The sunliquid Process: Bringing New Proven Solutions for ... · along the ethanol production chain...

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Bio World Congress 2017

Montreal, Canada

Clariant Group Biotechnology - July 25, 2017

The sunliquid® Process:

Bringing New Proven

Solutions for Commercial

Cellulosic Ethanol Production

Bio World Congress 2017, Montreal, Canada, Clariant Group Biotechnology - July 25, 2017

Clariant at a glance

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Business AreasNet result 2016 (CHF m)

from continuing operations

Sales 2016 (CHF m)


5847 263 4

17442EBITDA 2016 (CHF m)

before exceptionals

15.2%887EBITDA margin 2016

before exceptionals

140 in 53companies countries Employees 2016

A GLOBALLY LEADING COMPANY IN SPECIALTY CHEMICALS


The sunliquid® process for cellulosic ethanolHIGH PERFORMANCE TECHNOLOGY PACKAGE

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Best in Class Technology

The only validated integrated technology solution

Clariant: your committed partner for commercialization


Commercially Best in ClassFULLY INTEGRATED SUNLIQUID® PROCESS

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The chemical-free mechanical and

thermal pre-treatment enables an optimal

hydrolysis. Purification steps are

unnecessary and makes for a safer and

more environmentally friendly process.

Through the process integrated enzyme

production costs can be reduced to a

minimum. Enzymes are produced exactly

when and where needed, there are no

costs for logistics or formulation and no

dependence on external suppliers.

Clariant can quickly adapt enzymes to

new feedstock and process conditions.

This achieves a most efficient hydrolysis

with maximum yields and makes the

process flexible for different boundary

conditions.

The organism used for fermentation is

highly optimized and able to

simultaneously ferment both C5 & C6

sugars in a one-pot reaction. Thus the

ethanol yield increases by 50% compared

to only C6 fermentation.

Integrated

Enzyme

Production


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Overall chemicals savings of up 50 %

(~0.11 USD/gal)

Using only standard equipment from Paper

and Pulp industry

Risk Mitigation on chemical handling and

up-scaling

competitors

+50%

sunliquid

Clariant pre-treatment offers lower CAPEX, reduced OPEX and mitigates risks

Commercially Best in ClassCHEMICAL-FREE PRE-TREATMENT1

CHEMICAL COST COMPARISON CHEMICAL-FREE PRE-TREATMENT BENEFITS


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Commercially Best in ClassINTEGRATED ENZYME PRODUCTION1

ENZYME COST COMPARISON* INTEGRATED ENZYME PRODUCTION BENEFITS

Pre-treated biomass as source

No enzyme formulation & stabilization

No Transport

Advanced enzyme performance through

feedstock & process specificity

Ensures flexible on-site supply, continuous

performance improvement, and cost efficiency

* includes all operating and capital cost, but does not include transport cost for offsite enzymes which will further increase costs

SOURCE: “Integrated enzyme production lowers the cost of cellulosic ethanol” by Eric Johnson http://onlinelibrary.wiley.com/doi/10.1002/bbb.1634/full

Offsite

-23%

Onsite

-52%

Integrated

http://onlinelibrary.wiley.com/doi/10.1002/bbb.1634/full


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Commercially Best in ClassFEEDSTOCK & PROCESS-SPECIFIC ENZYMES1

SUGAR YIELD COMPARISON SUNLIQUID® ENZYMES BENEFITS

Feedstock and process specific enzymes show

superior performance

Higher sugar yields (>90%) ensure overall

efficiency of process

Optimal enzyme loading* leads to

approaching the theoretical yield

sunliquid ® offers highest performance &

maximum yields

* Enzyme Loading: enzyme per substrate in %

Performance at

ideal enzyme

loading*

Theoretical

yield (100 %)90%

78%

Commercial enzymes

sunliquid enzymes


Commercially Best in ClassECONOMIC BENCHMARKING

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Integrated enzyme production: no enzyme

supply cost and exposure

Highest yields per feedstock employed

through Clariant’s advanced, feedstock

specific enzymes and yeast

Chemical-free pre-treatment: reduced overall

chemical costs

Competitive to 1G ethanol and most

competitive amongst

2G ethanol technology providers

COST FOR DIFFERENT TECHNOLOGIES

Total costs per l EtOH incl. 10 year-depreciation

Cost estimates for different technologies

MAJOR COST AND PERFORMANCE BENEFITS

Top Competitor A

Top Competitor B

Top Competitor C

Top Competitor D

Top Competitor E

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sunliquid®

1G ethanol price


The only validated integrated technology solutionADDRESSING TECHNICAL ISSUES OF THE INDUSTRY

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Only very few tons producedBuilt commercial scale plants

?

