Strasbourg, M. Fröhling, F. Trippe, F. Trippe, F. Schultmann.

Transkript

1 Bewertung von Bioraffineriekonzepten Evaluation de concept de bioraffineries 1. Trinationale Konferenz: Nachhaltige Biomassenutzung am Oberrhein 1ère conférence trinationale : Utilisation durable de la biomasse dans le Rhin supérieur Strasbourg, INSTITUT FÜR INDUSTRIEBETRIEBSLEHRE UND INDUSTRIELLE PRODUKTION () Lehrstuhl für Betriebswirtschaftslehre, insbes. Produktionswirtschaft und Logistik M. Fröhling, F. Trippe, F. Trippe, F. Schultmann KIT Universität des Landes Baden-Württemberg und nationales Forschungszentrum in der Helmholtz-Gemeinschaft

2 Outline Background and motivation Characterisation of biorefinery concepts Assessment challenges Examples Conclusions 2 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

3 3 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

4 Background A plethora of material and energetic utilisations for biogeneous raw materials is currently under discussion and in development Expected advantages Reduction of climate relevant emissions Substitution of fossil raw materials Further positive effects along the value chain 4 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

5 Definition biorefinery A biorefinery is characterised by an explicitly integrative, multifunctional overall concept that uses biomass as a diverse source of raw materials for the sustainable generation of a spectrum of different intermediates and products (chemicals, materials, bioenergy/ biofuels), whilst including the fullest possible use of all raw material components. The by-products can also be food and/or feed. These objectives necessitate the integration of a range of different methods and technologies. German Federal Government (ed.): Biorefineries roadmap, Berlin, M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

6 Relevance of assessments in this context Research questions Are the new process chains in terms of sustainability advantageous (in comparison to existing bio-based supply chains based on fossil and renewable raw materials)? How can sustainability of the process chains be achieved? Which process chains are promising? Assessment To support concept and process development As a basis for decisions about funding policies As an objective basis for communication and discussion of the utilisation concepts Need for suitable techno-economic and ecological assessment methodologies Aim of this presentation Characterisation of the techno-economic and ecological assessment needs for biorefinery concepts Presentation of exemplary methods and applications 6 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

7 Outline Background and motivation Characterisation of biorefinery concepts Assessment challenges Examples Conclusions 7 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

8 Biorefinery concepts have to be regarded as bio-based supply chains Technical conversion processes Preparation and conditioning Primary conversion Secondary conversion Product upgrading Technical conversion as one step in a bio-based supply chain Raw material production Conversion Use End-of-life 8 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

9 Overview of possible utilisation pathways 9 M. Fröhling et. al., (Cherubini et al., 2009) Institut für Industriebetriebslehre und Industrielle Produktion ()

10 Characteristics of raw materials, their production and provision Natural environment influences Crop choice Yields Applicable machinery Feedstock variety Different feedstocks Varying composition Raw material production Composition of lignocelluloses Plant breeding So far aimed mainly as food, fodder or for energetic utilisation New crops through breeding or biotechnological modification Competition Direct: existing potentials Indirect: land use 100% 80% 60% 40% 20% 0% Hardwood Softwood Grasses + residues Other Cellulose Hemicell. Lignin (Puls, 2005) Limited storability and transportability 10 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

11 [kg CO 2 -Eq./kg oil] [ /t] [m²a/kg oil] Assessment of alternative raw materials for a vegetable oil biorefinery Dragonhead oil, linseed oil, crambe and erucic rapeseed oil in comparison to canola oil Estimation of biomass provision costs Provision costs Estimation of life cycle impacts Land use Conclusion: Disadvantages of alternative raw materials are caused mainly by lower yields Open questions: can lower yields be compensated through breeding and / or better raw material properties, e.g. other fatty acid patterns ,5 16,0 11,7 6,7 5,8 Dragon Drachenkopföl head Linseed Leinöl Crambe Krambeöl Erucic Erucarapsöl rapeseed 00-Raspöl 00-canola Dragon head Linseed Crambe Erucic rapeseed 00-canola Bereitstellungskosten Costs free plant (own frei calculations) Anlage (eigene Schätzung) Marktpreis Market price (fob.(fob Rotterdam, Rotterdam, Mittelwert average 2008/2009, 2008/2009, Quelle: data: USDA) USDA) frei Free Anlage, plant eigene (own calculations) Schätzung frei Free Anlage, plant LCI (lci Daten data: ecoinvent) aus Global warming potential 2,87 2,20 2,38 1,71 1,87 Dragon head Linseed Crambe Erucic rapeseed 00-canola 11 M. Fröhling et. al., frei Free Anlage, plant eigene (own calculations) Schätzung frei Free Anlage, plant LCI (lci Daten data: aus ecoinvent) (Meyer et al., 2011) Institut für Industriebetriebslehre und Industrielle Produktion ()

