Task 42 Booklet
Task 42 Booklet
IEA Bioenergy:T42:2009:01
Table of Contents
Page
Cover picture
C5/C6 sugar and lignin platform biorefinery for ethanol,
animal feed, power and heat from lignocellulosic residues.
Courtesy Inbicon IBUS, Denmark; and Task 42.
Biorefineries: adding value to the
sustainable utilisation of biomass
This feature article provides an overview of the work of Task 42: Biorefineries:
Co-production of Fuels, Chemicals, Power and Materials from Biomass. It was
prepared by the Task Leaders, Mr Ed de Jong, Avantium Technologies BV, and Mr
René van Ree, Wageningen University and Research Centre, the Netherlands.
Introduction
The energy and material needs of human society will reach a crisis point in the near
future. This will be due mainly to the rising cost of, and demands for, fossil resources
upon which we have become dependant for energy, fuels, chemicals and materials.
The world's population continues to grow and development is taking place at rates
unprecedented in our recent history, especially in areas that have traditionally had
very low per capita demand on our fossil resources.
Commensurate with these increasing demands it has become apparent that the
continued emissions of greenhouse gases (GHGs) and loss of carbon sinks are
influencing the world climate. The main strategy proposed to ameliorate the effects
of climate change is to reduce global demand for fossil fuel resources. Biomass can
provide a more positive solution – a renewable source of energy services, including
heat, electrical energy, and transportation fuels which can reduce CO2 emissions,
sulphur and heavy metals in the atmosphere while potentially improving rural income
and energy security through the substitution of coal, oil and natural gas. The use of
domestic bioenergy resources and biomass imports would generally contribute to
the diversification of the energy mix. The international bioenergy market is expected
to have a wide range of suppliers from several world regions and the importation
of bioenergy is therefore not affected by the same geopolitical concerns as are oil
and natural gas. However, the contribution of bioenergy to improving energy security
largely depends on decoupling the bioenergy system from oil and gas inputs.
It is recognised by many countries that energy security, environmental concerns and the
development of alternative, cleaner sources of chemicals and materials for manufacturing
and user industries is becoming a driving imperative.
These are just some of the drivers for the development of sustainable energy and
chemicals. The recent expansion of the bioenergy industries – power, CHP, gaseous energy
carriers, and biofuels for transport – together with a strong increase in many commodity
prices has raised concerns over the land use choices between energy needs and food
and feed. This conflict may not be as obvious as the popular press has reported. The
development of what we term ‘first generation’ biofuels may be seen as a necessary step in
the advancement of technology to a more sustainable and environmentally benign system.
The cost of environmental damage due to production and use of fossil fuel energy and
certain chemicals and materials leads us to the inevitable conclusion that new systems of
production must be developed. These should focus on reduction of pollution or hazardous
materials, producing safe and environmentally benign products in a green and sustainable
supply chain. For this to occur, a constant and renewable supply that has a low carbon
cost is required. Globally, the only source of such renewable feedstock is biomass.
This overview sets out to illustrate the developments in sustainable production for
commercial, and close to commercialisation, energy carriers and co-products developed
from biomass using biorefineries. Technology is developing rapidly in these areas. With
the understanding that biomass contains all the elements found in fossil resources,
albeit in different combinations, we can begin to understand that present and developing
technologies can lead to a future based on renewable, sustainable and low carbon
economies.
It should also be highlighted that changes in the world economy challenge us to develop
the industries of the future now, so that as we emerge from this changed world we are
ready, on a global scale, to advance the material wealth of human society in terms of
energy supply and materials for a new sustainable industrial development. Advanced
biorefineries may address many of the issues raised above. We set out here to paint a
broad picture of present and future developments.
4
The Role of Task 42
Figure 1: Schematic representation of the relationship of Task 42 to other IEA Bioenergy Tasks.
The participants in Task 42 act as National Team Leaders for biorefinery technology
knowledge transfer and reporting. The Task addresses issues such as:
• Biorefinery definition and biorefinery classification system.
