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LignocellulosicLignocellulosic residues use for residues use for energy and materials in the bioenergy and materials in the bio --economy: The Dutch experience economy: The Dutch experience
“Biofuels and their future in the power matrix”University of Chile
by
Jan E.G van DamJan E.G van Dam
Santiago de Chile 2009Santiago de Chile 2009
Product development for Product development for
BioBio --based Materialsbased Materials
04 11 09
Jan E.G van DamJan E.G van Dam
Div Div BiobasedBiobased ProductsProducts
Wageningen URWageningen UR
BioBio --economyeconomy
…….the solution for .the solution for sustainable developments sustainable developments
...?......?...
BioBio economyeconomy
…….the solution for .the solution for financial bubbles and financial bubbles and
crises ...?...crises ...?...
BioBio economyeconomy
…….the solution for .the solution for sustainable green sustainable green
developments ...?...developments ...?...
BioBio--economyeconomy and Sustainable developmentsand Sustainable developments
• KYOTO and CO2 neutral production
• Transition process Copenhagen 2009
• Renewable resources for energy and industries
• Exploitation of biomass from agro-industrial residues
• Value addition in materials, and ‘green’ chemicals
Dutch situation
• Densely populated• Restricted land area for bulk production• Specialized high productivity farming
• Highly industrialized• Logistic organisation• Long trading tradition
Dutch challenges: Milenium development goals
• Reduce oil dependency• Imports of biomass• Collecting and on site pre-processing
systems
• Biorefineries analogue to petrochemical refining
• Exports of value added “green chemicals”
Dutch Government and Industries vsBioeconomy
• Advise for CO2 neutral production• Alternative biomass farming
Energy crops / Marine crops / algae / seaweeds
• Suitable sources for imports for fuel and chemistry and biobased products
• Carbon emission trade• Development aid and CDM
Renewable Resources for energy and industries
• Industrial chemical feedstock– complex route– glucose based chemistry C6– lignin based chemistry C9– C1 / C2 chemical building blocks (syngas)
• Bio-refinery, bio-cascading, whole crop utilisation– opening, refining, extraction, etc
Biobased materials
Biomass for energy returns quickly CO2 in the atmosphere
Carbon sequestration can be achieved in durable goods:
Bioplastics (PLA, PHA/PHB and other), Cellulose and Starch plastics (CDA, cellophane),
CharComposites
Building materials (wood and fibre boards)
precipitation Coatings Biopolymersextract
sugars Alcohol / H 2
effluentdryingchoppingpelletising
residue
Feedgassifycombustion
Energy
waste compost
compostingdisposal
silica
fermentation
tar
ash
Protein, lipids
Biomass
fuel
extraction modification
refining fibre pulp Paper / boardadhesives
Biorefinery (cascading) of biomass
Biorefinery is “Green” Chemistry
Products
inter
Sepe
ratio
nun
it
processes
seed
leaf
tuber
mediate
Raw materials Processes
(bio
refin
ery)
PET NYLON
Biodiesel Bioelectricity
Polylactate
Biotechnology
Chemistry
EnzymologyMicrobiology
Logistics and rural economy,
Process technology and food technology–Plant breeding,GMO
Environmental economy Thermodynamics
Renewable Resources for energy and industriesRenewable Resources for energy and industries
•• Speciality crops Speciality crops –– cosmetics and cosmetics and pharmapharma -- small volume / high pricesmall volume / high price
•• NonNon--food cropsfood crops–– oil, fibre (textile, paper pulp), oil, fibre (textile, paper pulp),
–– fermentation feedstockfermentation feedstock
•• Energy cropsEnergy crops–– transport fuel and electricity transport fuel and electricity -- bulk volume/ low bulk volume/ low
priceprice
Biorefinery: raw material cost from Pharma to Fuel
70178.50.080.02--
Loss10% rendementMM € /y
700170850.850.170.0070.003Raw material MM € /y
20.000.0005.000.0002.500.00025.0005.000200100
Kton raw mat. (a 35/ton)
20.000.0004500.0002.000.00010.0001.000101Volume kton/y
0.0350.30.51.541502.500
€/kg
Endproduct
Electricity fuel
Transport fuel
Bulk chemical
Large volume (Glu.)
Small volume (Arg.)
Enzymes
Pharma
Linking of markets
F o o d
B io m a s s p r o d u c t io n
1 s t Ag r o lo g is t ic sFo o d p r e t r e a t m e n t
Fo o d p r o d u c t io nC o n ve r s io n
N o n -fo o d :• F e e d
• C o m p o s t
• W a s te m a n a g e m e n t.
