Fraunhofer Institute for Chemical Technology ICT. Rainer Schweppe. Environmenatal Engineering

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1 Fraunhofer Institute for Chemical Technology ICT Rainer Schweppe Environmenatal Engineering

2 Environmental Engineering Reation ans separation techniques Platform chemicals and monomers from sustainable raw materials, industrial biotechnology, mechanical and thermal separation processes Polymers and additives Polymer synthesis, chemical synthesis of materials, purification, impregnation and coating Recycling and waste management Recycling of plastics and material compounds, emission-optimised materials and components, analysis of emissions and waste material Environmental simulation and product qualification Climate, vibration and shock test, corrosive gas test and test of chemical stability, solar simulation and thawing Folie 2

3 Reaction technology rganic synthesis of platform chemicals from sustainable raw materials ( bio-refinery ) such as wood / straw sugars oils / fats synthesis capacity up to pilot scale High-pressure technology for synthesis for extraction purposes in various decomposition processes Pressure Folie 3

4 Separation technology Thermal separation processes retification distillation film evaporation falling film evaporation Extraction solid/liquid; liquid/liquid continuously or in batches with supercritical fluids Membrane processes from microfiltration to reverse osmosis dead-end and cross-flow Folie 4

5 Hydrothermal Synthesis of Nano oparticles Conditions Near- or supercritical water Up to 300 bar; C Low solubility of iron salts Precipitation it ti of nanoparticles Possibility to modify surface with organic molecules in situ rganic (l) Metal salts Products in supercritical water hematite (Fe 2 3 ) Me z+ (aq) Supercritical water H 2 (l) Me z/2 (s) Magnetite (Fe 3 4 ) Folie 5

6 Polymers based on renewables Monomers Process Development and pilot synthesis of chemicals and monomers from renewables Chemical transformation of oils and fats Phenolics (lignol), carbon diacids and -alcohols from wood (German lignocelluloses bio refiner ry) Polymers Development and synthesis of novel bio-polymers Polyurethane: new formulations with bio polyols Thermoplasts (Polyfuranester and Nylons X.18) Thermoplastic elastomers (e.g. TPE-CoPA, TPE- CoPU) Folie 6

7 Polymers und additives Biopolymers from 2-furancarboxylic acid polyamides polyesters R H N + CH N R 2 2 x H 2 R R H CH + 2 x H * N N CH 2 * x n * CH 2 * x n Bio-based flame retardants reactive epoxyphosphonate p (from fungi) Me P Me Na + Na + Me P Me Folie 7

8 Renewable e e Resources for Polyurethanes es (flexible & rigid, TPU, CASE) Synthesis of Polyols from renewables for PU foams Synthesis of P-rich Polyols from renewables E_2009e.ppt UE Folie 8

9 Renewable Resources for Polyurethanes Glucose Hydrothermolysis Reductive H-CH 2 CH Hydrothe rmolysis H H 5-HMF 5-Hydroxymethylfurfural H H DHD 2,5-Dihydroxydioxane H H H H H H H H H H Mannit Sorbit Polyalcohols Comp. stress (kpa) Compressive strength _ _ rise for reference #1 and formulation # Folie % compression Reference #1 Formulation #3

10 Synthesis of 2,5-Furandicarboxylic acid (FDCA) xidation of 5-Hydroxymethylfurane in water Catalyst: Pt, Pd Yield FDCA > 98 % Problem: Condensation of 5-HMF H H H H H H H H 5-(hydroxymethyl)furan-2-carbaldehyde 5-(hydroxymethyl)furan-2-carboxylic acid 5-formylfuran-2-carboxylic acid furan-2,5-dicarboxylic acid Folie 10

11 Furfural platform 5-Hydroxym methylfurfural Furandicarboxylic Acid 2,5-Dihydroxy ymethylfurane 25-Diaminomethylfurane 2,5 Polyesters, Polyamides, Thermoplastic Elastomers Polyesters, Polyurethanes Polyamides, Polyurethanes E_2009e.ppt UE Folie 11

12 FRAUNHFER Center for che emical and biotechnological processes CBP, Leuna E_2009e.ppt UE Folie 12

13 Challenges the feedstock utilization challenge Integration in existing manufacturing environments, e.g., for food- and feed production, pulp&paper industry, utilization of waste- and sidestreams. (Step 1) Biomass Food & Chemistry Energy Feed Successive, multiple l utilization necessary Fertilizer Utilization of non-food biomass in Bioreferies, integrated in chemical, energy and fuel production. (Step 2) Folie 13 Sources: JSW Consulting, VCI, InfraLeuna

14 Challenges the process-development and scale-up challenge Feedstock Conditioning Value generation Products* Fatty acid products Vegetables oils and fats Production of value-added Chem. building blocks Sugary feedstock Starch-containing feedstock Cellulosic feedstock Direct sugarification Multi-stage sugarification chemicals by biocatalysis and fermentation Conversion of value-added materials via physical, Separation of value-added products and Aromatic compounds lefin building blocks Industrial Enzymes Lignocellulose Processing, Fractioning chemical and purification Gases, H 2, C, C 2 feedstock biocatalytical Complex chemicals Aquatic biomass ptimization Cultivation, growth approaches Residue treatment thers Folie 14

15 Solutions At the Fraunhofer Process Center CBP in Leuna state-of-the-art facilities and equipment will be available for the development and scale-up of industrial biotech pro ocesses Biotransformation and dbioprocess- development Productprocessing and Process integration Industrial Bioproductmanufacture and Biotechnology -characterization within Bioprocessund Bioproductevaluation Center for Chemical-Biotechnological Processes - CBP Feedstock selection ect and -conditioning Fraunhofer Processsimulation and Enzyme automating screening, design & optimization 1 L 10 m³ Folie 15 Lab Lab II Pilot-scale Scale-up and process development Chemical site Leuna

16 Start-up projects Several approaches for the utilization of renewable resources are being explored in Leuna by Fraunhofer ils + Fats Lubricants, Surfactants, Amines, etc. Chemical building blocks from Lignocellulose lefins (e.g., Ethylene) Enzymes as Catalysts Microalgae and C 2 utilization Lign nocellulose Straw, Wood Starch, Sugar C 2, other Project A* Project B** Project C** Project D* Project E** thers: Biogas, Hydrothermal gasification Supported by German Government BMELV BMBF BMU Folie 16

17 The Fraunhofer CBP Technical area with 7 modular units E_2009e.ppt UE Utilitie s Media ffices/laboratory Folie 17 ffices

18 The Fraunhofer CBP With the CBP, the integrationn of industrial biotech into chemical manufacturing will be accelerated Center operational in 2012 pen to all interested parties wned and operated by Fraunhofer-Gesellschaft Laboratory- to pilot-scale process dimensions State-of-the art technologies and equipment: feedstock- pretreatment, conversion, down-stream processing Reduction of scale-up time and capital Integration of activities into chemical manufacturing network Subsidies for subsequent investments Nucleus and role model for industrial spending for participants available biotech activities Several product driven development pr rojects under-way Folie 18

19 Kontakt Gerd Unkelbach Fraunhofer center for chemical - biotechnological processes Postfach Leuna Phone ++49(0) )721/ gerd.u nkelbach@ict.fraunhofer.de E_2009e.ppt UE Folie 19