Prof' M' M' Sain

1

Bio-refinery of Natural Fibre in Green Economy

• Prof. M. M. Sain
• Toronto, Canada
• September 10, 2009

2
Fibre Total- A Global Concept
Extracting the FULL potential of WHOLE Fibre
.the ultimate, economical, and sustainable
approach
Matt Carr.Director, Industrial Environmental
Section.Biotechnology Industry Organization.March
23, 2006. http//www.bio.org/ind/presentations/Cle
anTech.pdf
3
General Scheme Lignocellulose
Feedstock Biorefinery
Michael Kamm and Birgit Kamm. 1st International
Biorefinery Workshop. U.S. DEO and European
Commission July 20 and 21, 2005, Washington D.C.
http//www.biorefineryworkshop.com/presentations/K
amm.pdf
4
Fibre Bio-refinery
Pathways and Opportunities
Products
Operation Processes
Pulp/Paper Fuels Energy Bio-products Base
Chemicals Food/feed Non-food products
Gasification/Combustion
Gas/Liquid Fermentation
Trans-esterification
Enzymatic conversion
Chemical synthesis
5
Biomass Availability A wide range of Forest/Agri
based feedstock
Residues/thinings
Conventional forests
Short rotation plantations
6
Managed Biomass Availability Vs Consumption
Non-food 5
Energy 33
Food 62
Global production
Consumption (only 5)
120x109 ton
Type of uses
6x109 ton
Oil seeds
Wood
2.2x109 ton
2x109 ton
Cereals
1.8x109 ton
Type of resources
Renewable resources and biorefinery-Ghent-Sep.1920
05/7
7
Natural Fibre Refinery Market OutlookUnderestimat
ed Importance of Biofibres
In 2008 Bio-fibre Product Market touches almost
2.0 Million MT Milestone

• Future
• Growth for wood pulp, MDF fibre, long bast,
  Micro- Nano-fibres, crystal, low cost carbon
• Driver
• Environmental footprint
• Functional properties
• Abundance

22.3
Nano-Fibre
77.3
Bast Fibre
Wood Pulp
MDF Pulp
Shives
8
Magnitude of Agricultural Waste in Ontario
Wheat straw
Corn
Soy stems and hulls
0.88 M tons
5.04 M tons
1.3 M tons
0.15 M tons
2.28 M tons
0.25 M tons
Barley
Hay
Rest
3.75 million tons/year wheat straw residues in
Canada
Source Agricrop and Statistics Canada Field
Crop Report Series
9
Global Wood Product Market Shift
10
Plant cell walls biomass for biorefining
The composition/structure of plant cell walls
have evolved to resist precisely the processes
needed for efficient, cost-effective biorefining
Cellulose partially microcrystalline -
inaccessible
Lignin inert, insoluble and resistanc
to microbial enzyme attack
Targets for change
Dianna Bowles CNAP, University of York, UK. 1st
International Biorefinery Workshop. U.S, 2005
11
Pulping Pathway to Bio-refinery
Future Pulp Mill a true biorefinery
Full utilization of the incoming biomass for
simultaneous production of fibres/paper products,
chemicals and energy
Agro and wood fibre
The Eco-cyclic Pulp Mill Vision
Peter Axegård, STFI-Packforsk. 1st International
BiorefineryWorkshop, July 20-21, 2005,
Washington, D.C
12
Material balance
a typical kraft pulp mill
Finished product 630 000 t pulp/y
Total By-products 984 000 t /y
13
World pulp production and price
Huge potential of Biorefinery in Pulp industry
1975 890/t
2005 700/t
14
Potential by-products
15
(No Transcript)
16
(No Transcript)
17
Natural Fibre pulping Motives for change
- Negative price trend of pulp 21 drop since
1975 - New revenues needed - Infrastructure
exists - Large potential for energy and
chemicals - Electricity, methanol/DME, solid
fuel (bark, lignin, forest residues) - Chemicals
from bark, black liquor and forest residues
18
Pulping-Current thrust areas Pre-pulping value
addition

• - Hot water extraction vessels (low pressure
  digesters)
• - Extraction of Soluble hemicelluloses
• - Acetic acid separation, and sugars fermentation
  to fuel grade ethanol with known processes
• - Removing the sugars improves throughput
  potential
• Producing high-value chemicals/ethanol by
  fermentation
• Bark/extractives utilization

19
Pulping-Current thrust areas Post-pulping value
addition

• Lignin separation and utilization
• (Precipitation, membraneseparation, washing,
  dewatering, fractionation, lignin, fenols, carbon
  fibers and high quality fuel)