Ag r i s o u r c e sAg r o -fo o d p r o d u c t io nB y p r o d u c t s & w a s t e
L o g is t ic s &s t o r a g e
p r o d u c t io nIm p o r t s
C o n ve r s io n Pr o d u c t io n
$
$
$
B io b a s e dP r o d u c t s• B io b a s e dm a te r ia ls• G r e e n
c h e m ic a ls• B io - fu e ls• B io -e n e r g y
Pr o d u c t io nP e r fo r m a n c e m a te r ia lsB a s e & p la t fo r m c he m ic a lsP e r fo r m a n c e c he m ic a lsB io En e r g y
Pr e -t r e a t m e n t & c o n ve r s io n
p h y sic a l& c h e m ic a l c on v e rsio n
p r o c e ss e ng in e e ri n g
b io c o n ve r s io n
F o o d
B io m a s s p r o d u c t io n
1 s t Ag r o lo g is t ic sFo o d p r e t r e a t m e n t
Fo o d p r o d u c t io nC o n ve r s io n
N o n -fo o d :• F e e d
• C o m p o s t
• W a s te m a n a g e m e n t.
Ag r i s o u r c e sAg r o -fo o d p r o d u c t io nB y p r o d u c t s & w a s t e
L o g is t ic s &s t o r a g e
p r o d u c t io nIm p o r t s
C o n ve r s io n Pr o d u c t io n
$
$
$
$$$
$$$
$$$
B io b a s e dP r o d u c t s• B io b a s e dm a te r ia ls• G r e e n
c h e m ic a ls• B io - fu e ls• B io -e n e r g y
Pr o d u c t io nP e r fo r m a n c e m a te r ia lsB a s e & p la t fo r m c he m ic a lsP e r fo r m a n c e c he m ic a lsB io En e r g y
Pr e -t r e a t m e n t & c o n ve r s io n
p h y sic a l& c h e m ic a l c on v e rsio n
p r o c e ss e ng in e e ri n g
b io c o n ve r s io n
B io b a s e dP r o d u c t s• B io b a s e dm a te r ia ls• G r e e n
c h e m ic a ls• B io - fu e ls• B io -e n e r g y
Pr o d u c t io nP e r fo r m a n c e m a te r ia lsB a s e & p la t fo r m c he m ic a lsP e r fo r m a n c e c he m ic a lsB io En e r g y
Pr e -t r e a t m e n t & c o n ve r s io n
p h y sic a l& c h e m ic a l c on v e rsio n
p r o c e ss e ng in e e ri n g
b io c o n ve r s io n
Pr e -t r e a t m e n t & c o n ve r s io n
p h y sic a l& c h e m ic a l c on v e rsio n
p r o c e ss e ng in e e ri n g
b io c o n ve r s io n
Natural Natural fibresfibres end useend use
•• Textiles, yarns and woven fabricsTextiles, yarns and woven fabrics•• Ropes, twines, cordage, netsRopes, twines, cordage, nets•• NonNon--woven fabrics, tissueswoven fabrics, tissues•• CompositesComposites•• Paper and boardPaper and board•• FibreFibre boards and insulationboards and insulation•• BioBio--ethanolethanol value additionvalue addition
•• FuelFuel•• Mulch and compostMulch and compost
€
The Word textile Fibres production
World fibre production 1920-2006 (kton)
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
1915 1925 1935 1945 1955 1965 1975 1985 1995 2005
Cotton
Synthetic (petro-based)
Man-made cellulose fibres *
BambooBamboo growinggrowing RegionsRegions
USA
EU
Cameroon
Nigeria
GhanaEthiopia
Kenia
Viet Nam
India
China
Fujian Province Economic and TradeCommittee
Nicaragua
Colombia
Brazil
Growing demand for Growing demand for biobiomass resourcesmass resources
Agricultural & Forestry crops for energy and materials
Transfer of technology and innovation
Biorefinery / bioconversion
cascading of biomass for value addition
Biomass conversion to energy
• Selection criteria process & products
biomass
pretreatment
Gassify(650 – 1200 ° C)
Combustion(850-1200 °C)
Pyrolysis(500 – 700 °C)
Liquefaction(< 300 °C)
Fermentation
(20 - 70 ° C)
Water % content
<15%
>85 %
CO2 H2 CH
Heat
Gas, oil, tar
Oil
ethanol,
butanol,aceton,
H2
CH4
Temperature / pressure
How to supply the How to supply the biobio --economyeconomy ??