• Country reports describing and mapping current processing potential of existing
biorefineries in the participating countries, and assessment of biorefinery-related
RD&D programmes to assist national governments in defining their national
biorefinery policy goals and related programmes.
• Bringing together key stakeholders (industry, policy, NGOs, research) normally
operating in different market sectors (e.g., transportation fuels, chemicals, energy,
etc.) in multi-disciplinary partnerships to discuss common biorefinery-related
topics, to foster necessary RD&D trajectories, and to accelerate the deployment of
developed technologies.
5
Why Biorefineries?
Although the biofuel and associated co-products market are not fully developed, first
generation operations that focus on single products (such as ethanol and biodiesel) are
regarded as a starting point in the development of sustainable biorefineries. The most
profitable of these is based on sucrose (sugar cane). Some of these ‘first generation’
plants are also subject to changes in market conditions such as strongly fluctuating
commodity prices, as has recently been seen with the price of wheat and corn. With the
increasing pressures for alternative sources of energy carriers, platform chemicals and
bio-based materials, ‘first generation’ production based on starch to ethanol and Dried
Distillers Grain and Solubles (DDGS) may have a limited lifespan. It may be argued that
advanced biorefineries have a distinct advantage over conventional refineries (mineral oil)
and first generation ‘single product focus’ operations e.g., recovered vegetable oil (RVO),
or rapeseed oil to biodiesel plants, in that a variety of raw materials may be utilised to
produce a range of added-value products. We will deal with the varying technologies later.
This biorefinery definition includes systems that may exist as a concept, a facility,
a process, a plant, or even a cluster of facilities. In this overview we present the
different kinds of biorefineries. More examples can be found in the forthcoming Task
42 brochure. The brochure indicates the scale (i.e., commercial, demonstration or
pilot) at which these biorefineries are currently operational. As an example, the port
of Rotterdam has a cluster of facilities that act together and can be considered a
‘biorefinery’.
A biorefinery should produce a spectrum of marketable products and energy. The products
can be both intermediates and final products, and include food, feed, materials, chemicals,
and energy (defined as fuels, power and/or heat). Task 42 considers a true biorefinery has
multiple energy and non-energy products.
The volume and prices of present and forecasted products should be market competitive.
The biorefinery systems which will come into operation within the next years are expected
to focus on the production of transportation biofuels. Some of the most interesting biofuels
might be ones that can be mixed with gasoline, diesel and natural gas, reflecting the main
advantage of using the already existing infrastructure in the transportation sector.
The saying ‘if you have energy you have everything’ is not strictly true. If we have energy we
can produce solutions for the other needs of humans from sustainable biomass feedstock
production. Biorefineries address these needs and will also address the environmental, social
and economic needs of our society. They will be instrumental in providing rural development
and employment, with relatively low carbon costs and decreasing production costs with
economies of scale and the development of emerging technologies.
The production of energy carriers and co-products that also make these systems more
economic, are the strengths of biorefineries. It is the variety of feedstocks that can be
regionally based, producing a variety of marketable products that identify this concept as
the strongest contender in future sustainable developments. Biorefineries address issues
of sustainability from all aspects – economic, social and environmental. The approach is
dependent upon the collaboration of the agro-engineering, chemistry, science, and marketing
disciplines requiring a new paradigm in sustainable development.
At present, biorefineries are classified based on, technological (implementation) status, type
of raw materials used or main type of conversion processes applied. A search of the literature
revealed a variety of terms describing biorefineries – see below.
Task 42 has further classified the different biorefineries. The proposed classification
system is based on the current main driver in biorefinery development, that is
efficient and cost-effective production of transportation biofuels, to increase the
biofuel share in the transportation sector. The classification approach consists of four
main features that identify, classify and describe the different biorefinery systems:
platforms, energy/products, feedstocks, and conversion processes (if necessary).
• The platforms (e.g., C5/C6 sugars, syngas, and biogas) are intermediates connecting
different biorefinery systems and their processes. The number of involved platforms
is an indication of the system complexity.
• The two biorefinery product groups are energy (e.g., bioethanol, biodiesel, and
synthetic biofuels) and products (e.g., chemicals, materials, food and feed).
