9105z-wa-wa-tec iea42 sugarbiorefinery · 2013-10-18 · zafes offstein, dr. wolfgang wach 2009/09...

Sugar Biorefinery

Wolfgang Wach, Südzucker AG Mannheim/OchsenfurtIEA-Bioenergy Task 42 Biorefineries – German Workshop on Biorefineries15th September 2009, Worms

ZAFES Offstein, Dr. Wolfgang Wach 2009/09 IEA Task42 Geman Workshop on Biorefineries in Worms 9105z-wa-wa, Bild 2

Content

Südzucker Group

Sugar factory and logistic aspects

Sugar as raw material for biobased economy

Bioenergy

Palatinose™ Isomalt

Gluconic acid

Summary


The Südzucker Group: Overview

Global operating German food group Segments sugar, special products, CropEnergies and fruit 18.000 employees € 5.9 billion annual revenues Sugar production: 4.2 million tonnes Leader in the European sugar market Member of the German MDAX


Core Competence of the Südzucker Group

“From Farm to Fork”

Transformation of agricultural raw materials into food/feed ingredients and agrochemicals

The Südzucker Group relies on its close cooperation with theagricultural industry, the basis of its commodities, the group's in-house research expertise, its extensive manufacturing knowledge in connection with processing renewable raw materials and itsmarketing experience, particularly in the B2B area.


Südzucker Group – Segment Overview

30 sugar factories and 3 refineries in

Germany, Austria,Belgium,

Bosnia-Herzegovina, The Czech Republic,

France, Hungary,Moldova, Poland,

Romania, Slovakia

Sugarsegment

BENEO-Group(Orafti/Palatinit/

Remy)Freiberger

PortionPack EuropeStarch

Special productssegment

Fruitsegment

Fruit preparationsFruit juice concentrates

37 production sitesworldwide

CropEnergiessegment

Bioethanol4 sites in Germany, Belgium and France


Sites of the sugar factories/refineries today

Südzucker Raffinerie Tirlemontoise Saint Louis Sucre AGRANA

France

Austria

Germany

Czech.Republic

Belgium

Slovakia

Hungary

Romanie

Moldova

Marseille

Eppeville

Roye

Etrépagny

Kaposvár

Tulln

Leopoldsdorf

HrusovanyOpava

Sered

Roman

Buzau

Drochia

Falesti

Alexandreni

Tienen

Wanze

Poland

Ropczyce

Strzyzów

Otmuchów

Swidnica

Cerekiew

Cagny

Warburg

WabernBrottewitzZeitz

Ochsenfurt

PlattlingRain

Status at: Mai 2009

Bosnia-Herzegovina

OffsteinOffenau

Strzelin

^

Brcko


““FromFromagricultural rawagricultural rawmaterials to materials to food ingredients and

agrochemicals””

Fruit juiceconcentratesFruit preparations

Fruit

EthanolSugar beet

Maize

Wheat

OligofructoseInulin derivatives

InulinChicory

Modified starchesInulin derivatives

StarchMaize, Potatoes

FlourStarchProteinsRice Bran

Rice

Invert sugar syrup, Fructose syrup, PalatinoseTM, Isomalt, Caramel sugar

SucroseSugar beet

ProductsAgricultural rawmaterial


Sugar beets – a powerful sugar producing crop


Südzuckers core competence‚From Agrocrops to Agrochemicals‘

Best available technology

biomass logistics processing conversion product market


Content

Südzucker Group



Bioenergy


Gluconic acid

Summary


Sugar plant data

Grown under contract campaign: mid September to begin January Typical sugar factory:

15.000 t beets/day, beet storage on site for max. 3 days 800 trucks/day, 24-h-delivery, 30 bis 40 trucks/h 1,5 … 2 million t beets/campaign 200.000 bis 300.000 t sugar/campaign 130.000 bis 180.000 t dry feed pulp/campaign or 330.000 bis 440.000 t pressed pulp/campaign

Costs for Logistics Transportation approx. 40 km Costs for loading, cleaning and transport approx. 6 €/t beets


Sugar Yield [t sugar/ha grown] - the last 26 Years

4

5

6

7

8

9

10

11

12

13

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

2002

2004

2006

SZ

[t Sugar/ha]


Amounts of nitrogen- phosphor- and potassium-commercialfertilizer used in sugar beet cultivation 1980 - 2005(Trials within „Verband Süddeutscher Zuckerrübenanbauer e.V., Würzburg“)

0

5

10

15

20

25

30

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

2002

2004

2006

NP2O5K2O

kg fertilizer / t sugar yield

NP2O5K2O

0

50

100

150

200

250

300

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

2002

2004

2006

kg h

a-1


Sugar beet harvest with topping of beets


Directly on the truck or beet clamp after harvest


Coverage of beet clampsoil cleaningfreeze protectionreducing sugar losses

Only short term storage – notfor months


Loading of the beets to trucks (no tractors)


