Second generation bioethanol: challenges and perspectives. Dr. Andre Koltermann, Group Vice President, Central R&D, Süd-Chemie AG

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1 Second generation bioethanol: challenges and perspectives Dr. Andre Koltermann, Group Vice President, Central R&D, Süd-Chemie AG Wien, October 15, 2009 Seite 1

2 For over 150 years Süd-Chemie observe sustainable growth by basic products and innovative solutions Generation of cleantech/greentech products: Biomass conversion Exhaust gas/air catalysis Lithium ion batteries CTL/GTL Access to pharma packaging and water treatment Acquisition of american-based Girdler/Chemetron Corp. (Catalysts) Industrial catalysts New products: bleaching earth and bentonite products Formation of BAG (today: Süd-Chemie AG) in Heufeld; Artifical fertiliser, Founding shareholder: Justus von Liebig Fertilizer Bleaching Earth/Bentonite Seite 2

3 Our challenges for a growing world Growing & aging world population Growing energy demand Climate/environment protection Globalization & developing markets The UNO assumes a yearly population growth of 78 Mio. people around 6.75 billion people are living on our earth Fossil resources are limited, e.g. crude oil should suffice for about 44 years The global ground level temperature increases during the last 100 years by about 0.7 C The statistically detectable global commodity trading increases about 27 times between 1948 und 2004 Seite 3

4 And our implementations Growing & aging world population Growing energy demand climate/-environment protection Globalization & developing markets - Health care - Nutrition - Drinking water - Quality of life - Growing energy demand - Limited fossil resources especially crude oil, natural gas - CO 2 -Emissions - Exhaust gas contamination - wastewater - Environmental legislation - More individual mobility - Increasing international freight transport volume - Growing prosperity Technologies for cleaning of edible oil, palm oil Protective and pharma packaging Wastewater treatment and drinking water preparation Bioethanol, Biorefineries, BTL, BTC (Biomass-to-liquid, -to-chemicals), CTL, CTC (Coal-to-liquid, -to-chemicals) GTL (Gas-to-liquid) Catalysis for energy efficient processes Exhaust air cleaning (e.g. N 2 O) Exhaust gas treatment (Dieselpartikelfilter, SCR, DOC) Technologies for low-emission processes (e.g. foundry) Best-in-class Cathode material for Li-Ion Batteries Technologies fuel cells "Creating Performance Technology" Seite 4

5 Süd-Chemie Group Global R&D presence Louisville/USA Needham/USA München/Germany Moosburg/Germany Heufeld/Germany Pohang/ Korea Toyama/ Japan Little Ferry/USA Novara/Italy Choisy-le-Roi/ France Jinhai/China Panjin/China Puebla/Mexico Belen/USA Cileungsi/ Indonesia Catalysts Adsorbents Biocatalysts & Biorefineries Nandesari/India Seite 5

6 Süd-Chemie Group Structure Group structure 2008 SÜD-CHEMIE GROUP Sales 1) : EUR 1,191.4 million, Employees 1)2) : 6,513 3) ADSORBENTS Sales: EUR million, Employees: 3,836 3 ) CATALYSTS Sales: EUR million, Employees: 2,271 3 ) Adsorbents and Additives Performance Packaging Catalytic Technologies Energy and Environment Foundry Products and Specialty Resins Water Treatment 1) business year ) including 406 employees in Central Functions (previous year: 334) 3) employees of joint ventures (50/50) allocated by quota Seite 6

7 Süd-Chemie Group Financial Statements Sales according to region 2008: EUR 1,191.4 million EUR million America: (18.9 percent) Australia/ Oceania: 8.9 (0.8 percent) Asia/ Middle East: (28.1 percent) Rest of Europe: (26.0 percent) Africa: 81.4 (6.8 percent) Germany: (20.2 percent) Seite 7

8 Süd-Chemie Green strategy SC develops system solutions for renewable feedstocks out of one hand (Biofuels and sustainable Chemistry). (White) Biotechnology Renewable Feedstock Products Heterogeneous Catalysis Adsorbents Separation SÜD-CHEMIE Technology Portfolio One-Stop-Shop! Seite 8

9 Value-adding from renewable feedstocks Biofuels Bioethanol 2G -process Renewable Feedstock Building Blocks E.g. Ethylene, Xylitol, Furfural, Lactic acid, Succinic acid, Citric acid, etc. Seite 9

10 Value-adding from renewable feedstocks Biofuels Bioethanol 2G -process Renewable Feedstock Building Blocks E.g. Ethylene, Xylitol, Furfural, Lactic acid, Succinic acid, Citric acid, etc. Seite 10

