Development prospects of biorefinery technologies

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1 Development prospects of biorefinery technologies Marlena OWCZUK*, Magdalena ROGULSKA, Dorota BOGUMIŁ Automotive Industry Institute, Warsaw, Poland; Krzysztof BIERNAT Automotive Industry Institute, Warsaw, Poland; Institute for Ecology and Bioethics of Cardinal Stefan Wyszynski University, Warsaw, Poland Please cite as: CHEMIK 2015, 69, 11, Introduction One of the priorities of the European Union is to strengthen the use of raw materials of biological origin in various industrial sectors, aimed at growth and economic recovery of countries [1]. For this purpose different kinds of initiatives addressing agricultural productivity and sustainability [2], smart specialization strategies of individual countries and regions [3] appeared as well as several actions in the environmental field were identified. In response to these trends, a key role in implementing the priorities will play a biorefinery, in which biomass renewable biological resource is used for wastefree production of a wide variety of bioproducts (biofuels, bioliquids, biochemicals, consumable goods from biomass etc.) and energy. These systems combine various industries and previously unrelated raw material producers, creating new value chains, replacing the production based on fossil fuels. The main objective of this joint technological initiative is to strive for a resource-efficient and sustainable low carbon economy and economic growth (especially in rural areas), as a result of the creation of sustainable and competitive industry, using technologically advanced biorefineries processing biomass in a sustainable manner [4, 5]. Biorefinery concept The concept of a system development of industry based on raw materials of biological origin (Bio-Based Industries) was proposed as a result of the review done in the EU countries concerning the progress in deployment of renewable energy sources [6]. Main assumption idea is to develop industry optimally using land and ensuring food safety: through sustainable, efficient processes and limiting the amount of waste, renewable biomass processing in a wide range of products of biological origin. In order to implement these principles Innovation Plan and Strategic Research (SIRA) was developed including following value chains [4,7]: 1. From lignocellulosic feedstock for advanced biofuels, chemicals and biomaterials, through the selection of raw material base and technology for a new generation of fuels, chemicals and materials. 2. Utilize the full potential of forest biomass through rationalization of afforestation and creating new markets and value-added products. 3. The use of agro raw materials enable sustainability of production through efficient agricultural production and new markets and value-added products. 4. Waste management, through the implementation of sustainable technologies for processing waste into valuable products. 5. Integrated biorefineries as a means of sustainable production of bioenergy, including biofuels, biomaterials, biochemicals etc. Achieving the objectives in accordance with proposed value chains could lead to the creation of biorefineries processing biomass in complex and waste-free way and will ensure the availability of biomass for foodstuffs, chemicals, transport, energy, etc. In addition, it may Corresponding author: Marlena Owczuk M.Sc. Eng., m.owczuk@pimot.eu increase the productivity and efficiency of biomass from agricultural land and forests, while utilizing the potential of streams byproducts and waste products [7]. Providing new markets for biomass producers will strengthen the economy and allow intensification of production in the sustainable system. To implement the actions contained in the SIRA consortium Bio- Based Industry Consortium (BIC) was formed, with tasks including the implementation of research projects aimed at filling the gaps in technological innovation and deployment of developed technologies on a commercial scale. Biorefinery characteristics There are many methods of converting biomass into energy sources which differ in the complexity of the process, the costs and availability of the installation and the degree of knowledge of the process. In general, biomass conversion can be carried out using mechanical processes (eg. disintegration) thermochemical (eg. pyrolysis, gasification), biological (eg. methane fermentation) and / or chemical (eg. esterification, hydrolysis) [8]. Biorefinery is a comprehensive integrated system, combining various biomass conversion processes and equipment to its processing in a single manufacturing facility. During the biorefinery design it is particularly important to optimize the selection of transformation chain, depending on the type of feedstock, the conversion