Soil separation during loading


Unloading of the beets in the plant


Unloading – here: dry

in many plants as well wet unloading


Storage and ventilation of beets in the plant


Sugar logistic – mainly on road


Feed material from sugar beet – wet or dry beet pulp (pellets)


Isomalt Syrups / Fructose

Burnt SugarsR&D

Offstein site (located 15 km from Worms) – biorefinery ‚nucleus‘

thick juice storage

Sugar factory campaigndaily beet capacity 15.800 tabout 19.000 ha beet areaSugar production 1.500 … 1700 t/dThick juice storage 2 x 50.000 m³


Content

Südzucker Group



Bioenergy


Gluconic acid

Summary


From classical beet process to sugar biorefinery

Unloading

Beet Storage Beet WasherCosette /

Juice MixtureTower Extractor

Raw Juice ExhaustedCossettes

Carbonation

Press-water

EvaporatingCrystallizers

Minglers

Centrifugals

Cooling and drying drums

SugarSilo

Screening

Packaging Dispatch

Steam Boiler

To Juice Heat Exchangers and Crystallization

Multiple Effect Evaporator

Melted LiquiorFilter

Dissolving

Steam turbine

Run off syrup

SlicingMachine

Liming

ThickeningFilter

White sugar Refinade sugarMolasses

Fuel

Exhauststeam

Run off syrup

Refinadesugar

Whitesugar

Raw-sugar

After product

Steam

Thick Juice

Thin Juice

Thin Juice toJuice Evaporation

fermentationto

bioethanol

Raw Juice

Thin Juice

Thick Juice

green syrup

MolassesBiomethan from

beet pulpBioethanol


CropEnergies sugar based bioethanol plant in Zeitz, Germany

Raw material: 150,000 t of thick juice/a

Ethanol 100,000 m3/a

Side product: 35,000 t/a vinasse

Fermentation: Batch wise

Start of production: June 2008

Distillation

Fermentation


Principle of ethanol production from thick juice (Zeitz)

1. Thick juice (65-70 % dry matter)

2. Diluted thick juice

3. Pasteurisation at about 80 °C

4. Batch fermentation

5. Distillation, rectification Ethanol

6. Evaporation of vinasse Feed, fertiliser

fresh water

backset vinasse

N-source, yeast, trace elements

Partial yeast separation


AGRANA opens first-of-its-kind biogas plant in Kaposvár, Hungary

In 2007 at the site of the Kaposvár sugar factory in Hungary, AGRANA installed a large-scale biogas facility that to date is unique in the European sugar industry.

The feedstock consists of the spent beet pulp produced during sugar beetprocessing, as well as of beet syrup. These organic by-products nowsupply a large portion of the energy needs of the sugar plant.

About 860 tonnes of beet pulp per day is fed into the plant’s fermentationprocess, corresponding to roughly one-half of the factory’s daily output of beet pulp. This results in the production of 110,000 cubic metres of biogasper day.

Quelle: press release 15.11.2007; www.agrana.com


71. IIR-Kongress am 13./14. Februar 2008 in BrüsselEugen Gaschler


Product Groups with high Potential

Product categories with revenue potential >> 1€

Food ingredients with special features / properties (functional food)

Renewable feedstocks, e. g. products with additional properties to

petro chemicals

Maximum utilization of intrinsic molecular structure, i. e.

Pursuing these targets beyond the present utilisation means:

„R & D in new technologies"


Sugar based Biorefinery

Sucrose

Fru/Glu mixturechrom. Glucose

Fructose

new technoloy

Specific catalysts

Gluconic acid

catalysis Mannitol-solution

Isomaltulose (solution)cryst.

Isomaltulosecat.catalysis

Isomalt50 GPM : 50GPS

Isomalt GS40GPM : 60 GPS

Isomalt LM

Isomalt DC

Isomalt HCcat.

new catalyst

new drying

new agglo.

Technology for material conversion

Chemical catalytic processes• Hydrolysis• Hydrogenation• Oxidation

Biochemical catalytic processes• Hydrolysis• Isomerisation• Transferases


O

HO

HOOH

OHO

O

OH

HOOH

OH

HydrolyseInvertase, H+

HO O

HO

OH

OHOH

O

OHHOHO

OH

OHHO

OH

OH

OH

OH

OH

HO

HO

OH

OH

OH

OH

Sucrose

Glucose

Fructose

H2

catalyst

Sorbitol

Sorbitol + Mannitol

Applied by Südzucker: H+ -fixed-bed ion exchanger (about 200kt/a)

