tokyo, april 2014 dr. thomas kuhlmann
TRANSCRIPT
1
European Sugar Beets:
Future „Crude“ for the
Chemical Industry
Tokyo, April 2014
Dr. Thomas Kuhlmann
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Pfeifer & Langen GmbH & Co. KG
Emil Pfeifer
1806 - 1889
Valentin Pfeifer
1837 - 1909
Eugen Langen
1833 - 1895
… an independent family business for more than 140 years
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Pfeifer & Langen IHKG: A strong group in food business
Pfeifer & Langen Industrie- und Handels KG
Turnover: 1.6 bn €
Employees: 3,000
Sugar: 2 mt
Instant beverages, chocolate,
dried milk products Snack products
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Worldwide Sugar Consumption
Food Industry
164 mio. t
Ethanol
40 mio. t
Chemical Industry 4 mio. t
Growth rate 2 % Growth rate 0 %
Growth rate 46 %
EU 18 mio. t
EU 1 mio.t
EU 1 mio.t
208 mio. t Sugar
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World Sugar Production by Company (2012/13 in 1,000 t)
0 500 1.000 1.500 2.000 2.500 3.000 3.500 4.000 4.500 5.000
20. Cosun
19. Tongaat
18. Cristal Union
17. Shree Renuka
16. Bajaj Hindusthan
15. Guanxi Nanhua
14. Turkseker
13. Sta Terezinha
12. American Crystal
11. Feesa
10. Thai Roong Ruang
9. Pfeifer & Langen
8. Wilmar
7. Biosev
6. Nordzucker
5. Mitr Phol
4. Tereos
3. Raizen
2. AB Sugar
1. Südzucker
9. Pfeifer & Langen
6 Quelle: Ribera CEFS – ISO Seminar 2013
Sugar Beet Factory
Ethanol Factory
Cane Sugar Refinery
Beet & Cane Sugar Refinery
Production sites of the European Sugar Industry
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Pfeifer & Langen in Europe
Production Site
Sales Office Lage
Appeldorn
Jülich
Könnern
Euskirchen
Elsdorf
Mieska Gorka
Glinojeck
Sroda
Gostyn
Oradea
Radechiv
Tchortkiw
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Top commodities in Agro business … World & Germany 2012*
http: //faostat.fao.org/site/339/default.aspx; (2012) FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS (Faostat)
rank commodity Production/Mt
1 Sugar cane 1.833
2 Maize 872
3 Rice, paddy 720
4 Wheat 671
…
7 Sugar beet 270
Top 10: World
rank commodity Production/Mt
1 Cow milk 31
2 Sugar beet 28
3 Wheat 22
4 Potatoes 11
5 Barley 10
Top 5: Germany
10 % of worldwide sugar beet production in Germany
Renewable Resources
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Agro commodities vs. crude oil … … carbon based price comparison
0
400
800
1200
1600
2000 2002 2004 2006 2008 2010
US$/
t Carb
on
crude oil (WTI)
sugar (NY no11)
corn (FOB, Gulf of mexico
Renewable Resources
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From field to factory …
A survey of our value chain …
sugar beets sucrose thick juice2
Extrac- tion
Purifi- cation
Concen- tration
Crystalli- zation
„Carbo-Kalk“ (CaCO3)
molasses beet pulp
pellets
raw juice1
1: 17% sucrose; 2: 64% sucrose
Cleaning
beet parts
soil
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The sugar beet
Some facts about sugar beets:
within Top 7 of worlds agro commodities
10 % of worldwide sugar beet production in Germany
Share of worlds sugar production: 20 %
harvested in autumn
water: 76,5 %
dry substance (DS): 23,5 %
sucrose: 16,5 %
pulp: 3,7 %
N-compounds: 1,0 %
ash: 0,5 %
other: ~1,8 %
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European sugar beets…
… comparing yields on the field 1)