12 Characterisation of the technical conversion processes Input characteristics Feedstock (direct input factors): solid and liquid raw materials with volatile specifications Preparation and conditioning Primary conversion Secondary conversion Utilities (indirect input factors): enzymes, catalysts, solvents, energy carriers Product upgrading Process characteristics Technology: mechanical-physical, thermochemical, chemical and biotechnological processes Process operation: continuous, semi-continuous, batch Output characteristics Products: solid, liquid, gaseous and energetic products Joint production with variable coefficients Necessity of adequate process modelling 12 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

13 Example: Upscale using thermodynamic process simulation Gasification step in a synthesis gas biorefinery on the basis of straw (1.000 MW th ) Approach O2PUMP HEATER Simulation model (Aspen Plus) Data determination pilot plant & literature OXYGEN SLURRYIN INERT NTRLGAS DECOCALC CALCULAT OR PREHEAT DECOMP PARTOX WATER RAWSYN WGSBYPAS HEATX1 CONDHOT WGS CONDCALC CALCULAT OR WATERSCR CONDH2O CONDSEP MIXWGSBY ADJSYN BYPASS WETSYN SYNCOOL COOLSEP SYNDRY COOLCOND Q-DECOMP CSEP PRODUCTS H2OSEP CALCULAT OR C-LOSS QUENCH H2OSPLIT WETGAS ASHSPLIT QENCHH2O QUENCHCO Investigated configurations Feed composition in % (biomass/coal) Operating pressure (bar) Gasification agent (oxygen O 2, steam H 2 O) Product gas composition (H 2 :CO ratio) Results: Material and energy balance (here output side) and configuration data 13 M. Fröhling et. al., WETPROD Case 1 Case 2 Case 3 Case 4 Case 5 Case 6 Case 7 Case 8 100/0 100/0 100/0 10/90 100/0 100/0 100/0 10/ O 2 O 2 + H 2 O O 2 O 2 O 2 Case 1 Case 2 Case 3 Case 4 Case 5 Case 6 Case 7 Case 8 Syngas, H2 + CO (Nm3/h) 216, , , , , , , ,833 Usable heat (MW) Temperature level usable heat ( C) Slag (t/h) SLAG O 2 + H 2 O LIQCOOL O 2 O 2 1:1 1:1 2:1 1:1 1:1 1:1 2:1 1:1 (Trippe et al., 2011) Institut für Industriebetriebslehre und Industrielle Produktion ()

14 Characterisation of use phase and end-of-life phase Use phase Differences in product qualities between fossil and bio-based products (durability, colour, odour, function, ) No emission allowances for CO 2 necessary due to its biogeneous origin Less dependency on fossil raw materials Access to public funding Price increases possible Use End-of-life phase Cascade utilisation: Recycling at different quality levels with a final utilisation as energy carrier or for sequestration End-of-life 14 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

15 Logistical aspects Feedstock provision Biogenic raw materials accrue spread over large areas Transport Transport over large distances is often uneconomic and causes climate relevant emissions due to high water contents and low material densities Over proportional increase of transport costs with increasing amounts Due to economies of scale large plants are envisaged n I I0 I 0 : Investment at capacity 0 I: Investment at capacity [monetary units] n: scaling factor [-] Raw material production 0 [monetary units] Conversion Use End-of-life Trade-off between minimising transport costs and achieving economies of scale 15 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

