bioenergy australia conference 2016 14-15 nov. 2016 ... · bioenergy australia conference 2016...
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tbw research GesmbH [email protected]
Bioenergy Australia Conference 2016 14-15 Nov. 2016 - Brisbane
Michael Mandl
Overview on Biorefining Activities in Austria
tbw research GesmbH [email protected]
Overview on biorefining projects in Austria
Details on 3 selected biorefiniery examples
(1) Ligno-cellulose biorefinery at LENZING AG (productions scale)
(2) OPTFUEL; optimising methane yield of an anaerobic digestion process (pilot scale)
(3) Green Biorefinery Utzenaich; producing amino acids & lactic acid and biogas from grass silage (pilot scale)
Recommendations on biorefining
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Outlook
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In a nut shell, biorefiney activities focus on
agricultural (waste) streams e.g. wheat straw,
Process residues of food/ feed production residues starch production (e.g. fist gen. bioethanol biorefinery, AGRANA), wheat bran, pomace (wine and different fruits), oil press cakes, de-lactosed whey permeate…
Co-products valorisation and pulp production Biorefinery concepts for chemicals, bioethanol, materials
Other biomass (grass, intercrops, algae ..)
Pyrolysis / gasification (e.g. pant in Güssing)
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Biorefining Activities in Austria
tbw research GesmbH [email protected]
Good source of information concerning national levels
Biorefining country reports Austria download via IEA Bioenergy Task 42 webpage
http://www.iea-bioenergy.task42-biorefineries.com/en/ieabiorefinery/Country-Reports.htm
Webpage operated by Austria R&D funding bodies covering activities for sustainable development https://nachhaltigwirtschaften.at/
via search option die abstract and contact persons of project can be found….
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(1) Ligno-cellulose Biorefinery at Lenzing AG, Austria
Source: Karin Fackler 2016
tbw research GesmbH [email protected]
Lenzing AG is a global producer of wood-based cellulose fibers
Produced from the raw material wood Natural wearing properties of natural fibers combined with the advantages of synthetic fibers such as purity and consistent quality
Source: Karin Fackler 2016
tbw research GesmbH [email protected]
Understanding the biorefinery Lenzing
Sustainable processing of beech wood into a spectrum of marketable products (chemicals, materials) and energy (power, heat)
Source: Karin Fackler 2016
tbw research GesmbH [email protected]
Lenzing biorefinery summary
Main product is pulp but recovery of co-products is operative more than 10 years at industrial scale
Co-products strengthen the entire process chain and deliver significant revenues
Recovery of furfural and acetic acids has significantly reduced the CSB of waste water and treatment costs
Xylose separation is made by an industrial partner
Revenue from products are much higher than the caloric value
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tbw research GesmbH [email protected]
(2) OptFuel
Opt-Fuel project at Asten/Linz in Austria
Optimising an
anaerobic digestion process to
fully exploit organic carbon of feedstock
for maximum methane production at
pilot scale
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Biogas production and utilisation
State of the Art: Biogas + CHP
State of the Art: Biogas + gas cleaning/upgrading process
Source: J. Lindorfer 2016
tbw research GesmbH [email protected]
OptFuel Approach
Goal: Full conversion of biomass`s carbon to energy carrier
Integrate additional processes (1) H2 production (2 stage fermentation, power-to-gas (2) Methanation (3) Gas membranes to separate methane and recycle C02
Source: J. Lindorfer 2016
tbw research GesmbH [email protected]
~ 55 % CH4
~ 45 % CO2
H2
CH4
methanation 4 H2 + CO2 → CH4 + 2 H2O
Pro
ject p
artne
r
biogas = CH4 + CO2
Additional methane yield by methanation
tbw research GesmbH [email protected]
Biogas production Methanation Gas processing
fermentation of biowaste materials 2-stage (vs. single-stage)
hydrogen stage methane stage
simple process control mesophilic, unsterile, mixed culture, no additives
chemical catalytic catalyst commercially available
process optimization process pressures space velocities loads methane in educt gas
raw gas conditioning drying and adsorption
gas processing by membrane separation technology operation optimization & simulation
H2-fermentation 30-60 °C; pH 4-6
HRT 5-50 h
Vf 150 L
methanationCH4-fermentation30-60 °C; pH 6-8
HRT 15 – 30 d
Vf 2.500 L
compressor
adsportioncondenser
membrane separation
H2
digestate
biogasmix CH4/CO2/H2
recycle
CH4 >96 vol-%
~ 105 NL/h
H2/CO2 CH4/CO2
condenser
5 L/h slurry5.3 – 11.7 % DM
66-82 % oDM
~ 5 L/h
Piloted process concept
Source: J. Lindorfer 2016
