1 Pilot Project Rockstedt Decentralised Production of Bioethanol Energetic Process Optimisation Dr.-Ing. Gerhard Schories ttz - Bremerhaven 4. European Bioethanol Technology Meeting Detmold April 2008 ttz Bremerhaven Umweltinstitut- An der Karlstadt 6 - D Bremerhaven Kontakt: Dr.-Ing. Gerhard Schories Technical Director
2 Content 1. Profile ttz-bremerhaven 2. Pilot Project Rockstedt 3. Profile of the Distillery Rockstedt and Previous R&D Activities 4. The Project Energetic Process Optimisation 5. Future R&D Activities
3 1. Profile ttz-bremerhaven
4 ttz-bremerhaven - Profile Your Ideas Need a Home - ttz Bremerhaven As a market oriented and independent provider of research services, we the team at Bremerhaven Technology-Transfer-Centre (ttz) give innovative ideas a home. We offer our clients from the business community, associations, ministries, district authorities and international organizations applied research, development and practical implementation in the following fields: Food technology and bio process engineering, analytics as well as water, energy and land use management at four locations in Bremerhaven. Clients from Germany, Europe and throughout the world have profited from our services for over 20 years
5 ttz-bremerhaven - Staff About 100 employees, mostly engineers and scientists fo different disciplines: Chemists and biologists Food technologists Chemical engineers Agronomists Environmental engineers Process engineers Mechanical engineers Economists Technicians Trainees, students
6 ttz-bremerhaven - Activities Indoor air quality Enzyme technology New ingredients Food safety and analyitics Convenience products New products & innovative processes Water treatment Energy efficiency and renewables Biomass Recycling of ressources Sustainable use of natural ressources
7 Motto Quality of Life LANDSCAPE MANAGEMENT ENERGY WATER Ina Küddelsmann
8 2. Pilot Project Brennerei Rockstedt - Holistic decentralised approach -
9 Holistic Decentralised Approach PILOT PROJECT ROCKSTEDT CO 2 CO 2 neutral Getreide Cereals CO 2 Product Fertiliser Dünger Bioethanol Animal Nutztierfutter feedstock By-product slop Closed loop No wastes
10 Holistic Decentralised Approach General situation Food supply in developing countries Rapid price increase for raw materials Need to reduce CO2 emissions Increased global food demand Limited land availability Bioethanol Lack of innovative mobility concepts Climate protection goals Limited fossil fuel ressources
11 Holistic Decentralised Approach General situation Food supply in developing countries Rapid price increase for raw materials Need to reduce CO2 emissions Increased SUSTAINABILITY Climate Bioethanol? global food protection demand goals Limited land availability Lack of innovative mobility concepts Limited fossil fuel ressources
12 Holistic Decentralised Approach The chances of success of the Rockstedt concept especially in comparison to large bioethanol plants depend on the following factors: costs of commodities energy supply and costs depreciation of investments other production costs (e.g. personnel) costs for waste disposal / revenues for side products subsidies and taxes
13 3. Profile of Brennerei Rockstedt and previous activities
14 Profile Distillery Rockstedt Profile: Agricultural distillery Annual production capacity: 60,000 hl Ethanol content in the product 85% About 100 plants in Germany with similar technological and economic conditions Pilot character for Germany Regional partners for commodities supply and products and by products utilisation
15 Profile Distillery Rockstedt Advantages: Cost effective ethanol production Loacl production of commodities marketing of producty and utilisation of by-products, respesctively Low transport costs due to decentralised approach Improved and facilitated monitoring of agricultural nutrient cycles regional economic value chain, local employment Sustainability!
