Bioethanol at Nordzucker - RESIPEre-si-pe.com/docs/2nd_workshop/Bioethanol at Nordzucker.pdf ·...
Transcript of Bioethanol at Nordzucker - RESIPEre-si-pe.com/docs/2nd_workshop/Bioethanol at Nordzucker.pdf ·...
Bioethanol at NordzuckerDr. Albrecht Schaper, Managing Director fuel21
Warsaw, June 17th, 2008
Dateiname: Warschau June 17, 2008.ppt
Verantwortlicher: Dr. A. Schaper
Ersteller: Dr. A. Schaper
Stand: 2008-06-12
Animation: ja
Sprache: english
Bioethanol in the EU
� Bioethanol in the EU
� Raw Materials
� Sustainability
� Bioethanol Production
� Vinasse
� Summary
European Political Framework (I)
� EU Directive 2003/30/EC from May 2003
Objective:
� 5,75 % cal. Biofuels by 2010, but voluntary
� Result was “27” different schemes for the implementation of the directive
� Mandatory Blending Quota
� Production quota
� Implementation of E85 at petrol stations
� Tax incentives
� Combinations of Tax incentives and quotas
� No implementation
No Common System and Market
European Political Framework (II)
� Fuel Quality Directive from January 2007
Objectives:
� allow higher blends of biofuel,
� reduce emissions from the fuel production chain (10% by 2020, article 7a).
� Renewable Energy Sources (RES Directive) from January, 23rd, 2008
Objectives: by 2020
� overall binding 20% renewable energy target,
� binding minimum 10% cal. renewable energy for transport
Biofuels in the EU 25
Development 2003 to 2006
0,0%
1,0%
2,0%
3,0%
4,0%
5,0%
6,0%A
ustr
ia
Be
lgiu
m
Cyp
rus
Cze
ch
De
nm
ark
Esto
nia
Fin
lan
d
Fra
nce
Ge
rma
ny
Gre
ece
Hu
ng
ary
Ire
lan
d
Ita
ly
La
tvia
Lith
ua
nia
Lu
xe
mb
ou
rg
Ma
lta
Ne
the
rla
nd
s
Po
lan
d
Po
rtu
ga
l
Slo
va
kia
Slo
ve
nia
Sp
ain
Sw
ed
en
Un
ited
e
Source: Member States Progress Reports in the frame of Directive 2003/30EC
� 2003
� 2004
� 2005
� 2006
Targets of EU Commission
2005
2010
Production of Bioethanol for fuel
� In 2006 USA have
overhauling Brazil as
biggest Bioethanol
Producer
� European Production
represents only 4% on
combined capacity
Brazil/ USA
1,77
0
5
10
15
20
25
Brasil USA EUsource: LAB, eBIO, F.O. Licht
Mio. cbm
� 2004
� 2005
� 2006
� 2007
Raw Materials
� Bioethanol in the EU
� Raw Materials
� Sustainability
� Bioethanol Production
� Vinasse
� Summary
Raw Materials for Bioethanol
� Sugar based
� Sugar beet
� Cane
� Starch based
� Corn
� Wheat
� Barley
� Rye
� Potato
� Rice
� Tapioca
� Cellulose based
� Straw
� Wood
� Mischathus
� Bran
� Bagasse
� Sugar Beet pulp
„2. Generation“
Sugar Beets have the same
potential as cane sugar
4.028
6.458
6.237
2.554
0 1.000 2.000 3.000 4.000 5.000 6.000 7.000
BtL
Bioethanol from
Cane
Bioethanol from
Sugar Beet
Bioethanol from
Wheat
Liters/haSource: FNR, Biokraftstoffe
eine vergleichende Analyse, 2006
Sugar beets delivers same
energy per hectare as BtL
135
137
132
54
0 20 40 60 80 100 120 140 160
BtL
Bioethanol from
cane
Bioethanol from
sugar beets
Bioethanol from
Wheat
GJ/haSource: FNR, Biokraftstoffe
eine vergleichende Analyse, 2006
Usage of Sugar Beet
Food:
- Sugar
Feed:
- Pulp
- Pellets
- Molasses
Energy:
- Bioethanol
- Biogas
Feed:
- Pulp
- Pellets
- Vinasse
Sustainability
� Bioethanol in the EU
� Raw Materials
� Sustainability
� Bioethanol Production
� Vinasse
� Summary
The RES Directive proposal
on sustainability
� Beginning of 2008 the European Commission proposed in its Renewable Energy
Directive sustainability criteria on:
� Greenhouse gas saving threshold (35%),
� Land use / Carbon stock release,
� Respecting biodiversity,
� Environmental requirements for agriculture.
