Welcome to the World’s most advanced biorefinery!
A Practical Discussion •Borregaard Business Model and History •The Technology and Value of Lignosulfonates •BALI Pretreatment: Viable Economic Business Model
Jerry Gargulak Gudbrand Rødsrud Martin Lersch Rolf Andreas Lauten Anders Sjøde
Borregaard products in daily life
Bio fuel
Construction products
Dust control
Pharmaceuticals
Paint
Food Flavour
Textiles, spectacle frames
Car batteries, gaskets, care products
Gypsum Board Copper pipe
Animal feed
Soil conditioner, fertilizers
Global presence
Borregaard 2010 Turnover: â‚Ź 660 mill. Employees: 1300 in 20 countries
Main office Sales office Production
LignoTech USA Inc.
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Part of LignoTech group since 1991
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Specialty Lignosufonate products
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Capacity: 75,000 MT dry solid/yr
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Powder and liquid products
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Proprietary process technologies
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Formulation capabilities
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75 Employees
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North American Legal entity –
Multiple sales locations
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Administration and customer service
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R&D, Tech support and BD Functions
True Biorefinery
• • • • •
Leading supplier of specialty cellulose Global leader in lignin performance chemicals, 50%+ market share Only producer of vanillin from lignocellulosics Production of lignocellulosic bioethanol since 1938 (20.000 m3/y) 100% renewable energy expected by 2013
From Paper Mill to Biorefinery
Oil or biomass – green or black carbon?
GREEN CARBON
Sustainable chemicals, materials, ingredients, biofuel
BLACK CARBON
Borregaard site in Sarpsborg, Norway
Head office - R&D - Production 800 employees, 2.5 bn NOK turnover From spruce: specialty cellulose, lignin products, biovanillin, 2G bioethanol
Other raw materials: basic chemicals, energy, fine chemicals
The Team
Further development of the biorefinery concept High
High
Cost/price
BioMaterials - Polymers - Composites
BioChemicals
Flavours Monomers Proteins Fine chemicals Speciality chemicals
BioFuel
- Bioethanol - Biodiesel - Biogas
BioEnergy
- Electricity/Heat - Liquid Fuels - Pellets
Low
Creating values
BIOREFINERY
-
Low
When you have choices you can optimize.
BIOETHANOL
A Practical Discussion •Borregaard Business Model and History •The Technology and Value of Lignosulfonates •BALI Pretreatment: Viable Economic Business Model
Pulping
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Pulping is the separation of cellulose from lignin and other components
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Lignin is rendered soluble
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Insoluble cellulose is filtered off
Production of lignosulfonate
Production of Lignosulfonate
Fermentation
ethanol
Worlds first sulfite ethanol plant started in Sweden in 1909 •
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First sulfite ethanol plant ever opened 1909 in Sweden, Skutskär, Uppland 33 plants in operation in Sweden, only one in operation after 1983: Domsjø, capacity of 15 000 m3/y Den svenska sulfitspritproduktionen
tom 100% sprit 80000
70000
60000
50000
40000
30000
20000
10000
0 1909 1914 1919 1924 1929 1934 1939 1944 1949 1954 1959 1964 1969 1972 1977 1982 1987 1992 1997 2002 år
Source: Persson, Bertil. Sulfitsprit. Förhoppningar och besvikelser under 100 år. Bjästa : DAUS Tryck & Media, 2007. ISBN: 91 7542 258-1.
17 Sulfite ethanol plants in Finland 1927 1977
1977 last sulfite ethanol production Early 1990’ies Last sulfite mill in Finland stopped production
Sources: 1. Biorefining in the pulp and paper industry. Niemelä, Klaus. Flensburg : s.n., 2008. 5th European Biorefinery Symposium. 2. Kaukoranta, Antti. Sulfittispiriteollisuus Suomessa vuosina 1918-1978 (Eng:"Sulphite alcohol industry in Finland in 1918-1978"). s.l. : Paino Polar Oy, 1981. ISBN 951-9479-25-2. 3. Niemelä, Klaus. Private communication. s.l. : VTT TECHNICAL RESEARCH CENTRE OF FINLAND , 2010.
Composition of crude LS solids
% RANGE Lignosulfonate Hexose Sugars Pentose Sugars Miscellaneous Hemicellulose, Sugar Acids Resins and Extractives
SOFTWOOD HARDWOOD 65 52 14 5 6 20 12 3
20 3
Sulfite Pulping
Three dimensional structure
20 nm
1000 nm
20 nm
Typical size exclusion curve
Particle Size of Lignosulonates
Some Applications
Dispersing
Agricultural formulations Concrete Ceramics, refractories Dyestuffs Gypsum board Oil drilling muds Pigments Carbon black Water treatment & industrial cleaning
30.04.03 -
Binding Briquetting bricks Dust control Paper & board Particle board Pelleted feeds
Other
Emulsion Stabilization Batteries Cement Retarders (oil well) Soil conditioner Protein Bypass Flotation aid
Interfacial Agent • Common denominater in these applications is that lignosulfonate is used as an interfacial substance.
• This means that an application specific system (emulsion, suspension, formulation) is manipulated or processed to concentrate lignosulfonate at the interfaces between solid particles or oil droplets and suspending medium (usually water) • Once located at the interface, lignosulfonates performs.
• Lignosulfonates are present and used at interfaces, i.e. liquid-solid, liquid-liquid, liquid-gas, solid-gas • Lignosulfonate may or may not adsorb onto an interface. There has to be an affinity between lignosulfonate and the interface in question. A low affinity can be overcome by processing techniques.