1): Source: FAO Stats; sugar, starch or potential yield by cellulose hydrolysis
“carbohydrate” per hectare and year
10 t/a 5 t/a
Top 25 % suppliers: 16,5 t/ha in 2011
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1990 2011 1950
Yield in: t sugar/ha
10
5
5.0
7.8
11.6
7.6
8.9 10.6
13.8
European sugar beets …
… an economic, reliable and sustainable
feedstock Pfeifer & Langen beets
Ø cane
Ø beet
Pfeifer & Langen’s beet acreage is ~ 87,000 ha: 1 t/ha yield increase lead to 87,000 t additional sugar
Ø2011 yield Pfeifer & Langen suppliers: 13.8 t/ha; Top 25%: 16.5t/ha; genetic potential 25 t/ha
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feed
Bagasse Beet pulp
Flexible use of co-products only in the beet industry
33 % Energy surplus at sugar
production
23 % Energy surplus at sugar
production
Pulp material: cane vs. beet
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Beet pulp as raw material
feed biogas fuel chemistry materials
Areas of application for beet pulp …
… today and tomorrow
Today‘s application
Pilot scale
Concept idea
Dried / Pressed pulp
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Thick juice
Thick juice
Composition: 68 % DS
64 % sucrose
4 % „non sugar components” (Amino acids , salts, etc.)
Today: - intermediate product in sugar production
- ethanol production
Storage: - bulk, in tanks, up to 9 month
Opportunities: - all season available feedstock for „over the fence
production concepts“
- good properties in whole cell fermentation processes1
The all round substrate …
… all season available, easy to handle
1: Calabia, B. P. und Tokiwa, Y.; Biotechnol. Lett. (2007); 29; 9; 1329-1332.
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Feedstock from sugar industry for fermentation processes
amino acid content of substrates related to amino
acids from yeast extractat 120 g/L C-source and 15 g/L yeast extract
0%
5%
10%
15%
20%
25%
30%
35%
alan
ine
glyc
ine
valin
e
leuc
ine
allo-iso
leuc
ine
isoleu
cine
thre
onine
serine
+ga
ba
proline
aspa
ragine
aspa
rtic acid
met
hion
ine
glut
amic a
cid
phen
ylalan
ine
glut
amine
lysine
histidine
tyro
sine
tryp
toph
ane
Conte
nt
in r
ela
tion t
o a
min
o a
cid
s
from
yeast
extr
act
/ %
cane sugar
corn starch
thick juice
raw juice
only in raw juice
Amino acid content of potential feedstock
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strain A105; end of fermentation
0%
20%
40%
60%
80%
100%
no YE 15 g/L YE 30 g/L YE
yie
ld /
%
crystalline sugar
thick juice
raw juice
Saving costs with beet syrups by nutrient potential benefits for fermentation industry
Example: lactic acid fermentation
Benefits of sugar syrups in real applications
Potential to save process costs
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molasses
Molasses
Composition: 74 – 77 % DS
47 – 48 % sucrose
30 % „non sugar components“
(3 % betaine, proteins, ash, etc.)
Today: - substrate for yeast production
- substrate for ethanol production
Storage: - bulk, tank
Opportunities: - use as substrate for ethanol fermentation (and ETBE)1
1: Šárka et al., Zuckerindustrie (2012), 138, 2, 105-111
The „crude oil“ of sugar industry
… all season available, yeast industry´s favorite
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Crystalline sugar
Crystalline sugar
Composition: white sugar ≥ 99,5 °S < raw sugar
Today: - used for food
- used in chemical industry
- used for fermentation processes (ethanol, etc.)