� These criteria apply on biofuel and bio-liquids. Criteria on biomass to be proposed in
2010.
� It is a EU scheme: Member States cannot add-on criteria
� But this is not applicable for biofuels from non EU Member States
Greenhouse gas impact
� Sustainability criterion:
� Minimum requirement for GHG saving, relative to fossil fuel, of at least 35%.
� Furthermore relevant:
� Waiver until April 2013 for current plants (Art. 15.2).
� Rules for calculation of GHG saving. Biofuels producers can choose to:
� Use default values for production pathways (Annex VII.A),
� Show actual values with better results (Annex VII.C).
� GHG Emission savings (RES Directive, Annex VII.A)
typical value default value
� Sugar beet 48 % 35 %
� Wheat 21-69 % 0-67 %
� Corn 56 % 49 %
� Cane sugar 74 % 74 %
Land use impact
� Sustainability criterion:
release of carbon stock (art. 15.4 + Annex VII.C.7 and 8).
� Land use change is counted in the greenhouse gas calculation.
� No conversion of wetland or ‘continuously forested area’.
� Specific incentive for crops from “idle lands” and desert.
� Effects on indirect land use changes are not (yet) incorporated.
Biodiversity and good
agricultural practice
� Biodiversity (art. 15.3): no raw material from:
� Forest undisturbed by significant human activity,
� Highly biodiverse grassland,
� Nature protection areas (unless compatible with nature protection).
� Good agricultural and environmental condition (art. 15.5):
� All biofuel production must comply with the “cross compliance” rules already
applied under the CAP (only for EU produced biofuels)
� But this is not applicable for biofuels from non EU Member States
Bioethanol Production
� Bioethanol in the EU
� Raw Materials
� Sustainability
� Bioethanol Production
� Vinasse
� Summary
Fuel21/Nordzucker
Contracts for ethanol beets
� 3.200 farmers have a binding contract for ethanol beets
� Contract time 4 years
� Contracted beets and over-quota beets counts for 1.300.000 T
� Beet price is fluctuating with the ethanol price (sharing of chances and risks)
� e.g. 18 EUR/T at 550 EUR/cbm Ethanol, or 20 EUR/T at 600 EUR/cbm Ethanol
(basis prices for beets at 16% sugar content)
� Additional payments for high sugar content, early/late delivery, quality, by-product
revenue, etc. (comparable with quota beets payments at Nordzucker)
� Delivery of contracted ethanol beets is mandatory, if not, penalty is applied
Pu
lp
Connections between sugar and
Bioethanol production
Su
ga
r Be
et
Raw Juice Thick JuiceExtraction Evaporation
Th
ick
Ju
ice
Crystallization
Su
ga
r
Raw
Ju
ice
Mo
las
se
s
Bioethanol Production
Sugar Plant
Mass Balance concept for
130.000 m³ Bioethanol
at Klein Wanzleben
Beet
Raw Juice
(WZL)
White Sugar
Thick Juice
(other plants)
Thick Juice
(WZL)
Bioethanol 130.000 m³/a
66.000 t/a Sugar from Raw Juice
156.000 t/a Sugar fromThick Juice
222.000 t/a Total Sugar
Quota Sugar Beets 7.000.000t/a
EtOH-Beet 1.300.000 t/a
1.000.000 t/a
Number of Employees: Initial 50 Staff member
Target 35 Staff member
Electricity to Grid
Pulp
Vinasse
Interfaces
Nordzucker AG – fuel 21
Bioethanolanlage
fuel 21
Nordzucker AG
SugarrefinerySugar Beets
Raw Juice
Thick Juice
Steam
Power Waste Water
Vinasse
Ethanol
Byproducts
(Head at Tails)
Bioethanol productionSugar Plant
Production of Bioethanol
Raw Juice
Thick Juice Fermentation
Distillation/Rectification
Dehydration
Storage
VinasseEvaporation
Utilities
Sales and shipment
Vinasse Storage
Power & Steam
Molasses