technology, final products, as well as economic efficiency. Depending on the processes bioproducts (eg. alcohols, chemicals), biofuels (eg. synthetic fuels / hydrocarbons, gaseous fuels) and energy will be produced. Products of biorefinery processes may be a final ones or intermediate ones to be used in other processes. The concept of biorefineries is based on the use in the processes in the field of WTL (wastes to liquid) or BtL (biomass to liqiud) of waste materials of biological origin. For this purpose are used: byproducts of other substances processing, biodegradable waste products of vegetable or animal origin, dedicated plants grown for energy purposes, waste from forestry, biodegradable fraction of industrial and municipal waste. The general scheme of the complex biorefinery is shown in Figure 1. There are four basic biorefinery systems due to the nature of the raw materials used and technological capabilities [10, 11, 12]: whole crop biorefinery in which the substrate is a whole plant crop. A variety constitute oleorafinerie, which use oil seeds (eg. rapeseed, sunflower, soya), biorefineries green using inedible green parts of plants or entire energy crops (eg. wet biomass, green grass, alfalfa, clover, immature grain, not suitable for farming and the food industry plants or parts of them), lignocellulosic biorefineries, based on lignocellulosic biomass (eg. wood, straw, waste from the forest industry, wood, paper), 2-platform biorefineries (producing syngas and sugars in a single technological platform, with simultaneous production of fuels in the second platform), based on renewable raw materials (biomass waste from agriculture, forestry, food industry, biodegradable municipal waste). 754 nr 11/2015 tom 69

2 In 2014 IEA Bioenergy Task 42 has developed a new clasification of biorefineries based on platforms, products, feedstocks and processes, which allows on consistent description of different systems [9]. Biorefinery systems in the world examples There are more than 80 biorefineries (pilot, demonstration and commercial ones), of which approximately 31% is located in the Netherlands, 16% in Canada and approx. 12.5% in Austria. The rest is located in Denmark, Germany, Italy, New Zealand, United States, Australia and Ireland [9]. In addition, planned is commissioning of new installations in other countries, eg. in the UK and in Finland. Currently, work is underway on the optimization of the use of existing raw material (forest and agricultural biomass) and the development of new raw material supply chains (eg. forest waste, agricultural waste, or lignocellulosic dedicated crops), as well as the use of organic streams of industrial and municipal wastes. The following figures (4 11) are block diagrams of selected biorefinery systems divided into commercial, demonstration and pilot projects. Figure 4 shows the idea of 2-platform biorefinery, located in Pischelsdorf (Austria), using a sustainable agricultural raw materials for the production of bioethanol, starch, gluten and animal feed. science technique market Fig. 1. General scheme of biorefinery installation [9] Fig. 4. Agrana biorefinery, Austria [9] Fig. 2. Pyramid of market value of products from biomass [9] Fig. 5. INEOS biorefinery, USA [9] Fig. 3. Estimation of EU market demand on bioproducts till 2030 [13] Figure 2 shows a pyramid of products that could potentially be produced from biomass. According to the forecasts of market development of bio-products in the EU countries the increase of market size of bioproducts from EUR 28 billion (2013) to 50 billion EUR in 2030 is expected [13]. Looking at individual product segments, the biggest increase is forecasted for bioethanol, base chemicals and biopolymers, with moderate growth in biogas and antibiotics (Fig. 3). Figure 5 shows a commercial 2-platform installation producing bioethanol and energy from organic wastes by fermentation of synthesis gas. Installation can produce annually 8 million liters of third generation bioethanol from biomass (plants, biodegradable municipal solid waste), also generating 6 MW (gross) of clean green energy. Surplus energy can be made available to the local community. Another solution is shown in Figure 6, it is 2-platform biorefinery Victoria, located in Barnawartha in Australia. It produces biogaseous fuel (biogas), liquid biofuels and technical glycerin (98.5%) and potassium sulphate, from oilseeds, used frying oils and low quality animal fats. Waste oils, using the methods of extraction and refining are converted to crude oil, which then is converted by transestrification to the methyl ester (biodiesel) and glycerol. nr 11/2015 tom