Is there enough biomass available Is there enough biomass available
that can be utilized that can be utilized
without negative effects without negative effects
on food supply and bioon food supply and bio --diversitydiversity
????
Competing claimsCompeting claims for biomass resourcesfor biomass resources
Sustainable production
food supply security FAO / UNEP / UNIDO / IEA
land use
deforestation NGO
rural development
Rapid expansion of demand for energy purposes
DEVELOPMENT OF BIOREFINERY
For human consumption For human consumption
6 6 GtGt is harvested each year is harvested each year
for food, feed and nonfor food, feed and non --food food
((or 3.5% of total plant production)or 3.5% of total plant production)
Transition to the Transition to the biobio --economyeconomy
Current world wide land use: Current world wide land use:
1010--12% cultivated terrestrial surface12% cultivated terrestrial surfaceor 50% of the suitable arable land areaor 50% of the suitable arable land area
and 25% forest area and 25% forest area (including plantations)(including plantations)
Transition to the Transition to the biobio --economyeconomy
What are the What are the biobio mass resources mass resources
where are those available where are those available
at what costs at what costs
????
Transition to the Transition to the biobio --economyeconomy
What are the What are the biobio mass resources mass resources
where are those available where are those available
And for which sustainable application?And for which sustainable application?
Transition to the Transition to the biobio --economyeconomy
How much biomass is needed How much biomass is needed
to supply industries to supply industries
at viable economical scale at viable economical scale
and of what quality and of what quality
?? ??
Transition to the Transition to the biobio --economyeconomy
Unused biomass resourcesUnused biomass resources
Agricultural crops Agricultural residues
Food industry wastes
Forestry crops Forestry residues
Black liquorWaste paper
Animal waste ManureMunicipal solid waste SewageMarine crops Algae,
Fishery residues
VariousVarious CropsCrops and and RegionsRegions
Cotton
CottonCorn
Sugarcane Soya
Sugar beet
Palm oil CoconutCoconut
Cassava
Algae
Soft WoodSoft Wood Soft Wood
Cotton
Hard Wood
Hard Wood
Wheat Soya
Rice
Wheat
EucalyptEucalypt
Cacao
Soya
Bamboo
BambooBamboo
• Agroresidues of food and non-food crops– cotton stalks – rice straw / hull– sugar cane bagasse– corn cobs– coconut husk– jute fibre and other fibre crops – palm oil residues– eucalypt bark– verge grasses / bamboo
Renewable raw materials and sustainable development
R&D activities for sustainable developments (1)R&D activities for sustainable developments (1)
•• Supply managementSupply management
•• Upgrading of existing and innovative Upgrading of existing and innovative technologies to ecologically improved technologies to ecologically improved productionproduction
•• Novel innovative markets for renewable Novel innovative markets for renewable products products
•• Valorisation of residuesValorisation of residues
R&D activities for sustainable developments (2)R&D activities for sustainable developments (2)
•• AgroAgro--logistics, storage, transport and packaginglogistics, storage, transport and packaging
•• ‘‘WhiteWhite’’ biotechnology, biotechnology, biorefinerybiorefinery
•• Product developmentProduct development–– Renewable energy from biomass residuesRenewable energy from biomass residues
–– Building and construction materials Building and construction materials
–– ‘‘Green chemicalsGreen chemicals’’ and bioand bio--polymers, adhesives, additives polymers, adhesives, additives and coatingsand coatings
Biomass from agroBiomass from agro--industrial residuesindustrial residues
World production capacity coconut husk 15-20 million tons /year
Husk preparation (CFC/ FAO project)Husk preparation (CFC/ FAO project)
Coconut husk
Opening Milling
Coconut
coconut based boards
• High quality wood substitute products – High strength – Moisture – Good workability– Fire resistance– Resistance to biodegradation
• Added value for wasted resource– abundantly available– Highly competitive cheap resource
• Non need for expensive chemical additives– Ecologically save material– CO2 neutral
• Fits in policies for sustainable development
Economical evaluation
• Production: – 10,000 tonnes board/year– 400,000 boards 4 ft*8 ft* 0.25 inch
� 1,333 boards/day
• Raw material– 77,650,000 husks/year
� 260,000 husks/day
• Investment estimate– 650,000 US$
Eucalypt bark applicationsEucalypt bark applications
• Binderless fibre board / particle board