16 Site boundary Logistical aspects (2) Decoupling of supply chains Spatially Temporal Raw material production Conversion Use End-of-life Preparation and conditioning Primary conversion Secondary conversion Product upgrading Location and network strategy Integration in existing production sites or networks Upstream, e.g. saw mills Downstream, e.g. integrated chemical production sites New production sites and networks Production units and service provider on site Power plants Road Terminals Rail Stations Pipe racks Energy production and distribution Vehicle cleaning service Water supply Logistic service Waste water ZAB Waste Disposal Road Fire brigade Security Security and emergency management Site coordination Site development Facility management Communication Medical Service Laboratory Road Rail National grid River Saale 16 M. Fröhling et. al., (VDI 6310) Institut für Industriebetriebslehre und Industrielle Produktion ()

17 [kg CO 2 -Eq. / GJ fuel] [kg PO 4 -Eq. / GJ fuel] Example: Assessment of logistics concepts for a synthesis gas biorefinery Results (excerpt) Cost minimal locations Wood residues - central Costs and transport load in the scenarios Scenario Wood residues central Wood residues decentralised Total costs [ /a] 17 M. Fröhling et. al., Production costs [ /l] Transport load [t km] Straw central Straw decentralised Wood residues - decentral Environmental impacts in the scenarios in comparison to conventional diesel fuel Global warming potential ,59-11,72 97,32-30,2-30,98 Wood residues - central Straw - central Conv. diesel 0,07 0,06 0,053 0,05 0,04 0,03 0,02 0,01 0,00 Eutrophication 0,061 0,050 0,052 0,019 *) inklusive Kraftstoffnutzung in PKW Wood residues decentral (10) Straw decentral (10) (Kerdoncuff, 2008) Institut für Industriebetriebslehre und Industrielle Produktion ()

18 Objective criteria Economic aspects Choice of suitable methods to assess new bio-based supply chains according to their state of development Raw material production Conversion Use End-of-life Ecological aspects Choice of relevant assessment methodologies Choice of functional unit Energy-based unit Mass-based unit Functional and qualitative equivalence Social aspects Allocation Consideration of multiple objective criteria 18 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

19 Genauigkeitsschwankung [±%] Uncertainties Data of the technical processes Raw material production Conversion Use End-of-life Raw material and utility prices 40 F Demand and revenues for products 25 E Further parameters 12 D C Zeit B A A Lieferangebote auf Festpreisbasis 19 M. Fröhling et. al., B C D E F Komplette Spezifikationen und Zeichnungen Detaillierte technische Daten ohne Zeichnungen Detaillierte Kenntnisse des Prozesses und der kennzeichnenden apparativen Leistungs- und Auslegungsdaten Kenntnis des Fließbildes und der Hauptbestandteile Kenntnis der Relation zu bekannten, ähnlichen technischen Ausführungen Institut für Industriebetriebslehre und Industrielle Produktion ()

20 Outline Background and motivation Characterisation of biorefinery concepts Assessment challenges Examples Conclusions 20 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

21 Conclusions Important role of assessment tasks for Process development Funding decisions Communication and discussion of the utilisation concepts Particularities of biorefinery concepts are given on all stages but may differ for different from concept to concept Consideration of particularities on all supply chain stages and for whole concepts Consideration of logistical issues Consideration of multiple objectives Consideration of uncertainties Tailored assessments necessary for the assessment purposes and supply chains 21 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

22 Thank you for your attention. PD Dr. Magnus Fröhling Karlsruhe Institute of Technology (KIT) Institute for Industrial Production () French-German Institute for Environmental Research (DFIU) Hertzstraße 16 D Karlsruhe Germany T: E: magnus.froehling@kit.edu 22 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

23 References Cherubini, F.; Jungmeier, G.; Wellisch, M.; Willke, T., Skiadas, I., van Ree, R., de Jong, E. (2009): Toward a common classification approach for biorefinery systems. In: Biofuels, Bioproducts and Biorefining, 3 (2009), 5, pp German Federal Government (ed., 2009): Biorefieneries Roadmap, Berlin. Kerdoncuff, P. (2008): Modellierung und Bewertung von Prozessketten zur Herstellung von Biokraftstoffen der zweiten Generation, Dissertation, Universitätsverlag Karlsruhe, Karlsruhe. Meyer, J.C.; Fröhling, M.; Schultmann, F. (2011): Integrierte Bioproduktion Produkt- und Prozessbewertung. Interner Zwischenbericht zum Forschungsprojekt Forschungsverbund: Integrierte chemisch-biotechnologische Herstellung von Synthesebausteinen auf Basis nachwachsender Rohstoffe in einer Bioraffinerie gefördert von der Fachagentur Nachwachesende Rohstoffe, Karlsruhe. Trippe, F.; Fröhling, M.; Schultmann, F.; Stahl, R.; Henrich, E. (2011): Techno-economic assessment of gasification as a process step within biomass-to-liquid (BtL) fuel and chemicals production. In: Fuel Processing Technology, 92 (2011) 11, S VDI-Richtlinie 6310: Gütekriterien für Bioraffinerien (Entwurf, Stand 5/2012). 23 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