11 - Process for second generation bioethanol Cellulose Enzyme Glucose Bioethanol Lignocellulosic Feedstock Xylan Enzyme Xylose Bioethanol/ Chemicals Lignin Energy Seite 11

12 - Process for second generation bioethanol Lignocellulose Pretreatment Enzymatic Hydrolysis Fermentation Downstream Processing On-site Enzyme Production Bioethanol Seite 12

13 - Process for second generation bioethanol Seite 13

14 Crop straw Crop straw Crop straw Rice straw Crop straw Bagasse and corn straw World feedstock availability (lignocellulose) Lignocellulosic feedstock in different regions of the world In Mio. t Wheat straw Bagasse Asien Europa USA Indien Russland Brasilien Germany and France belong to the world TOP10 wheat producers. Rice straw Quellen: UN Food & Agriculture Organisation; FAO, Faostat, 2006, USDA, DoE Report, 2005 Seite 14

15 Perspectives: Bioethanol substitution potential EU Gasoline consumption 1 : 120 Mio. t Straw available (up to 60% of total) 2 : 180 Mio. t Conversion Straw to EtOH: 5:1 Fuel value EtOH : Benzin: 65% Gasoline equivalent: 23,5 Mio. t Gasoline substitution by Bioethanol 2G: 20% and more More potential by other agricultural by-products such as wood or corn stover. E.g. EU25: MiotOE EU25, sustainable, w/o imports 3 Major EU gasoline consumption could be substituted! Scources: 1: EUROSTAT; 2: TLL; 3: Biofuels in the European Union, A VISION FOR 2030 AND BEYOND Final draft report of the Biofuels Research Advisory Council, Biofuels in the European Union: An overview on the EU biofuels policy Bolter, I., Bacovsky, D., Wörgetter, M. (2007) Seite 15

16 - Process for second generation bioethanol Lignocellulose Pretreatment Enzymatic Hydrolysis Fermentation Downstream Processing On-site Enzyme Production Bioethanol Seite 16

17 cost [$/gal] Enzymes are key for low production costs 1,6 1,4 other 1,2 CAPEX 1 0,8 labor, supplies, admin ,6 0,4 enzymes other CAPEX labor, supplies, admin 0,2 feedstock 1.8 enzymes feedstock 0 by-products 3.3 by-products -0,2-0, Prospect Source: White Biotech Report, Mc Kinsey 2005 Seite 17

18 - Process for second generation bioethanol Lignocellulose Pretreatment Enzymatic Hydrolysis Fermentation Downstream Processing On-site Enzyme Production Bioethanol Seite 18

19 Enzyme development and optimization Fully automated ultra-highthroughput Screening (uhts) Seite 19

20 Automated uhts for biocatalysts Hardware Software Implemented for - strain development - biocatalyst development Seite 20

21 Pilot I plant for the sunliquid process Start installation 09/ 08, Completion 02/ 09, On stream since March 09 Enzymatic Hydrolysis - Saccharification Seite 21

22 - Process for second generation bioethanol Lignocellulose Pretreatment Enzymatic Hydrolysis Fermentation Downstream Processing On-site Enzyme Production Bioethanol Seite 22

23 Pilot I plant for the sunliquid process Pretreatment Seite 23

24 - Process for second generation bioethanol Lignocellulose Pretreatment Enzymatic Hydrolysis Fermentation Downstream Processing On-site Enzyme Production Bioethanol Seite 24

25 Pilot I plant for the sunliquid process Fermentation Downstream processing Seite 25

26 - Process for second generation bioethanol Lignocellulose Pretreatment Enzymatic Hydrolysis Fermentation Downstream Processing On-site Enzyme Production Bioethanol The sunliquid-process is a mature process validated in a pilot plant scale. Seite 26

27 sunliquid Demo plant Concept engineering Estimation of invest costs Screen Pilot II Seite 27

28 Planned scales Pilot I 2 t/a Pilot II 1 kt/a Production kt/a mechanical complete test runs start 02/2009 under planning Partnering ongoing Seite 28

29 Offers to our customers Experienced partner in the field of green chemistry System solutions for cellulosic bioethanol and green chemicals Complete technology portfolio from enzymes and strains via catalysts and adsorber to (bio)processing Adding value with green chemistry out of one hand! Seite 29

30 Contact: Dr. Andre Koltermann Tel: / Süd-Chemie AG Staffelseestr Munich Germany Seite 30

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