What are known technical issues of

the industry?

Biomass transportation within plant

(e.g. clogging, abrasion …)

Specific & custom-developed

equipment used for pre-treatment

Process steps not harmonized to each

other

STATE OF THE INDUSTRY

Optimal process established after

performance testing of various

components & materials

Pre-treatment process designed using

commercially established and proven

equipment

From the beginning all process steps

were co-developed towards a fully

integrated solution

Solutions

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The only validated integrated technology solutionTHE SUNLIQUID® PRE-COMMERCIAL PLANT

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~ 4 Start of operation at

pre-commercial plant

1,0002012t/a output of ethanol

~ 4,500 t/a feedstock ** (cereal straw, corn stover, sugarcane

bagasse & others)

Years confirmation of

commercial-scale design

up to


The only validated integrated technology solutionPROVEN PERFORMANCE RUNS

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4 years of performance runs at pre-

commercial scale plant on different feedstock

Successful conversion of 45 containers of

sugarcane bagasse and straw from Brazil

Best process conditions were optimized and

defined particularly with Pre-Treatment

Extensive experience in handling of

feedstock variations in quality and

composition

Equivalent to up to 300 liter Ethanol per ton of

dry bagasse

Front-end feedstock loading of bagasse and

straw validated with know-how developed on

quality control

Successful and stable fermentation with

yeast recycling that included “wild type yeasts”

Ethanol fermentation yield of 48 % with

Clariant’s proprietary yeast of a theoretical

max of approximately 50 %

95 % sugar recovery in solid-liquid separation

Dry lignin cake was obtained and

successfully burned in CHP plant (both

fluidized bed and grate boilers)

Vinasse used in fertilizer field tests

PERFORMANCE RUNS KEY ACHIEVEMENTS


The only validated integrated technology solutionSUNLIQUID® ETHANOL COMMERCIALLY DEPLOYED

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APPLICATION AS CAR FUEL APPLICATION AS CLEANING AGENT

− sunliquid® cellulosic ethanol from straw

replaces 100 % of conventional ethanol in

Frosch® Multisurface-Cleaner (by Werner &

Mertz)

− World’s first cleaning solution with cellulosic

ethanol

− Gasoline-Ethanol blend containing 20 %

cellulosic ethanol from Clariant’s pre-

commercial plant was tested in Mercedes’ fleet

− Test showed attractive environmental profile

− Today’s vehicles can already use E20 blends


The only validated integrated technology solutionSUNLIQUID® ETHANOL COMMERCIALLY DEPLOYED

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APPLICATION AS TRUCK FUEL

- Since its implementation, the partnership with

Scania for the ethanol-powered trucks used at the

Clariant Suzano Brazil plant has reduced CO2

emissions by approximately 90%

- The ethanol fuel used is manufactured with the

Master Batch ED 95 additive produced by Clariant

in Brazil

- The Ecotrucks, as they are known, started using

second-generation ethanol produced from

sugarcane bagasse using Clariant's sunliquid®

technology


Your committed partner for commercialization A GLOBALLY LEADING COMPANY IN SPECIALTY CHEMICALS

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Business AreasNet result 2016 (CHF m)


Sales 2016 (CHF m)


5847 263 4

17 442EBITDA 2016 (CHF m)

before exceptionals

15.2%887EBITDA margin 2016

before exceptionals

140 in 53companies countries Employees 2016

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Your committed partner for commercialization GROUP BIOTECHNOLOGY

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Munich R&D Center

− Since 2006

− 118 employees

− Lab and office space: 6,500 m²

− Pilot plant since 2009

− Over 15 different feedstock

tested on pilot-scale

Straubing pre-commercial plant

− Since 2011

− 22 employees

− Area: 2,500 m²

− Wheat straw, corn stover, and

sugarcane bagasse and straw

converted to Ethanol

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PRE-COMMERCIAL

PLANT OPERATIONAL

Capacity 1,000 t/a

Ethanol

Validation on wheat

straw

2012 20152013 20162014

FEEDSTOCK VALIDATION

Corn stover & sugarcane

bagasse

ISCC CERTIFICATION OF

PLANT

PROCESS DESIGN PACKAGE

For commercial-size plants

E20 FUEL TESTING

With Mercedes Benz &

Haltermann

Your committed partner for commercialization SUNLIQUID® – EN ROUTE TO COMMERCIALIZATION3