• The two main feedstock groups are ‘energy crops’ from agriculture (e.g., starch
crops, short rotation forestry) and ‘biomass residues’ from agriculture, forestry,
trade and industry (e.g., straw, bark, wood chips from forest residues, used cooking
oils, waste streams from biomass processing).
• The four main conversion processes are biochemical (e.g., fermentation, enzymatic
conversion) [orange squares], thermo-chemical (e.g., gasification, pyrolysis) [blue
squares], chemical (e.g., acid hydrolysis, synthesis, esterification) [blue squares] and
mechanical processes (e.g., fractionation, pressing, size reduction) [white squares].
The biorefinery systems are classified by quoting the involved platforms, products,
feedstocks and, if necessary, the processes.
Lignin platform biorefinery for materials, power and heat from lignocellulosic 9
crops or residues. Courtesy Zellstoff Stendal, Germany; and Task 42.
Fractionation Grain Straw
Separation and/or Straw
pressing Pretreatment Pressing
Fiber Gasification
Separation
Pyrolysis, HTU
Hydrolysis
Anaerobic Extraction
digestion
Water Separation
gas
shift
Hydrogenation
Fermentation Chemical
Methanisation
reaction
Chemical Combustion
reaction Estherification
Upgrading
Steam
reforming Water
electrolysis
Chemical
reaction
A full overview of the platforms, products, feedstocks and conversion processes is given in
Figure 3.
This biorefinery classification is based upon feedstocks, platforms, products, and conversion
processes. It presents a clear framework for defining the various feedstocks utilised and
conversions within any given system.
Daka Biodiesel Fat from Biodiesel, glycerol and Operational for one year with
slaughterhouses potassium sulphate a capacity of 55 million litres
per year.
France
Novance Vegetable oil Oleochemistry for non- Production of solvents,
food markets lubricants, biodiesel, resins
DRT Terpenes, resins Chemicals from paper Resin, gum rosin, resin, fine
and pulp industry chemicals, tall oil derivatives,
by-products surfactants
Roquette Wheat, potato, Starch, food, feed, bulk Physical, chemical and
maize, pea straw and fine chemicals, fermentation processes
succinic acid, ethanol…
ARD, Cristal Wheat, sugar Food, feed, ethanol, Physical, chemical and
Union, Chamtor beet, succinic acid, cosmetics, fermentation processes
electricity
Tembec, Wood Cellulose, paper, tall Production of products and
Smurfit. oil, lignosulfonates, energy
electricity, steam 11
Country Feedstock Products Description
Germany
Südzucker Sugar, grain Sugar, palatinose, food Logistics, sugar/starch-
additives, feed, ethanol refinery, palatinose
biogas, electricity plant, CropEnergies for
ethanol and by-products
Zellstoff Stendal Wood Cellulose, paper, tall oil, Production of products
methanol, turpentine, and energy from wood
electricity, steam by cooking, bleaching,
drying, power plant
waste water treatment
Emsland-Stärke GmbH, Whole crop biorefinery Potato starch and Integrated unit for
Wietzendorf (potato starch and biogas bioproducts and
biogas) demonstration bioenergy
and commercial
Biowert Grass Biogas, insulation Production of fibres
material, biocomposites and juice from grasses
CropEnergies Sugar, grain Ethanol, DGGS, See Südzucker
electricity
Netherlands
Bio MCN Glycerin Methanol Upgrading of the
biodiesel by-product
glycerin to biomethanol
for transport
Vierhouten Vet Waste oils/fats Biodiesel Waste plant oils and
animal fats used in
the food industry are
upgraded to biodiesel
Ecoson/Vion Waste meat industry Biogas, CHP, Biodiesel Integrated production
of biogas, fats and
biodiesel from meat
waste
BioValue Waste oils/fats Biodiesel, fuel additives Integrated production
of biodiesel, and fuel
additives from glycerin
fraction
Ten Kate Vetten Raw animal fats Consumable fats, Integrated production
aromas and flavours, of food and CHP
gelatine, CHP
Food industry Various Various Various
Some of the initiatives mentioned are not real biorefineries within the scope of the present
definition. However, these initiatives are mentioned because they represent facilities that
could easily be upgraded to biorefineries, for example by adding value to the process
residues or by potential alternative applications of the main intermediates produced
(pyrolysis oil, syngas, biogas, etc).