Building of Boiler house
� Conversion of Steam boiler from Sugar Plant
Munzel
� 55 t Steam at 60 bar
� Steam temperature 500 ºC
� Combustible: Natural Gas (light fuel oil)
� Installation of a Gas turbine
with 5,5 MW electric Capacity
fuel21
Storage of Thick juice
� 2 Storage Tanks in Klein Wanzleben
� 1 Storage Tank in Nordstemmen
� Each Tank contains 60.000 cbm
ful21
Fermentation
� Operations can be
changed between
batch or continuous
Fermentation
� 3 preparation tanks
� 6 production tanks
� 1 Distillation feed tank
fuel21
Distillation,
Rectification, Dehydrogenation
� Distillation with two Double effects Column
� One Pressure Column, one Vacuum Column
� Separate column for aldehyds
� Dehydration by adsorption on molecular sieves
Distillation and Fermentation
fuel21
evaporation of vinasse
� 6 effect evaporation
� Capacity up to 140 t/h with Thin Juice
� Capacity with Thick Juice 45 t/h
Storage
� 2 Storage tanks for Daily production
� 2 Storage tanks for Final products
� 3 Storage tanks for Byproducts (Aldehyds, Vinasse)
Vinasse
� Bioethanol in the EU
� Raw Materials
� Sustainability
� Bioethanol Production
� Vinasse
� Summary
Definition Vinasse
� Vinasse, from Latin „vinacaeus“ and stand for Wine yeast
� From Beginning to the 20th Century Vinasse became the common ex wording for
concentrated, fermented Sugar beet molasses in Europe (LEWICKI 2002)
� According to the German Animal feed law since 1975 Vinasse is allowed for Ruminant
animal feed
� Vinasse as Byproduct is under the Nr. 5.04.01 in the „Positivlist“ registered
� International Vinasse is called „Condensed Molasses Solubles“ (CMS)
Origin of Vinasse
� Vinasses concentrated residues of fermentation processes, dry substance 50-70%
� Fermentations industry can be (Yeast-, Alcohol-, Amino acid-, Citric acid-, Glutamate,
Lysine and other)
� After Fermentation of molasses the final sugar free solution contains yeast, salt,
Amino acids, etc
� After Concentration of this Solution it is called Vinasse
Application as Feed
Cattle and Sheep Feed
� for Cattle and Sheep feed is Crude protein interesting
� Mixed Cattle feed 3-5% can be used
Pig Feed
� Pigs are sensitive to high ash content, specially to Potassium and are to Sulfate
� Crude protein shows low digestibility
� in Pig feed only 2-3% can be used
Limiting factor to Application is Potassium content (max. 6%)
Feed preparation
� Feed preparation can contain 4-8% Vinasse, depending on the Dry substance. Used
like Molasses to improve moldability
Application as fertilizer
Application as Fertilizer
� Application as Nitrogen-Potassium fertilizer trough Appendage
� Use according Fertilizer regulation feasible
� French Ethanol producer use from Vinasse as Fertilizer
Summary
� Bioethanol in the EU
� Raw Materials
� Sustainability
� Bioethanol Production
� Vinasse
� Summary
Sugar beets are best placed for
Bioethanol production
� Easy to handle and to convert
� Highest Bioethanol yields per hectare
� Integration in Sugar Plants saves investments and production costs
� Sustainable agricultural production of sugar beets in the EU
� Bioethanol from Sugar beets is now available and not in a few years
Bioethanol from Sugar beets
� Secures the agriculture in Europe
� Saves income and jobs in rural areas
� Gives a positive effect on GHG Emissions
� Ensures the crop rotation in agricultural practice
� Keeps the food supply chain stable
� Reduces the needs of energy imports (also from Biofuels)
Thank You
for Your Attention