24 Conceptual framework Natural, socio-cultural, legal, economic, and technical environment I. Determination of system boundaries, level of detail and basic configuration II. Modelling of material and energy flows (material and energy flow balancing, analysis, process simulation) Material and energy flows (feedstock, utilities, products, residues, emissions, energy) for the considered process configuration III. Assessment & planning Economic Ecological Scenario and sensitivity analyses 24 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion ()

25 Assessment of alternative raw materials for a vegetable oil biorefinery Dragonhead oil, linseed oil, crambe and erucic rapeseed oil in comparison to canola oil Investigation of possible raw materials for an oil plant biorefinery Raw material analysis: Determination of Chemical composition and Further properties of the oils Data determination from literature and field tests Cultivation conditions Usage of machinery and personnel Material flow model for dragonhead provision (Example Umberto) Material and energy balancing, e.g. Material and energy flow analysis 25 M. Fröhling et. al., Institut für Industriebetriebslehre und Industrielle Produktion () (Meyer et al., 2011)

26 Annual production costs [k /a] Example: Upscale using thermodynamic process simulation Gasification step in a synthesis gas biorefinery on the basis of straw (1.000 MW th ) Investment estimation using differientiated surcharge factors Results (excerpt) n FCI Fixed capital investment I ME 1 f i I ME Investment for installed main equipment i 1 components Estimation of annual production costs f i Ratio factor for direct/indirect capital investment i = 1...n C Produtcion FCI pa pm pt pi pwc CPersonnel CConsumables p a Annuity factor p m Percentage of FCI for maintenance p t Percentage of FCI for taxes p i Percentage of FCI for insurance p WC Interests on working capital C Personnel Labour costs [ ] C Consumables Material and energy flow costs [ ] vgl. (Peters et al., 2006) Case 1 Case 2 Case 3 Case 4 Case 5 Case 6 Case 7 Case 8 Configurations 26 M. Fröhling et. al., (Trippe et al., 2011) Institut für Industriebetriebslehre und Industrielle Produktion ()

27 Example: Assessment of logistics concepts for a synthesis gas biorefinery Investigated process chain Biomass (wet) Biomass Gasifi- Syngas Gas Drying Pyrolysis Slurry Syngas (dry) cation (raw) cleaning Synthesis Fuel. Investigation of scenarios Category Property Biomass Wood residues Straw Logistic concept Central integrated Decentralised preparation with ten preparation units Consideration as a capacitated warehouse location problem Objective function: Minimisation of decision relevant costs Min F = C + C + C + C + C + C + C 27 M. Fröhling et. al., PU PU PU FTU FTU FTU Biomass Transport variable fixed Transport variable fixed PU: Preparation unit, FTU: Gasification and synthesis unit (Kerdoncuff, 2008) Institut für Industriebetriebslehre und Industrielle Produktion ()

28 [kg CO 2 -Eq. / GJ fuel] [kg PO 4 -Eq. / GJ fuel] Example: Assessment of logistics concepts for a synthesis gas biorefinery Results (excerpt) Cost minimal locations Wood residues - central Costs and transport load in the scenarios Scenario Wood residues central Wood residues decentralised Total costs [ /a] 28 M. Fröhling et. al., Production costs [ /l] Transport load [t km] Straw central Straw decentralised Wood residues - decentral Environmental impacts in the scenarios in comparison to conventional diesel fuel Global warming potential ,59-11,72 97,32-30,2-30,98 Wood residues - central Straw - central Conv. diesel 0,07 0,06 0,053 0,05 0,04 0,03 0,02 0,01 0,00 Eutrophication 0,061 0,050 0,052 0,019 *) inklusive Kraftstoffnutzung in PKW Wood residues decentral (10) Straw decentral (10) (Kerdoncuff, 2008) Institut für Industriebetriebslehre und Industrielle Produktion ()