Storage: - bulk, silo
Opportunities: - for enzyme processes/ chemical conversion
requiring high purities
Price/ market: EU market is devided:
1. Quota system: for food use
2. Out of quota:1 for non food industrial applications
Just pure like …
1: fabricator needs a licence
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Isobutanol>Isobutene >Buthylrubber
Sugars as Feedstock for industrial biotech
Isoprene
Levulinsäure
Lactic Acid 1,4 BDO Succinic Acid
1,3 PDO
Ethanol
5 HMF
PHA´s
High performance molecules for Pharma Functional food et ceterea …
Chemical Way
Biotechnological Way
Renewable raw materials
Sebacinacid Polyamide (Nylon)
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Classical Route:
Example 1: Succinic Acid*)
„Green Route“:
n-Butane
+ O2 [VPO]
Maleic Anhydride
Benzene
+ O2 V2O3/MoO3
Mannheimia
Succiniproducens Succinic Acid + CO2
C6-Sugar
*) Wagemann, K.; CheManager; 6/2014; S. 6
Examples for renewable Raw material in chemical industry
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Classical Route:
Example 2: 1,4-Butanediol*)
„Green Route“:
Acetylene
Butadiene
*) Wagemann, K.; CheManager; 6/2014; S. 6
2CH2O
[Cu] Butynediol
C6-Sugar 1,4-Butanediol
Escherichia coli
+ H2O -2CH3COOH
+ H2
1,4-diacetoxy- 2-butene
CH3COOH
O2
Examples for renewable Raw material in chemical industry
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Example 3: Acrylic Acid*)
Propene
*) Wagemann, K.; CheManager; 6/2014; S. 6
Acrylic Acid
Lactic Acid
3-Hydroxypropionic Acid [3PHP]
Acetylene
O2
C6-Sugar Lactobacillus
- H2O
Glycerol Acroleine - H2O
+CO /
+H2O
Examples for renewable Raw material in chemical industry
„White Route“:
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Sugar Factory as a biorefinery…
… a win-win situation
Biorefinery concepts in sugar & glucose industry
Raw sugar
Beet
White sugar (Food)
Thick juice (Storage)
Sugar Factory Biotechnology
Biochemicals
Bioenergy By-products By-products
Expanding capacities of sugar factories Cheap raw sugar raffination „green energy“ from by-products
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Tomorrow: „Chemical site“
Beet Raw sugar (Cane)
Bioenergy From residues and
wind energy
BioTechnology Bioethanole Bioethylene
Food Glasshouses, (use excess heat and + CO2 from production)
Food Sugar
Feed
Biorefinery concepts in sugar & glucose industry
Example: Agro & Food Cluster „New Prinsenland“
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Combined site with a glucose factory
Example: Natureworks (Blair, Nebraska, USA)
Evonik: L-Lysin (Feed additive, capacity: 280.000 t/a)
Purac / Nature works: Lactic Acid for PLA (Bioplastic, capacity: 140.000 t/a)
Cargill: Sweetener Bioethanol
Biorefinery concepts in sugar & glucose industry
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Könnern … one of the largest and
modern sugar factories in Europe
Sugar Factory Könnern
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Daily production of the sugar factory „Könnern“
18.000 t sugar beets
2.700t sucrose
4.900 t thick juice
Extrac- tion
Purifi- cation
Concen- tration
Crystalli- zation
630 t „Carbo-Kalk“ (CaCO3)
450 t molasses 4.600 t beet pulp
pellets
18.000 t raw juice
Cleaning
180 t “beet parts”
900 t soil
A sugar factory as a production site
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Thick Juice tank
Power Plant
Waste Water Treatment
Water Reservoir
Stockyard for Beets
Sugar Production
External Biogas
Water reservoir
... sugar factory meets demand of a biorefinery
Opportunities for a sugar based biotechnology
Fact sheet: Könnern
Processing:
1.4 mt beets per campaign
16.500 t beets per day
Storage capacity:
140.000 t crystalline sugar1)
160.000 m³ thick juice
On site:
CHP Plant
Waste water treatment
…
1) 80.000 t thereof in planning
A sugar factory …
… is the interface between agro-industry and chemical industry
… offers a feedstock, energy, supplies and infrastructure like a chemical site
… makes a seasonable crop all season available
… helps saving investments costs by various synergy effects
Bio-refinery
Sugar Silo
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どうもありがとうございました