3 Fig. 6. Victoria biorefinery, Australia [9] Fig. 7. BioGasol/Estibio biorefinery, Denmark [9] Among the pilot plant particularly noteworthy is 3-platform biorefinery BioGasol/Estibio, located in Denmark, in Ballerup. The substrate is lignocellulosic biomass (straw) as well as agricultural waste, from which gaseous fuel (biogas, biomethane), solid biofuels, bioethanol, chemicals and fertilizer are produced. The pre-treatment of lignocellulosic waste is done at Carbofrac and Estibio installations, where by enzymatic hydrolysis and under high temperatures, individual sugars are extracted. Fig. 9. LanzaTech biorefinery, New Zeland [9] In the 2-platform biorefinery Lanza Tech (Fig. 9) for the production of bio-ethanol and hydrocarbons C2-C5 waste biomass from the manufacture of wood and solid organic fraction of municipal waste is used. Installation was founded in New Zealand in 2005, based on original technology of synthesis gas fermentation to bioethanol. A different concept is illustrated in Figures 10 and 11, where in the biorefineries algae (microalgae) are used. The first installation (ACRRES), which is in the pilot phase, is located in the Netherlands. This biorefinery is supplied by biodegradable waste and waste water from which the biogas is produced a well as proteins, microalgae, bioethanol and components of feed and fertilizers. The possibility of processing wastes eg. from farms is analysed. The second one (3-platform demo installation) located in Bruckan der Leitha in Austria, produces from microalgae biofuels, electricity and heat, omega-3/6 and fertilizer. The company Ecodua is a global technology leader in the construction of the algae cultivation systems. Innovative technology enables the production of biomass of microalgae on an industrial scale. Fig. 10. ACRRES biorefinery, Netherlands [9] Fig. 8. Bioliq biorefinery, Germany [9] Another pilot plant, 3-platform Bioliq biorefinery is located in the German city Karlsruhe (Fig. 8), producing from biomass (straw, wood) pyrolysis oil, syngas, BTL (Biomass to liquid) fuels as well as electricity and heat. By gasification of the organic wastes the synthesis gas is obtained which can be converted further into transport fuel or by catalytic processes in the chemicals. On the basis of presented above examples, we can conclude that there are a number of concepts of biorefinery systems that differ in the type of feedstock, used technological processes and final products obtained. In these plants the biomass of various origins is converted into a mixture of liquid components, and then undergoes processing (treating, fermentation, purification, etc.) to receive biofuels, bio-based products and energy. The authors of this paper have developed their own concept of the construction of 2-platform biorefinery, based on biomass feedstock rich in carbohydrates and lignocellulose (Fig. 12). Due to the designed chemical and biochemical platform sugar carbohydrate fraction is converted into a biofuel, bioethanol and biopolymers. The use of hightemperature and high-pressure processes can convert lignocellulosic fraction of the biochemicals and energy into synthesis gas platform. 756 nr 11/2015 tom 69

4 Fig. 11. EcoduaAlgae biorefinery, Austria [9] Fig platform biorefinery PIMOT concept [14] However, the implementation of such solutions in Polish conditions requires the performance of several works, including studies on the physicochemical properties of the biomass in order to optimize its composition and analysis of possible ways of the pentose conversion into biofuels or high-value chemicals with particular emphasis on furan compounds and biopolymers. Also research on optimization of all processes (eg. hydrolysis of the carbohydrate fraction, alcoholic fermentation, gasification of biomass) is required. In the final stage, it is necessary to develop techniques for optimizing the quality of the final products according to the regulatory requirements (eg. the purification of fermentation synthesis gas), recycled catalyst, and refining and separation of the resulting bio-chemicals. At PIMOT was also developed an original concept of a biorefinery based on the existing petroleum refinery. This solution is especially costeffective due to the possibility of using the existing technical resources and administration, including human resources and technological potential. Research problem which now is studied is the optimization of the technology of converting biomass to bioliquid phase. The use of HTU (hydrothermal upgrading) technology, together with the HDO (hydrodeoxygenation) process is planned. the environment (eg. reducing greenhouse gas emissions and waste) and economic development (creation of jobs) as well as country s economic development (increased decoupling from such media as crude oil, coal, natural gas). Innovative and efficient biorefineries can revitalize existing industries and even contribute to the development of previously unused land in Europe (up to 35% in 2030). According to the strategic objectives of the already mentioned the SIRA document a 20% increase in the supply of biomass, its 30% share in the production of chemicals and materials, as well as 25% biofuels share in total demand for energy in transport are assumed to be reached in Europe by 2030 [15]. Literature 1. COM(2012) 582. Komunikat Komisji do Parlamentu Europejskiego, Rady Europejskiej, Rady, Europejskiego Komitetu Ekonomiczno-Społecznego i Komitetu Regionów: Silniejszy przemysł europejski na rzecz wzrostu i ożywienia gospodarczego. Aktualizacja komunikatu w sprawie polityki przemysłowej. 