16 Previous R&D Activities ETHAV and BIOKRAFT: Biogas CHP - Supply of electicity and heat for steam production and fermenter heating using biogas produced from regionally grown biomass
17 Previous R&D Activities BIOFERM: Advanced manufacture of industrial bio-products by activated fermentation process, Co-operative Research Project supported by the EC in the 6th Research Framework Programme, COOP-CT AGROBIOGAS: An Integrated Approach for Biogas Production from Agricultural Waste, COLLECTIVE RESEARCH Project supported by the EC in the 6th Research Framework Programme, COLL-CT PROBIO: Production of biogas and fertilisers out of wood and straw, Co-operative Research Project supported by the EC in the 6th Research Framework Program, COOP-CT
18 4. The Pilot Project Decentralised production and utilisation of bioethanol from renewable ressources - energetic process optimisation -
19 Objectives Overall Objective Overall objective of the Pilot project is to demonstrate that bioethanol from medium sized decentralised plants can compete with large industrial plants and can meet sustainability criteria. Key issue is the regional approach. Technical objectives 1. Energetic process optimisation the energy demand should be covered completely by means of locally produced renewable ressources - renewable ressources from the region - energy recovery, heat interconnections - local re-use of slops 2. Balancing and analysis of the Pilot Project, determination of real production costs and economic evaluation - mass and energy balances - CO2-balance for bioethanol from decentralised production - costs in comparison with large plants
20 Work Packages 1. Energetic process optimisation the energy demand should be covered completely by means of locally produced renewable ressources 1.1, State-of-art and determinbation of all relevant operating parameters. In order to determine all relevant operating factors and impacts, the follwing parameters have to be measured: mass flow of raw materials, water, slop, ethanol, steam and enzymes, heat flows and temperature levels, water treatment, etc.. A comprehensive process characterisation has to be carried out.
21 Work Packages 1. Energetic process optimisation the energy demand should be covered completely by means of locally produced renewable ressources 1.2 Measurements during plant operation Measurement of the following parameters during plant operation: Temperature, flow rates, pressures, pressure drop, electricity consumption, etc. The first set of data is supposed to be collected before optimisation, the second after implementation of optimisation measures. All main process steps will be investigated: - Pre-treatment -Fermentation - Distillation
22 Work Packages 1. Energetic process optimisation the energy demand should be covered completely by means of locally produced renewable ressources 1.3 Evaluation of data, energy and mass balances. Balancing of the following units: grinder, heat exchanger, storage tanks, fermenter, distillation column, gas motors, steam boilers. Determination of physico-chemical properties (density, viscosity, specific heat, starch/sugar content) of raw material, fermentation broth, slop.
23 Work Packages 1. Energetic process optimisation the energy demand should be covered completely by means of locally produced renewable ressources 1.4 Determination of the optimisation measures. All optimisations leading to an increased energy efficiency shall not negativle influence the production process. Savings potentials will be identified, heat interconnections and implementation of further heat-power-connections will be investigated. Process simulation will be applied to elaborate optimisation measures. 1.5 Energetic opmimisation of process steps and the entire process. Implementation of the results of task 1.4. Meeting teh process energy demand by biomass in general and bioethanol in particular (autarcic supply situation).
24 Work Packages 1. Energetic process optimisation the energy demand should be covered completely by means of locally produced renewable ressources 1.6 Preparation / update of documentation. After introduction of improvements a new / updated technical documentation will be prepared (P&I diagrams, process flow sheets, specific units of the general arrangement (3D Autocad of important details) 1.7 Evaluation and justification of applied measures, definition of future tasks, reporting. After implementation of proposed optimisation measures, operational measurements and balance calculations have to be repeated in order to finally evaluate the practical impacts of the process optimisation, i.e. re-calculation of the process simulation and comparison. Based on the results, future tasks will be defined. The findings will be summarised in a report.
25 Arbeitspakete 2. Overall balancing of the decentralised concept of Pilot Project Rockstedt, economic evaliation, determination and justification of production costs 2.1 The overall concept for decentralised bioethanol production in medium sized plants will be investigated. Definition of balance sections and data collection (local energy supply, bioethanol production, slop treatment and re-use). The local impact of the decentralised concept will be investigated. 2.2 Balancing of mass flows and energy supply chain. Determination of data for raw materials logistics and water supply / demand. Set-up of the entire energy supply concept incl. electricity demand, steam consumption, electricity and heat supply by means of a biogas plant.
