Pilot Project Rockstedt

(1)

Pilot Project Rockstedt

Decentralised

Production

of Bioethanol

Energetic

Process

Optimisation

Dr.-Ing. Gerhard Schories

ttz - Bremerhaven

(2)

1. Profile

ttz-Bremerhaven

Content

2. Pilot Project „Rockstedt“

3. Profile of the Distillery Rockstedt

and Previous R&D Activities

4. The Project

– Energetic Process

Optimisation

(3)

(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

(5)

ttz-Bremerhaven - Staff

Chemists and biologists

Food technologists

Chemical engineers

Agronomists

Environmental engineers

Process engineers

Mechanical engineers

Economists

Technicians

Trainees, students

About 100 employees, mostly engineers and

scientists fo different disciplines:

(6)

New products

&

innovative

processes

Convenience

products

Food safety

and analyitics

Sustainable use of

natural ressources

Enzyme

technology

New

ingredients

ttz-Bremerhaven - Activities

Water treatment

Recycling of

ressources

Biomass

Energy

efficiency and

renewables

Indoor air quality

(7)

Motto – Quality of Life

WATER

ENERGY

LANDSCAPE

MANAGEMENT

(8)

2. Pilot Project Brennerei Rockstedt

‘Holistic decentralised approach‘

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-PILOT PROJECT ROCKSTEDT

Holistic Decentralised Approach

Getreide

Bioethanol

Nutztierfutter

Dünger

CO

₂

neutral

CO

₂

CO

₂

Product

By-product

Cereals

Bioethanol

Animal feedstock

Fertiliser

CO

₂

neutral

CO

₂

CO

₂

slop

Closed loop

No wastes

(10)

General situation

Food supply in

developing

countries

Need to

reduce CO2

emissions

Rapid price

increase for

raw materials

Holistic Decentralised Approach

Increased

global food

demand

Limited land

availability

Climate

protection

goals

Limited fossil

fuel

ressources

Lack of

innovative

mobility

concepts

Bioethanol

(11)

General situation

Food supply in

developing

countries

Need to

reduce CO2

emissions

Rapid price

increase for

raw materials

Holistic Decentralised Approach

Increased

global food

demand

Limited land

availability

Climate

protection

goals

Limited fossil

fuel

ressources

Lack of

innovative

mobility

concepts

Bioethanol

SUSTAINABILITY ?

(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

(13)

3. Profile of ‘Brennerei Rockstedt‘

and previous activities

(14)

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)

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-2003-508169

• 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-2006-030348

• 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-2003-508174

(18)

4. The Pilot Project

Decentralised production and

utilisation of bioethanol from

renewable ressources

(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

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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..

(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.

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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).

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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

(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.

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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)

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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

(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 22019206) from the

budget of „Bundesministerium für Ernährung,

Landwirtschaft und Verbraucherschutz“ (BMELV).

Financial support: 83.782,00 €

(32)

Ongoing Activities – Accomplished Tasks

(33)

Ongoing Activities – Measurements and Calculations –

to Be Continued

• Operational measurements

• Determination of physico-chemical parameters:

¾ Density

¾ Specific heat

¾ Ethanol yield

• Mass and energy balances:

¾ Grinder

¾ Heat exchangers

¾ Hydrolysis

¾ Buffer tanks

¾ Distillation column

¾ Steam demand

(34)

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Recent Situation in Germany

9

9 Rapid

Rapid

increase

of

costs

for

raw

materials

(

wheat

:

from

ca. 160

€

/to

increase

to 240

-

250

250 €

€

/to)

9

9 Low

Low

market

demands

and

prices

for

Ethanol (5 %

blending

of

petrol

?

–

higher

blending

rates

postponed

)

9

9 E85 as alternative

E85 as alternative

fuel

not

yet

established

9

9 Intensified

Intensified

positive

bioethanol

promotion

as well as

consequent

law

enforcement

required

9

(36)

R&D activities of ttz-Bremerhaven

Continuous ethanol fermentation by means of MBR technology

•

• continuous

continuous

process

•

• higher

higher

product

yields

•

• low

low

energy

demand

•

• increased

increased

production

capacity

•

• optimum

optimum

substrate

utilistion

, no

waste

problem

•

• rejection

rejection

and

recovery

of

enzymes

possible

,

potential to

use

lignocellulosic

substrates

Die F

ö

rderung erfolgt durch das Land Bremen

aus dem

Ö

kologiefonds/F

ö

rderprogramm

Angewandte Umweltforschung und aus dem

Europ

ä

ischen Fonds f

ü

r regionale Entwicklung

2007

-

2013. EUROP

Ä

ISCHE UNION: Investition

in Ihre Zukunft

–

Europ

ä

ischer Fonds regionale

Entwicklung.

Start of

the

project

: 01.01.2008

enrichment

Membrane

filtration

water

yeasts,

enzymes,

substrate

ethanol

substrate

(37)

Thank you!

Dr.-Ing. Gerhard Schories

Technical Director

TTZ-Bremerhaven – Environmental Institute

An der Karlstadt 6

27568 Bremerhaven

Tel. 0471 9448 702

[email protected]

www.ttz-bremerhaven.de