from fossil- to bio-based refineries · linde-kca-dresden gmbh 3 august 2009/uwe welteroth from...

Uwe WelterothDirector Biotechnology PlantsLinde-KCA-Dresden GmbH

From fossil- to bio-based refineriesCase Study Biorefinery Leuna

Linde-KCA-Dresden GmbH 2 August 2009/Uwe Welteroth

IEA-Bioenergy Task 42 Biorefinery – German WorkshopWorms, September 15th, 2009

Agenda

From fossil- to bio-based refineries

— Key drivers

— Status and development trends

— From TODAY'S bio-based production to FUTURE integrated Biorefineries

Vision "Biorefinery Leuna"

— "Bioethylene" as an example for the integration into the value chain

— Why Bioethylene?

— Future integrative scenario

Conclusion & Outlook


From fossil- to bio-based refineries – Key drivers

Feedstock change – trend to renewable raw materials

— securing supply (shortage of fossil feedstocks)

— rising costs of fossil feedstocks

— autonomy of supply

Sustainability

— neutral/positive C02-balance

— energy, water, resources, environmental burdon

Political will

— to establish a bio-based economy in Europe

— to keep Europe in a leading position in White Biotech

— to support European agriculture

Economics

— new/innovative products

— cheaper production processes

Triple P principle


From fossil- to bio-based refineries – Status & development trends

Use of renewable raw materials TODAY

1G Biorefineries(e.g. Bioethanol, starch, pulp & paper)

FUTURE trends

(petro)chemical sites with individual biotech plants

Sour

ce:

Pres

s ph

oto

Südz

ucke

rSo

urce

: Pre

ss p

hoto

BASF

2nd/next generation

Biorefineries

fully integrated biotechnological

and chemical production sites

A

B


new integrative plant concept

From TODAY'S 1G bio-based refineries to FUTURE Biorefineries

Quelle: Pressefoto Südzucker

expansion of product range

→ chemical intermediates

improve sustainability

expansion of raw material basis→ LC biomass

improve efficiency

A


From TODAY's chemical sites to FUTURE integrated bio/chem sites – Leuna as an example

Source of picture and diagram: Infraleuna

Leuna chemical site – Refinery at night Site internal network –companies and major feedstock/product lines

Infraleuna owner & operator of Infrastructure/utilities facilities on site

Linde Gas/Linde Gas shareholder

B


Leuna chemical site – infrastructure & service on siteSi

te b

ound

ary

Waste Disposal

River Saale

Laboratory

Site coordination

Security and emergency management

Medical Service

Communication

Site development

Facility management

Production units and service provider on site

Power plants

Road

Terminals

Rail

Stations

Vehicle cleaning service

Logistic service

RailRoad

Pipe racks

Energy production and distribution

National grid

Water supply

Road

Fire brigade

Security

Waste water

ZAB

Waste Disposal

River Saale

Laboratory

Site coordination


Medical Service

Communication

Site development

Facility management

Laboratory

Site coordination


Medical Service

Communication

Site development

Facility management

Production units and service provider on site

Power plantsPower plants

Road

Terminals

Rail

Stations

Road

Terminals

Rail

Stations

Vehicle cleaning service

Logistic service

RailRoad

Pipe racks

Energy production and distribution

National grid

Water supply

Road

Fire brigade

Security

Road

Fire brigade

Security

Waste water

ZAB

Advantage for bio-based processes upon integration:

— use of existing site facilities (infrastructure, utilities, services)

— integrated energy concept

— support in approval processes

Source: Infraleuna

cheaper than greenfield

investment!