tbw research GesmbH [email protected]
Results of economic assessment
*Full cost caluculation for the OptFuel-process concept for a scale of 90 Nm³/h CH4-Output
Central european prices and cost structures anticipated
Technological learning and electrolyser / electricity input cost reduction is responsible for estimated cost degradtion
Fossil benchmarks based on IEA and EU prognosis
• Cost competitiveness is primarily reachable in the transport segment
• Additional income for waste disposal, capacity increase and balancing energy possible
6.1 5.9 3.8
9.2 11.2
9.0
13.0
5.5 4.1
1.4
1.4
1.4
0.0
5.0
10.0
15.0
20.0
€-C
en
t/kW
hL
HV
taxes & duties
price (excl. taxes)
2016* 2030*
8.3 7.0
4.1
7.4
13.5 11.7
9.8
5.5
4.1
1.4
1.4
1.4
0.0
5.0
10.0
15.0
20.0
€-C
en
t/kW
hL
HV
taxes & duties
price (excl. taxes)
Source: J. Lindorfer 2016
tbw research GesmbH [email protected]
Results of OptFuel pilot project
Proof of concept accomplished: Integration of unit operation from 3 Partners to one continuous operation
Gas quality according to Austrian standard (ÖVGW G31) was achieved under moderate test campaign conditions
The operation of the overall system was possible with fluctuating biogas composition
Process was able to handle extremely high fluctuations in composition of the bio-waste feedstock
Methane from the Optfuel process has significant reduction potentials of greenhouse gas emissions compared to fossil benchmarks (if power from renewable resources is used)
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(3) Green Biorefinery
Green Biorefinery processes green biomass for products & energy targeting on utilizing
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Proteins (amino acids)
Soluble sugars (or products after fermentation of sugars; e.g. lactic acid)
Ligno- cellulose fraction ( e.g. fibres)
Special/ fine chemicals
Minerals (e.g. fertilizer)
Energy (e.g. biogas)
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Motivation for Green Biorefinery
Grass has become a surplus biomass in some regions due to change in agricultural sector
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„..from cow
to
„technical cow“
From grass for cattle towards grass for bio-industry
Food Products milk, beef and manure
Biobased Products food/feed, materials,
bulk and fine chemicals,
biofuels and energy…
tbw research GesmbH [email protected] page 19
Set-up of Pilot Green Biorefinery in Utzenaich/ Austria
Grass Biomass (Grass, Clover, Lucerne)
Silage
Pre-treatment
and pressing
Press-
cake
Amino acid
separation
Lactic acid
separation
Residues
Anaerobic
digestion
Fibre-
utilisation
Conversion to
liquid biofuels
Amio acids high grade
Lactic acid food grade
Fertilizer
Biogas CHP, BioCNG
Fibre
Juice
2nd gen.
biofuels
Demonstration plant Utzenaich
tbw research GesmbH [email protected] page 20
Primary processing
First step: Mechanical fractionation to generate a
juice and a solid fraction from grass silage
Juice for product
separation
Solids feedstock
for biogas
Grass
Silage feedstock
quality
important
tbw research GesmbH [email protected] page 21
Down stream processing of silage juice
Combination of different separation processes:
Ultra & nano filtration
Electro dialysis
Reversed osmosis
Ion exchange
tbw research GesmbH [email protected] page 22
Results Green Biorefinery Pilot
Process Quality of grass silage is very important Grass contains all 20 essential amino acids! (BCAAs >25%)
Economy Economic feasibility of processing is possible at moderate scales (app. 10.000 DM/a feedstock) Required revenue for amino acid mixture > 4-6 €/kg Co-valorisation of grass press cake has strong effect on economics (Green power tariffs for biogas CHP)
Implementation AA products from grass are new! USP: Vegan source of AAs
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Conclusions / Take home message
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Biorefineries are essential to transfer towards circular bioeconomy
More development is still needed to make impact; bottle neck is at pilot/demonstration stage
There is NO general biorefinery solution but the NEED of customised - reginal embedded solutions
Feedstock logistics determine size of a biorefinery
Clip-on biorefineries have high potential (valorisation of process wastes, extending existing processing etc.)
Cross-sectorial cooperation is key for implementation
tbw research GesmbH [email protected]
Aknowledgments/ Contacts
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Thanks for you kind attention! DI Michael Mandl tbw research GesmbH, Vienna [email protected]
Special thanks for contributions from
We kindly acknowledge support, grants and funds provided by Austrian Research Promotion Agency
Dr. Karin Fackler Lenzing AG [email protected]
Dr. Johannes Lindorfer Energieinstitut an der J. Kepler Universität Linz [email protected]