PERFORMANCE RUNS

With sugarcane residues

(bagasse, tops & leafs)

With wheat & barley straw

GERMAN INNOVATION

PRICE

for Climate &

Environment (IKU)

COOPERATION WITH

WERNER & MERTZ

sunliquid® ethanol in

cleaning supplies


Your committed partner for commercialization PROCESS DESIGN PACKAGE

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Comprehensive

process design

Modular concept

Standard, proven

hardware

Technological

blueprint

for 50.000 to 150.000

metric tons of

cellulosic ethanol

production

For a 50 kt/a plant, a footprint of approx.

14–18 acres (5.5–7.5 ha) is required

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Your committed partner for commercialization OFFERING A COMPREHENSIVE PACKAGE

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Integrated Technology Package:

Integrated process technology package including all steps

along the ethanol production chain

Starter cultures for proprietary process-integrated enzyme

production

Starter cultures for the proprietary fermentation organism which

converts C5 and C6 to ethanol

Energy efficient design to ensure overall cost efficiency

Service Package:

Develop project customized to specific needs of client

Process Design Package to provide technical specifications

and input for engineering

Testing of customer-specific feedstock in our pre-commercial

plant and pilot plant

Support for feedstock logistics and sourcing, off-taking and

regulatory affairs

Training of customer employees in pre-commercial plant


sunliquid®: high performance technology packageBENEFITS IN A NUTSHELL

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Commercially Best in Class

The only validated integrated technology solution

Clariant as your committed partner for commercialization

Fully integrated process ensures cost and performance efficiency

Most competitive amongst 2G ethanol technology providers

Problems seen in the industry tackled and solved

True and diligent technology validation through performance runs at pre-commercial plant

Global network and outreach

Offering a comprehensive package around technology and services


Commercial site location characteristics for potential licensors

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Feedstock 1 (corn, wheat, sugarcane, rice)

Straw

Feedstock 2

Bagasse

Yearly feedstock dry tons

~250,000

Feedstock Products

Main product

~50,000 tEthanol

Side product

~50,000 tVinasse (dry)

Side product

~100,000 tLignin (dry)


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Mandate adopted

Mandate proposed

Discussion favourable to 2G

Non EU

ILUC decision creates market for advanced biofuelsStatus of ILUC implementation in the EU-28

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* based on energy consumption in transport Eurostat 2015 of 359 mtoe, 0,8 tEthanol/toe, 50kta plant size

** Mandate in France includes includes molasses and C-starch

1 plants

2-5 plants

6-20 plants

>20 plants

**

• non-binding target 0.5% per 2020 adopted

• binding target 3,6% per 2030 proposed - binding

EU target for adv. biofuels will be implemented,

currently volumes & timing unclear.

0,5% advanced biofuels corresponds to a

potential of 45 advanced biofuel plants in

Europe*

Germany adopted its climate protection plan for 2050

with GHG reduction targets for the transport sector. The

German gov. recognizes adv. biofuels as one important

solution to curb emissions from transport sector in

addition to electro mobility.

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Montreal, Canada


GHG profile of sunliquid®

cellulosic ethanol technology


Sunliquid cellulosic ethanol is non-waste technology and with GHG savings over 95%

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Production of Ethanol from Wheat-straw (steam from straw CHP) (no allocation of agricultural cultivation) Version 3 - Public

Overview Results

All results in Non- allocated Allocation Allocated Total Allocation factors Emission reductiong CO 2,eq / MJ Ethanol results factor results Ethanol plant Fossil fuel reference (petrol)

Cultivation eec 0.0 100.0% to ethanol 83.8 g CO2,eq/MJ

Cultivation of wheat-straw 0.00 100.0% 0.00 0.0% to lignin GHG emission reduction