Vision „Biorefinery Leuna“–Integration of Bioethylene in the value chain

I N F R A S T R U C T U R E I N F R A S T R U C T U R E

PA-Compounds

Refinery

Methanol

H2S

DMF

Glues

Methanol

Steam-reformerSteam-

reformer

Hydrogen-peroxide

H2 H2

Caprolactam,Polyamide 6,

Fiber production

H2

S8

Propylen

Air separation

plantO2

N2O2

LDPE

PE-Wax

EVA-Copolymere,

Additives

NaHS

Plastic-dispersions

Surfactants

Resins

CatalystsCatalysts

Lubricants

Fine Chemicals

Formaldehyde

MMA

CO

Crude oil Ammonia EthyleneNatural Gas

Amines

EthanolButanoletc.

CO2„Bio-Refinery“

Sugar, Starch, Cellulose, Hemicellulose, Lignin, Algae, etc.

Bio-oils-surfactants

Bioethylene

CO2 H2

Complex Chemicals

AromaticsEnzymesProteinesetc.

New Investors

MethanolPA 6 / PA 6.6

Epichlorohydrin

Glycerin

EBS

EthanolButanoletc.




Bioethylene

CO2 H2

Complex Chemicals


New Investors


Epichlorohydrin

Glycerin

EBS

EthanolButanoletc.

EthanolButanoletc.




Bioethylene

CO2 H2

Complex Chemicals


New Investors


Epichlorohydrin

Glycerin

EBS Power-plant

Source: InfraLeuna


Expansion of the product range – Ethanol as Biofuel or building block for chemical intermediates

Lignocellulosic Biomass

Cellulosic Ethanol

CHEMICAL BUILDING BLOCKBIOFUEL

Acetaldehyde

Ethylene

Acetic acid

others Chem

ical

s&

Pol

ymer

s

1. via enzymatic treatment and fermentation 2. via gasification and syngas fermentation


Bioethylene5 000 – 100 000 t/a ethylene

ca. 1 200 - 1400 €/twhen produced on sitewith a 30-50 kta plant

Mega plants1 m t/a ethylene~ 1 bn € invest volume

ca. 800 - 1 000 €/twhen transported by pipeline

Container & Cylinder< 1 000 t/a ethylene+ liquefaction/filling (300 €/t)+ transport (400 €/t)

around 1 500 – 1 700 €/twhen transported by trucks

… and in between?

Ethylene market – a heterogeneous business with potential for renewable raw materials


ExistingInfrastructure

InfraLeuna

Existing Production in Leuna

Refinery / Linde Gas / Polymers / Chemicals …

Biomass Disintegration

EthanolProduction

2G Bioethanol Plant

Bioethylene

Biorefinery – potential future integrative scenario for Leunafirst project phase - 2G Bioethanol plant central module

30 kta

Bioethylene

20 kta 12 kta

30 ktaEthanol purchase

18 kta


ExistingInfrastructure

InfraLeuna

Existing Production in Leuna

Refinery / Linde Gas / Polymers / Chemicals …

Biomass Disintegration

EthanolProduction

2G Bioethanol Plant

Bioethylene

Biorefinery – potential future integrative scenario for Leunafuture extension – adjustment to the needs of the site

Step 1

Step 2 Biomass Disintegration

EthanolProduction

2G Bioethanol Plant


Integration bioethanol & bioethylen – Real life scenario


Conclusion & outlook

Future trend - from fossil based sites to integrated next generation Biorefineries

Fossil based refinery Challenge bio-based

highly integrated mature technologies technology development

well known fossil raw materials complex new raw materials

established products and value chain partially new products for value chain

Option:

replacement of fossil-based refineries by new large-scale greenfield biorefineries?

feasible short to midterm solution:

Integrative bio/chemical "Verbund" concept tapping the full synergy potential of existing sites

an ideal place: the Leuna Biorefinery

Thank you for your interest.

Uwe Welteroth

Director Biotechnology Plants

Phone +49.(0)3 51.250-3389

Fax +49.(0)3 51.250-4814

E-Mail [email protected]

LINDE-KCA-DRESDEN GMBH

Bodenbacher Strasse 80

01277 Dresden

Germany

http://www.linde-kca.com

from fossil- to bio-based refineries · linde-kca-dresden gmbh 3 august 2009/uwe welteroth from...

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