Lignin pellets
Peter Axegård, STFI-Packforsk. 1st International
BiorefineryWorkshop, July 20-21, 2005,
Washington, D.C
20
Pulping- emerging trends
21
Pulping
Harvesting Genetically modified plantations
Tree, Kenaf, Hemp, Flax, Sisal, Abacca, .
D. R. Raymond .The Integrated Forest Biorefinery
. http//www.biorefineryworkshop.com/presentations
/Raymond.pdf
22
Cellulose
23
(No Transcript)
24
Applications of New Value-added Cellulose
Derivatives Coatings-casings, medical sponges,
fibres
25
Pulp Fibre- a new dimension Pulp-based
thermoplastic structural composites

• -Extensive research in progress
• Prototypes development in furniture/automotive
  sectors
• An extra value addition to low-priced pulp

26
Microfibre and Biocomposite production
Bleached kraft pulp
Liquid N2
Filtration
Cryocrushing (High impact)
PFI Refiner (High shear)
Disintegrator
Microfibres (aqueous suspension)
Polymer
Internal mixer
Compression molding
Biocomposite film 0.2 mm thick
27
(Laser Confocal Microscpy)
Microfibre Biocomposite
Cellulose microfibres in Starch Polymer

10 ?m
10 ?m
28
Nanofibre Isolation
Chemical Treatment
Nanofibers
29
Nanofibre characterization/Film casting
500 nm
500 nm
soybean stock - AFM
hemp - AFM
Nanofiber-PVA film (soybean stock)
Nanofiber-PVA film (hemp)
30
Hemicellulose
31
(No Transcript)
32
Fibre Biorefinery-Innovative products Biobutanol
the fuel of future

• Extensive RD efforts to produce biobutanol from
  cellulose, sugar beets and corn
• Higher energy value than ethanol
• Less water soluble
• Less evaporative

Collaboration between BP and DuPont started in
2003 First marketing of Biobutanol as gasoline
bio-component in UK in 2007
33
Lignin
34
Top Value-Added Chemicals from Biomass
Biorefinery Lignin
35
Biorefinery Lignin
36
Lignin Carbon Fibre
ORNL
37
Bark Extractives
38
Eye-opener
ESTABLISHING BIOMASS, RD PRIORITIES. European
Perspectives. Dr. Markku Karlsson.SVP
Technology.UPM- Kymmene, Finland Biorefinery
workshop, July 21-22, 2005, Washington
39
Liquid Wood
Fibre Biorefinery-Innovative products

• Tecnaro is a producer of high-quality
  thermoplastics for injection moulding
• Made from lignin, natural fibres (e.g. flax,
  hemp) and some natural additive
• Current capacity 300 tons p.a.
• Marketed as liquid wood

40
Value-added Sludge Utilization
Overview
Recovered sludge fibre
Papermill Sludge
Paper
Bio-Composite

• 12,000 MT/day

Recovered fines
ß-D-glucose
Renewable Energy
41
Value-added Sludge Utilization

• Constraints
• Drying Handling
• Variability

42
Drying Approach
Value-added Sludge Utilization

• Wet sludge is dropped into the throat of the
  mill.
• Material is subjected to repeated violent
  collisions with the spinning rotor and strike
  plates.
• Material is fractured and water vapor and
  droplets are released.
• Cost to dry from 50 solids to 93 is 18/tonne

Product
43
Sludge Utilization- Strategy
44
Fibre-biorefinery-Fuels/Energy
Bio-energy Vision Transforming concept into
reality
45
Integrated biorefinery fuels/chemicals
Clean Hydrogen-rich Synthesis Gas
Fuels from biomass
Växjö University, Sweden
CHRISGAS Clean Hydrogen-rich Synthesis Gas.
Växjö University, Sweden. 1st International
BiorefineryWorkshop, July 20-21, 2005,
Washington, D.C http//www.biorefineryworkshop.com
/presentations/Bengtsson.pdf
46
Lignocellulosic Fermentation
Future Process
An integrated biorefinery concept for production
of fuels and chemicals. Birgitte K. Ahring.
Danish Center for Biofuels. BioCentrum DTU
47
Lignocellulosic Fermentation
Challenges
Pre-treatment High Sugar Recovery of High Biomass
Concentration with Low Environmental
Burden Hydrolysis High Enzymatic Hydrolysis with
Low Enzyme Loading at High Biomass
Concentration Fermentation High Ethanol Yields
and Productivity of All Sugars at High Sugar
Concentrations Value-Adding Products Recovery of
Valuable Products from Non-Carbohydrates
Left after Bioethanol Production
48
Fuels/Energy- European Initiatives
Birgitte K. Ahring. Danish Center for Biofuels.
BioCentrum DTU. http//www.biorefineryworkshop.com
/presentations/Ahring.pdf
49
Fuels/Energy Range of Lignocellulose biomass
50
North American initiatives
Estimated targets for national bio-based
industry-USA
Based on NRC report 2000 T.E. Amidon. The
biorefinery in New York. J. