develops advanced biorenewables processes
… and more to come !
DḀB
The other 70% : FDCA for “BioPEF”
biomass
HM-furOH
• Top-12 value-added chemicals from biomass
• Platform chemical - market size 4-12 bn $/yr
• Replace terephthalate in 15 mio ton polymers
• Concept in B-Basic (TUD/TNO - ’09) – FDCA direct production from lignocellulosic HMF
• indust biocat (BIRD Eng /TUD-’09) – bioprocess (BIRD –’10) – invest round - piloting (BE-Basic-’11)
• 2013 - acquisition of BIRD Eng / FDCA by Purac kg-scale process
trends in biobased production
production [kT/yr]
concentration from reactor [kg/m3]
0,01
0,1
1
10
100
1000
10000
0,001 0,1 10 1000 100000
petrochemicals
bio-bulk
active ingredients
biopharma
Cooney, ‘84
0,01 1 10 100 1000
MAb, HSA
antibiotics, nutraceuticals
bioplastics(PLA, PHA, PDO, ...)
(2nd gen) biofuels
cost
pric
e ($
/lb)
Bioconstruction materials (self-healing, cement, bioconcrete,biogrout,
bioasphalt,, …)
In-situ concrete by carbonate fixation
Biogrout & bioconcrete: from soft soil to rock solid
100 micrometer (10-4 m)
Van Paassen Animations ©
9
49
palmitic acid
glycerolsugars
methane
butanol
propionic acid
ethanol
succinic acid
citric acid
lactic acid
p-xylenecrude oil
syngas
0.25
adipic/acrylic
ethylene
propylene
jetfuel/diesel
1,4 BDO
0.5
1.0
0.3
1.1
0.4
0.3
CO2
biomass
ligninemethanol
feedstocks
Hcomb
105 J/kg
600
0
biomass yield
Combined (drop-in/substitute/-out) scenarios ?products
$400/ton
$50..130/ton
$660/ton
$6/ton biocon-struction
advanced fuels
connect 2 sectors w mega-volumes
conclusions
• biorenewables can play critical role in chemical &
materials industry, far ‘beyond bioethanol’ and
• in sustainable (people, planet, profit) development
• no premiums & subsidies: need to be integral part of
chemicals/ fuels/ food/ energy /logistics system
• fuels with priority for sectors w/o alternatives
• open innovation models can speed-up development
and implementation, in professional setting
ECO‐BIO conference 2016:
“Challenges in Building a Sustainable Biobased Economy”
Tentative date: 6‐9 March 2016
World Trade CentreRotterdam, The Netherlands
SAVE THE DATE!
Chair:
Bram BrouwerBioDetection SystemsVU University Amsterdam
Chair:
Luuk van der WielenDelft University of TechnologyBE‐Basic Foundation
More information: info@be‐basic.org
B(E)-Basic Foundation
T +31 15 – 2782363
W www.be-basic.org
or
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