2. COM(2012) 79. Komunikat Komisji do Parlamentu Europejskiego i Rady w sprawie europejskiego partnerstwa innowacyjnego na rzecz wydajnego i zrównoważonego rolnictwa. 3. DG REGIO (2012) Connecting Smart and Sustainable Growth through Smart Specialisation ( Łączenie inteligentnego i zrównoważonego wzrostu dzięki inteligentnej specjalizacji ): Praktyczny przewodnik dla instytucji zarządzających EFRR. 4. Dziołak P., Biernat K.: Badania nad technicznymi i technologicznymi możliwościami kompleksów biorafineryjnych w Polsce, Warsztaty Naukowe IEiB UKSW, Warszawa, 27 maja 2009r. 5. COM(2013) 496, Rozporządzenie Rady w sprawie wspólnego przedsiębiorstwa na rzecz przemysłu opartego na surowcach pochodzenia biologicznego, Bruksela, dnia r. 6. Dirk Carrez, The Bio-based industries Initiative (BBI) and the Bioeconomy Observatory, Brussels, 26th November 2013r. 7. Biernat K.: Kierunki rozwoju biogospodarki, jako nowej gałęzi przemysłowej w Unii Europejskiej, Czy Biotechnologia jest inwestycją we własną przyszłość, materiały konferencyjne, V Warsztaty Biotechnologiczne, Spytkowice, 5 6 Czerwiec 2014r. 8. Huber G. W., et al.: Synthesis of Transportation Fuels from Biomass: Chemistry, Catalysis and Engineering. Chemical Review 2006r. 9. IEA Bioenergy, Task 42, Biorefining: Sustainable and synergetic processing of biomas into marketable food & feed ingredient, chemical, materials and energy (fuels, power, heat), Raport IEA, sierpień 2014r. 10. Biernat K.: Rozwój technologii wytwarzania biopaliw, Czysta Energia, 11/ Final Report Summary BIOPOL (Assessment of biorefinery concepts and the implications for agricultural and forestry policy. 12. Soetaert W.: Defining biorefineries and different concepts, BioreFuture 2009, Biorefinery Euroview BIOPOL, Brussels, 30 th March 2009r. 13. Overcoming hurdles for innovation in industrial biotechnology in Europe, Market Roadmap: Draft 3, BIO-TIC. 14. Narodowa Strategiczna Agenda Badawcza w Zakresie Biopaliw, opracowanie Polskiej Platformy Technologicznej Biopaliw pod red. K. Biernata, Warszawa, 2008r. 15. Strategic Innovation and Research Agenda (SIRA), Bio-based and Renewable Industries for Development and Growth in Europe, March 2013r. science technique market Conclusions Biorefinery systems, producing biofuels, energy and various biomaterials, are a key element of sustainable and competitive development of the industry. Larger quantities and a wide range of manufactured products allow the use of different renewable biological resources (with the reduced amount of non-renewable resources), as well as to maximize the benefits of such a solution (the sale of biofuels, energy, the use of products for own use, etc). Beside these, undoubtedly important benefits are connected with the protection of Magdalena ROGULSKA Ph.D., graduate of the Faculty of Physics at the University of Warsaw. Ph.D. in agricultural engineering. Since 2011 the main expert on renewable energy at the Automotive Industry Institute. She specializes in the sustainable use of biomass for energy and transport. Coordinator of research and demonstration projects funded by the European Commission (DG Research, DG TREN, EACI). Leads the Polish secretariat of the Swedish-Polish Sustainable Energy Platform. European expert evaluating projects under HORIZON nr 11/2015 tom

5 *Marlena OWCZUK M.Sc. Eng., graduate of the Faculty Biotechnology and Food Sciences at Lodz University of Technology. In 2005 she joined the Automotive Industry Institute. Senior researcher at the Department of Bioeconomy. In her work deals with the development of fuel production, liquid biofuels and alternative fuels. The author and co-author of many research papers, publications and presentations. Dorota BOGUMIŁ M.Sc. Eng., graduate of the Faculty of Chemical and Process Engineering at Warsaw University of Technology (specialization Industrial Biotechnology). Since 2015 employed in the Automotive Industry Institute in the Department of Bioeconomy. In her work she focuses on the production of biofuels using biochemical biomass conversion. Aktualności z firm Krzysztof BIERNAT - Ph.D., (Eng.), is a professor of the Automotive Industry Institute (PIMOT), acting as Head of Bieconomy Department and Coordinator of