26 Arbeitspakete 2. Overall balancing of the decentralised concept of Pilot Project Rockstedt, economic evaliation, determination and justification of production costs 2.3 Economic evaluations. The decentralised approach for bioethanol production will be technically and economically evaluated. Actual production costs will be determined. Costs for raw materials, investment depreciations, personnel, maintenance, and energy (regional prices for electicity and natural gas, as well as biogas) will be considered, as well as revenues for slops re-use. 2.4 Environmental impacts of the regonal concept. Determination of local environmental impacts by the decentralised concept, especially the local mass balance, of the pilot project, determination of weak points, proposal of improvements. Particular attention will be paid on the impact on agricultural growth of the raw material (nutrients, soil quality, etc.) and the utilisation of by-products (animal feedstock, fertiliser)
27 Work Packages 2. Overall balancing of the decentralised concept of Pilot Project Rockstedt, economic evaluation, determination and justification of production costs 2.5 Re-use of by-products and residues. The by-products and residues shall be locally re-used as animal feedstock, fertiliser and co-substrate for biogas production, respectively. Analysis and optimisation of slop logistics, handling (dewatering), water treatment for process integrated re-use. Highlighting the pilot character of the project. 2.6 Comparison Pilot Project Rockstedt with a large industrial plant. All technical and economic results of the decentralised concept for bioethanol production will be compared to a large industrial plant. Evaluation parameters will be: production costs, energy consumption, CO2 balance, by-products and residues utilistaion.
28 Work Packages 2. Overall balancing of the decentralised concept of Pilot Project Rockstedt, economic evaliation, determination and justification of production costs 2.7 Conclusions and reporting. Conclusions, proposal for further technical improvements, determination of future R&D activities, final report. 3. Project Management - Coordination of tasks - Monitoring of performance -Reporting
29 Gantt Chart Milestone Milestone 1: Energetic process optimisation accomplished Milestone 2: Blancing and evaluation completed Milestone 3: Project successfully completed
30 Consortium Distillery Rockstedt Energetic optimisation of unit operations and the entire process, balancing and optimisation, local marketing of bioethanol and the by-products, dissemination activities. J.H.K. Anlagenbau und Services GmbH, Bremerhaven Support of energetic process optimisation, technical modifications, dissemination activities. ttz-bremerhaven, Environmental Institute Energetic optimisation of unit operations and the entire process, overall balancing and evaluation, dissemination activities, coordination
31 Aknowledgement The project is funded by Fachagentur für Nachwachsende Rohstoffe (FKZ ) from the budget of Bundesministerium für Ernährung, Landwirtschaft und Verbraucherschutz (BMELV). Financial support: ,00 Project duration:
32 Ongoing Activities Accomplished Tasks P&I Diagram
33 Ongoing Activities Measurements and Calculations to Be Continued Operational measurements Determination of physico-chemical parameters: Density Specific heat Ethanol yield Mass and energy balances: Grinder Heat exchangers Hydrolysis Buffer tanks Distillation column Steam demand
34 5. Outlook
35 Recent Situation in Germany Rapid increase of costs for raw materials (wheat: from ca. 160 /to increase to /to) Low market demands and prices for Ethanol (5 % blending of petrol? higher blending rates postponed) E85 as alternative fuel not yet established Intensified positive bioethanol promotion as well as consequent law enforcement required Development of more efficient and sustainable processes
36 R&D activities of ttz-bremerhaven Continuous ethanol fermentation by means of MBR technology continuous process higher product yields low energy demand increased production capacity optimum substrate utilistion,, no waste problem rejection and recovery of enzymes possible, potential to use lignocellulosic substrates Die Förderung F erfolgt durch das Land Bremen aus dem Ökologiefonds/Förderprogramm Angewandte Umweltforschung und aus dem Europäischen Fonds für f r regionale Entwicklung EUROPÄISCHE UNION: Investition in Ihre Zukunft Europäischer Fonds regionale Entwicklung. Start of the project: : substrate Membrane filtration enrichment ethanol yeasts, enzymes, substrate water
37 Thank you! Dr.-Ing. Gerhard Schories Technical Director TTZ-Bremerhaven Environmental Institute An der Karlstadt Bremerhaven Tel