Lignosulfonate
Lignosulfonate - emulsifier and dispersing agent
Lignosulfonate
stabilize emulsions disperse color pigments disperse pesticides
Flow table test
Concrete Additives • Additives for concrete admixture formulations • Water reducer for concrete – Stronger, lower cost concrete • Borresperse®, Norlig®, Wanin®, Wafex®, Ultrazine®
Essential Component for Lead Acid Batteries Improve life 3,200
Life @ 41 C
Modified Lignosulfonate –Vanisperse A Maintains charge capacity Improves cold cranking Longer lifetime
0
0.0
0.3
Vanisperse A Dosage:
0.6
% on weight of leady oxide
Increase cold crank ability 33
Cold Crank @ -18 C
• • • •
20
0
0.3
Vanisperse A Dosage: % on weight of leady oxide
0.6
Organic Expanders
Increase the surface area of negative active material yielding sponge lead Preserve fine, porous lead crystal structure on cycling Promote formation of small lead sulfate crystals on discharge Promotes formation of a porous lead sulfate layer
0.5% Vanisperse A
No Organic Images from D. Boden
III BLT Latin th
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A Practical Discussion •Borregaard Business Model and History •The Technology and Value of Lignosulfonates •BALI Pretreatment: Viable Economic Business Model
Sugar platform pathways – how to choose? Hydrolysis processes • Dissolving cellulose and hemicellulose leaving hydrolysis lignins undissolved – – – – –
Strong acid Weak acid Enzymatic Microbial Supercritical water
Hydrolysis Lignin (S)
Cellulose (L) HemiCellulose (L)
LIQUID
SOLID
Pulping processes • Dissolving lignin and (hemicellulose) leaving cellulose undissolved – – – – –
Kraft Soda Sulfite Solvent Extrusion
Lignin quality depends strongly on process and biomass source Hemicellulose/xylan form and quality depending on process
Lignin (L) Cellulose (S) HemiCellulose (L) LIQUID SOLID
Pretreatment challenges • Lignins bind to enzymes – high enzyme dosage required for acceptable yield/reaction time – prevents recycling •
Lignins are often impure and often strongly condensed
– unattractive feedstock for chemicals
• Unfavorable mass balance – low yield of valuable product – large fraction of feedstock used for energy production Inspired by today’s existing biorefinery Borregaard has developed a modified chemical pretreatment that addresses these issues
BALI™ process in a nutshell
Feedstock handling
Pretreatment
Lignin processing/ marketing
Hydrolysis
Fermentation
Product purification
BALI – a significant simplification and spin-off opportunity
High cost raw material
Traditional woodpulp Biorefinery
Lignin
Cellulose
Low cost raw material
BALI Biorefinery
Energy
Lignosulfonate
Sugars for fuel or chemicals
BALI vs Woodpulp biorefinery: -
Significantly reduced raw material cost Reduced complexity and capital requirement Value creation from lignin compared to other processes Generates growth opportunities Change in business model for Lignosulfonate Improved competitiveness through value creation
Dose-response curves with Novozymes Cellic® CTec2 BALI alkaline pretreated bagasse
140 %
140 %
120 %
120 %
Glucan conversion
Glucan conversion
BALI acid pretreated bagasse
100 % 80 % 60 %
24 hours
40 %
48 hours 72 hours
20 %
100 %
80 % 24 hours
60 % 40 %
48 hours
20 %
72 hours
0%
0% 0
2
4
6
8
10
12
Enzyme dosage % v/w (Cellic® CTec2 from Novozymes)
6.3% glucan loading DS: 9.2% DS (acid) and 11.3% (alkaline) 50 °C, 200 rpm in shaking incubator 50 mM sodium citrate buffer at pH 5 50 g total reaction mass in 100 mL flasks 0.01% NaN3 for microbial control Sugar analysis by HPLC (> quantitative yield due to underestimation of glucan in raw material analysis)
0
2
4
6
8
10
12
Enzyme dosage % v/w (Cellic® CTec2 from Novozymes)
Novozymes comment: ”This is probably among the best 10-15% of all results we have seen”
BALI project: Next steps Pilot : Cost and complexity
• Commercial production
• Necessary for further technology development
• Several plants
• Scale up • Adapt and improve technology • Process optimalization (reduce VC) • Test products to external customers • Base case for dimensioning full scale plant
• Development and test of concept • Choice of technology • Analytical methods • Initial product tests
2007-2011 R&D Lab and miniplant
2011-2013
2014 Pilot plant
Time to market
Full scale plant (green – or brownfield)
Pilot demonstration plant • • • • • • • •
Location: Sarpsborg, Norway Flexible feedstock Flexible process conditions 1 metric ton dry matter/day (50 kg/h) Commissioning expected May 2012 800 m2 total area Total cost approx 24 mill USD Continous operation Feedstock handling
Pretreatment
Lignin processing
Hydrolysis
Fermentation
Product purification
BALI Pilot – Status construction Concrete work ready: 22 September Steel structure ready: 25 October
Sealed building: 15 November Building finished: January 2012
Funding Biomass2Products Borregaard receives 19 mill NOK from the Norwegian Research Council (2009 – 2012) EuroBioRef Borregaard receives 3.0 M € from FP7 through the EuroBioRef consortium (2010 – 2013) Pilot plant 58 mill grant from Innovation Norway. BIL Board approval 72 mill NOK
Technoport award for innovative environmental technology
BALI • PILOT
BALI SUMMARY •
BALI pretreatment process, enables good economy in a biorefinery
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A good solution for a limited number of biorefineries – market for lignin performance chemicals is not unlimited
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Borregaards strategy is to produce biochemicals, not biofuels