Processing ep 1.3 95.4%

Ethanol plant 1.34 100.0% 1.34

Transport etd 2.5

Handling & storage of wheat straw 0.16 100.0% 0.16

Transport of wheat straw 0.82 100.0% 0.82 Calculations in this Excel sheet……

Transport of ethanol 1.10 100% 1.10

Filling station 0.44 100% 0.44

Land use change el 0.0 100.0% 0.0 0.0

esca + eccr + eccs 0.0 100% 0.0 0.0

Totals 3.9 3.9 As explained in "About" under "Inconsistent use of GWP's"

follow JEC calculations by using GWP

values 25 for CH4 and 298 for N2O

strictly follow the methodology as given in

Directives 2009/28/EC and 2009/30/EC

GHG savings 95%

Non-waste technology and energy self-sufficient

GHG savings of 95%

• Chemical free pretreatment

• Water recycling >90%

• No waste solid, water and gas

• All by-products with high value and usage without complicated downstream process

• Energy self-sufficient

ConfidentialPublic


sunliquid® is certified as sustainable under high German standard

ISCC certification

Clariant certified the Straubing demonstration plant

according to the ISCC-EU scheme (International

Sustainability and Carbon Certification)

Demonstrating the sustainability of the production and

management system so that the produced cellulosic

ethanol can be credited towards the target of the RED

(EU Renewable Energy Directive 2009/28/EC)

High GHG savings of sunliquid® confirmed making it

the most sustainable biofuel on the market

ConfidentialPublic

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Montreal, Canada


Sunliquid®

Derivatives Platform


Cellulosic

Ethanol

sunliquid® is the ideal technology platform for highly sustainable bio-based products

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sunliquid® sunliquid®

Catalytic conversionsunliquid®

Sugar platform standalone

Development opportunities for

biobased products

Extensive know-how in

biocatalysis, strain optimization

and heterogenous catalysis

Biotechnology

Catalytic conversion

BiotechnologyBio-based

chemicals

Catalytic

conversionCellulosic

Sugars

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Clariant’s sunliquid® Cellulosic Ethanol Links with Partner Scientific Design’s Catalytic C2-Technology

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EthanolEthylene

Key facts about Scientific Design

50:50 Joint Venture between Clariant and SABIC

Licenser of Ethylene Oxide/Ethylene Glycol Technology (SD awarded ~80% of non-captive licenses since 1980 with

30 licenses since 1990)

Licenser of alcohol dehydration technology (SD awarded two ethanol-to-ethylene and six ethanol to EO/EG licenses

since 2006)

Technology integration study has been completed between sunliquid technology & SD downstream conversion (including site retrofit and integration)

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Sunliquid Sugar platform

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FeedstockPre-

TreatmentHydrolysis

Purification(optional)

ConcentrationFermentation (by Clariant customers)

Integrated

Enzyme

Production

Lignin

Feedstock and process

specific enzymes

Chemical-free

pre-treatment

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The sunliquid® sugar platform opens access to a large variety of biobased chemicals

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Cellulosic

sugars

Alcohols

Organic acids

– Thanks to the flexible process design, cellulosic sugars can be generated as an

intermediate product within the sunliquid® technology platform

– Specifications can be adjusted to the need of the added downstream processing.

Enzymes

Fatty acids

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sunliquid® cellulosic sugars are a viable substrate for different fermentation applications

Proof of concept: Validation of suitability of sunliquid® hydrolysate in case studies:

- Growth of production strains could be proven for several different applications

- Good performance compared to synthetic medium

- Flexible process strategies offer access to tailor-made sugar solutions

- High optimization potential through process flexibility and strain development

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Alcohols Organic acids EnzymesFatty acids

synthetic reference*

sunliquid® hydrolysate

* synthetic reference = pure glucose and xylose in water. Additional nutrients added where necessary for fermentation protocol.

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sunliquid® sugars can be optimized for a wide range of fermentations

– There are five main product groups present in sunliquid® sugar solutions:

– Depending on the specifications needed for each fermentation process, the solution

can be optimized by different means to ensure premium performance:

- Feedstock

- Process conditions

- Concentration

- Established conditioning methods

– Quality specifications vs. economics is the key aspect

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Salts

(Na+, K+, Cl-…)

Organic acids

(Formic,

acetic,…)

Furan

derivatives

(HMF,

Furfural,…)

PhenolsSugars

(C6, C5)

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For further information please contact:

Martin A. Mitchell

Global Business Development Manager

Group Biotechnology, Biofuels & Derivatives

Clariant Corporation

309 Court Avenue

Des Moines, Iowa 50309 USA

Phone: +1 515 699 8518

E-mail: [email protected]

For more information on sunliquid® technology visit www.sunliquid.com

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mailto:[email protected]

http://www.sunliquid.com/

The sunliquid Process: Bringing New Proven Solutions for ... · along the ethanol production chain...

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