Large-scale production of fructose by Südzucker

Mannitol (sorbitol)-production of SZ-products by customers

H2

catalyst


Sucrose

PalatinoseTM Fructooligosaccharide NeoamyloseIsomaltTM

HOO

HOOH

OH

O

O

HO

OHOH

OH

HOO

HOOH

OH

OHO

OH

OH

OH

O

HOO

HOOH

OH

OOH

OH

OH

OH

OH

HOO

HOOH

OH

OHO

OH

OHO

OHO

OH

O

OHO

OHOH

O

n

HOO

HOOH

OH

OO

HOOH

OH

OO

HOOH

OH

OHn

- sweet- crystalline- water-soluble

- delayed digestible glucosesource

- caloric energy 4 kcal/g- very low GI- very low I I

- toothfriendly

- sweet- crystalline- water-soluble- little digestible- caloric energy

regulatory EU: 2,4 kcal/gphysiological USA: ~2 kcal/g

- very low GI- very low I I- fiber- bifidogenic- toothfriendly

- less sweet- crystalline- very well water-soluble- indigestible- caloric energy ~ 1,5 kcal/g- very low GI- very low I I- fiber- bifidogenic- higher mineral resorption

(long-chain inulin)

- not sweet- crystalline- insoluble in water- indigestible- caloric energy 1 kcal/g- very low GI- very low I I- fiber


Production of PalatinoseTM

2

1

3

Palatinose™ Protaminobacter rubrum

Trehalulose Pseudomonas mesoacidophila

Leucrose Leuconostoc ssp.

Palatinose™Saccharide

O

HO

HO

OHO

O

OH

HOOH

OH

OH

Protaminobacter rubrum1,2 1,6

Technical production

O

HO

HO

OHO

O

OH

HOOH

OH

OH

2

1

3

HO O

HO

OH

OHO

OH

OHO

OH

OH


What is Palatinose™?

Palatinose™: The ONLY fully digestible, low GI carbohydrate providing prolonged energy release in the form of glucose

Like sucrose composed of glucose and fructose

A natural constituent of honey

Produced via non-GMO enzymatic rearrangement of sucrose

Sugar

Origin and molecular structure of Palatinose™

• Generic name: Isomaltulose• (6-0-α-D-glucopyranosyl-D-fructofuranose)• CAS Reg. No. 13718-94-0• Total molecular formula: C12H22O11 x H2O• Molecular weight: 360.32


Chemical catalytic process with Ni-catalyst

in fixed bed

Hydrogenation of Palatinose™ to Isomalt

OH

O

HO

HOOH

OHO

OH

OHOH

OH

1,1 GPM1-O--D-glucopyranosyl-

D-mannitol

O

HO

HOOH

OHO

OH

OH

OHOH

OH

1,6 GPS6-O--D-glucopyranosyl-

D-sorbitol

Palatinose™

H2

O

HO

HOOH

OHO

O

OH

HOOH

OH

Isomalt is the only bulk sweetener made from sucrose which can replace sugar in a 1:1 ratio


Palatinose™/Isomalt - Production plant

Offstein, Deutschland


Sugar Beet

Glucose

Gluconic Acid

Oxidation on Au / Al2O3

Oxidation of Carbohydrates

COOH

H

H

H

H

OH

OH

OH

C

C

C

C

CH OH2

HO

Lactobionic Acid

Milk

Starch

Lactose

COOH

OH

H

OH

OH

H

H

CH2OH

O O

HH

OH

OH

H

OH

H

CH2OH

T = 40-60°CpH = 7-9

High activityExtreme high selectivity > 98%High long term performanceSimple synthesisNo leaching

or

or

Complexing agent, acid regulatoringredient for cosmetics,

pharmaceuticals & cleaners


Oxidation of Carbohydrates using supported gold catalystAdvantages vs. fermentative process

Simple synthesis Applicable for diverse feed (Glucose /- syrups, Maltose, Lactose) Outstanding properties (high activity, selectivity, long-term

stability) High productivity

130 gGluc l-1 h-1 vs. 15 gGluc l-1 h-1 fermentative

63 gglucon acid g-1Kat h-1 vs. 5 gglucon acid g-1

BioM h-1 fermentative

Economically and environmentally friendly process

+ ½ O2

Glucose Sodium gluconate

+ H2ONaOH

Au/Al2O3

HO O

HO

OH

OHOH

HO

OH

OH

OH

OH

O

ONa


Summary

Sugar biorefinery needs strong agricultural industry

research expertise (along the value chain)

extensive manufacturing knowledge in connection with processingrenewable raw materials

crossfunctional teams


Thank you for your attention!

Contact:

Dr. Wolfgang WachSüdzucker AG Mannheim/Ochsenfurt

Wormser Straße 1167283 Obrigheim/Pfalz

[email protected]

9105z-wa-wa-tec iea42 sugarbiorefinery · 2013-10-18 · zafes offstein, dr. wolfgang wach 2009/09...

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