• Pyrolysis oil for ‘green’ chemicals (resins)
• Non-woven erosion mats (geotextiles)
• Charcoal and micro-powder
• Pellets for fuel
• guaranteed supplies
– sufficient quantities of raw material– whole year availability– constant quality – competing price
Biomass requirement for industrial board production
Durability increase by acetylation
Conclusions:
• 3-5 x life time extension of jute, flax and cocos
• Very well rooting of plants
• After 5 yrs only cocos can be retraced
Technology for natural fibre reinforced plastics
Compression (one-shot) moulding
Injection moulding
Raw materials agrofibrePP
Granules
Extrusion
Production of high yield pulps from green jute
• Newsprint quality• High yields• Low chemical input• Low COD and BOD demandsOptions considered:
– Extrusion pulping– Refiner mechanical pulping– Enzyme pretreatment
Oil Palm (Oil Palm (MalaysiaMalaysia, , IndonesiaIndonesia))
27 millions of tons a year, 23% of the World’s vegetable oil production (2003)
Extensive global expansion (from 2 to 7 million ha in last 20 years)
80% of the World production on account of Malaysia and Indonesia
Palm oil and palm kernel oil are the only “products” (9% of the produced biomass), the rest is “waste”
UtilisationUtilisation of Palm of Palm oiloil residuesresidues
Lignocellulosic fibres at estate– fronts (10.5 tons /ha/yr)
– trunks (70 tons / ha / 25 yr)
Residues at palm oil mill– empty fruit bunch (1 ton / ton palm oil)
– mesocarp fibre (0.6 ton / ton)– shells (0.4 ton / ton)
– effluent (0.4-1.0 ton/ton)
partly used as boiler fuel
OptionsOptions forfor sustainablesustainable residueresidue utilisationutilisation
Bio-diesel (residual oil / pressing cakes)Bio-gas, H2 / ABE and ethanol fermentationBio-polymers (PLA, PHA)Bio-oil pyrolysis (BTG) / CharcoalFibres for paper, building boards and
compositesDissolving cellulose“green” chemicals (lignin and furfural
adhesives)
Sustainable building
• Renewable materials• High performance
• Competing for quality• for comfort• for safety
Bamboo fast growing Bamboo fast growing biobiomass resourcemass resource
Industrial application in
textile fibre
paper & pulp
cellulose materials
particle boards and laminated structures
China: shortage of wood resources
non-polluting bamboo innovation
Innovations for bamboo fibre
cellulose processing cellulose modification (acylation)xylan product developmentlignin conversionsilica & waxbamboo carbon fibre
recycling and chemical recovery
Sustainability criteria
• Ecological .. Wood substitute products to prevent deforestation
• Carbon credits / CDM• Socio-economic – labour, income and housing• Addressing poverty by supporting the incomes
and livelihoods of commodity producers• Fair trade and quality certification
ConclusionsConclusions
By-products utilisation for added value is beneficial to the sustainability of crop production
Essential for certifying the sustainability of biomass energy and products.
Multi-stakeholder involvement needed.
Include outsider (food vs non-food) industries involved in energy and fibre products
Developmental strategyDevelopmental strategy
Demonstration of • technical feasibility laboratory and pilot scale• socio-economic potential field study• marketing potential• business plan
Identification of partners • in primary production and industry • investors and stakeholders
Industrial implementation of R&D
• difficult and slow• remain at the level of laboratory or pilot scale
• lack of investors• small size of the industries involved in innovation (SME)
•not capable of organising •raw materials supplies•maintenance of quality standards•marketing tools to penetrate market niche fast enough
Dutch Government new initiatives Nov 2009
• Ministries of Economic Affairs and Agriculture join efforts to boost investments in bio-economic developments:– Support for Pilot and demonstration plants for biorefinery
to make food medicines, feed, chemicals biofuels and materials 10 M€
– Subsidies for gassification of biomass 13.5 M€– Financial injection in R&D for aquatic biomass (algae
and seaweeds) 1.3 M€
Innovation agenda energy: “clean & efficient”
Outlook markets for biobased materials
Many innovative industrial projects possible…
but
Not without industrial investment and government commitment
Bio-based economy is investment in the future
companies TO GET INVOLVED:
• Primary processors / biorefineries• Fibre pulping industries• Cellulose manufacturing • Cellulose textiles • Bio resin producers• Fibre board producers• Fibre composites producers• Activated carbon • Bio plastics • Building industries .. And many more.. And many more