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A SWOT Analysis of Biorefineries
Strengths Weaknesses
• Adds value to the sustainable use of • Broad undefined and unclassified area
biomass • Needs involvement of stakeholders from
• Maximises biomass conversion efficiency – different market sectors (agro, energy,
minimising raw material requirements chemical, ...) over the full biomass value chain
• Produces a spectrum of bio-based products • Most promising biorefinery processes/concepts
(food, feed, materials, chemicals) and not clear
bioenergy (fuels, power and/or heat) • Most promising biomass value chains, including
feeding the full bio-based economy current/future market volumes/prices, not clear
• Strong knowledge of infrastructure • Still at a stage of studying and concept
available to tackle any non-technical and development instead of real market
technical issues potentially hindering the implementation
deployment trajectory • Variability of quality and energy density of
• Is not new, and in some market sectors biomass
(food, paper, etc.) it is common practice
Opportunities Threats
• Make a significant contribution to • Biorefinery is seen as hype that still has to prove
sustainable development its benefits in the real market
• Challenging national, European and • Economic change and drop in fossil fuel prices
global policy goals – international focus • Fast implementation of other renewable energy
on sustainable use of biomass for the technologies filling market needs
production of bioenergy • No level playing field concerning bio-based
• Biomass availability is limited so the raw products and bioenergy (assessed to a higher
material should be used as efficiently standard)
as possible – i.e., development of multi- • Global, national and regional availability and
purpose biorefineries in a framework of contractibility of raw materials (e.g., climate
scarce raw materials and energy change, policies, logistics)
• International development of a portfolio • High investment capital for pilot and
of biorefinery concepts, including demonstration initiatives difficult to find,
designing technical processes and existing industrial infrastructure is not
• Strengthening of the economic position of depreciated yet
various market sectors (e.g., agriculture, • Fluctuating (long-term) governmental policies
forestry, chemical and energy) • Questioning of food/feed/fuels (land use
competition) and sustainability of biomass
production
• Goals of end users often focused upon single
product
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The current perceived conflict between energy and food production can be allayed
by developing technologies that are not fully based on starch, such as lignocellulosic
materials. Biorefining is a concept that is dependent upon continued innovation presenting
opportunities to all sectors. The building of a bio-based economy has the capacity to not
only address present difficulties but also result in an environmentally benign industry.
Final Comments
One of the critical success factors for biorefineries is bringing together key stakeholders
normally operating in different market sectors (e.g., agriculture and forestry,
transportation fuels, chemicals, energy, etc.) into multi-disciplinary partnerships to discuss
common biorefinery-related topics, to foster necessary RD&D direction, and to accelerate
the deployment of developed technologies (platform function).
In 2009, the number of participants in the Task have increased to 10 with the addition of
Italy and Australia. Our target for the next triennium is the addition of at least two more
countries – with more participants more progress can be achieved. Task 42 can contribute
to the growth of biorefineries by identifying the most promising bio-based products, i.e.,
food, feed, added-value materials and chemicals (functionalised chemicals and platform
chemicals or building blocks) to be co-produced with bioenergy, to optimise overall
process economics, and minimise the overall environmental impact. Major initiatives in
the immediate future include the preparation of a review and guidance document on
approaches for sustainability assessment of biorefineries, and a strategic position paper
‘Biorefineries: Adding Value to the Sustainable Utilisation of Biomass on a Global Scale’.
14
Key Contacts in Task 42
Website: www.iea-bioenergy.task42-biorefineries.com
Website:
www.ieabioenergy.com
Secret ar y:
John Tus tin
PO Box 6256
Whakarewarewa
Rotorua
NEW ZEALAND
Phone: +64 7 348 2563
Fax: +64 7 348 7503
Email: jr tus [email protected]