Polish Technology Platform for Biofuels, member of Coordinating Committee of Polish Technology Platform for Bioeconomy. He is also the Deputy Director of Institute of Ecology and Bioethics at state Cardinal Stefan Wyszynski University in Warsaw. He represented Poland in European Technology Platform of Biofuels and in Renewable Heating and Cooling European Technology Platform. He is also a member in American Council on Renewable Energy. He specializes in chemical thermodynamics of environmental processes as well as obtaining technologies, quality evaluation and use of exploitative liquids, including biofuels, and biorafinery systems. He is an author of above 200 publications in area of properties and exploitative conditionings of fuels, biofuels and other liquids as well as environmental protection. He is a member of many national and foreign scientific societies including American Chemical Society and American Association for the Advancement of Science. News from the Companies Dokończenie ze strony 753 RYNEK Zakład Badawczy Kopolimerów ICHEMAD PROFARB Sp. z o.o w strukturach SYNTHOS SA Od 1 października br. Zakład Badawczy Kopolimerów będzie prowadzony pod firmą Synthos Dwory 7 spółka z ograniczoną odpowiedzialnością spółka jawna. Długofalowa strategia SYNTHOS SA zakłada sukcesywne budowanie wartości rynkowej biznesu dyspersji i klejów. Połączenie to jest kolejnym krokiem w budowaniu pozycji wiodącego dostawcy produktów chemicznych i lidera rynku oferującego wysokiej jakości rozwiązania w segmencie dyspersji i klejów, realizowanym przede wszystkim z myślą o odbiorcach i użytkownikach końcowych. Celem jej jest maksymalne wykorzystanie potencjału zakładu w postaci wiedzy, receptur i technologii wodorozcieńczalnych produktów chemii organicznej kopolimerów. (kk) ( ) Dobre wyniki Grupy ORLEN we wszystkich segmentach Po 9. miesiącach tego roku Grupa ORLEN wypracowała wynik EBITDA wg LIFO (bez uwzględnienia odpisów wartości aktywów) o prawie 3 mld PLN wyższy niż rok wcześniej. Ostatni, III kwartał br. Grupa ORLEN zakończyła z zyskiem operacyjnym (EBITDA wg LIFO) na poziomie 2,1 mld PLN (przed odpisem wartości czeskich aktywów petrochemicznych w kwocie 0,1 mld PLN). Koncern osiągnął wyższą sprzedaż we wszystkich segmentach i rekordowy wynik w detalu. Sprzyjające otoczenie makroekonomiczne, tj. wzrost marży downstream oraz dalszy spadek cen ropy naftowej, wspierało osiągnięcie dobrych wyników. Miniony kwartał był szczególnie istotny w kontekście realizacji strategicznych projektów rozwojowych Grupy ORLEN. W obszarze petrochemii zawarto umowę budowy nowej instalacji polietylenu (PE3) w zakładzie w czeskim Litvínovie. We wrześniu br. rozpoczęto w Płocku prace budowlane w projekcie największej w Polsce elektrociepłowni o mocy 596 MWe. Rozpoczęto również proces przejęcia perspektywicznych złóż ropy oraz gazu w Polsce i Kanadzie. (kk) ( ) PGE pozyskała kredyt o wartości 2 mld PLN od Europejskiego Banku Inwestycyjnego PGE Polska Grupa Energetyczna zawarła z Europejskim Bankiem Inwestycyjnym dwie umowy kredytowe na łączną kwotę prawie 2 mld PLN. To kolejne, po kredycie konsorcjalnym o wartości 5,5 mld PLN, środki pozyskane przez Grupę PGE na finansowanie planu inwestycyjnego. Wśród kluczowych projektów inwestycyjnych prowadzonych przez Grupę PGE wymienić należy budowę nowych, efektywnych mocy wytwórczych, na czele z flagowym projektem budową bloków 5 i 6 w Elektrowni Opole. Grupa PGE założyła sobie także ambitny program modernizacyjny, mający na celu dostosowanie funkcjonujących w jej portfelu aktywów wytwórczych do stopniowo zaostrzanych norm środowiskowych. Grupa sukcesywnie poprawia również parametry w obszarze dystrybucji zapewniając niezawodność dostaw. Łącznie, na inwestycje budujące wartość Grupy, PGE zamierza przeznaczyć do 2020 r. kilkadziesiąt mld PLN. (kk) ( ) ORLEN przejmuje kolejną spółkę wydobywczą w Kanadzie PKN ORLEN, za pośrednictwem spółki zależnej ORLEN Upstream Canada, zawarł umowę rozpoczynającą proces nabycia 100% akcji spółki Kicking Horse Energy. Ich wartość uzgodniono na poziomie 293 mln CAD (ok. 842 mln PLN), co oznacza cenę 4,75 CAD (13,65 PLN) za jedną akcję. Finalizacja transakcji możliwa będzie po wypełnieniu wszystkich warunków umowy i planowana jest w czwartym kwartale br. (kk) ( ) ORLEN kupuje aktywa wydobywcze w Polsce PKN ORLEN za pośrednictwem swojej spółki zależnej ORLEN Upstream zawarł umowę, która rozpoczyna procedurę przejęcia całościowego pakietu akcji FX Energy, spółki notowanej na nowojorskiej giełdzie NASDAQ. Uzgodniona kwota 1,15 USD (4,27 PLN) za akcję zwykłą i 25 USD (92,87 PLN) za akcję uprzywilejowaną, przekłada się na wartość transakcji wynoszącą ok. 83 mln USD (około 308 mln PLN). Akwizycja powiększy bazę zasobową (2P) Koncernu o 8,4 mln baryłek ekwiwalentu ropy (boe). (kk) ( ) Dokończenie na stronie nr 11/2015 tom 69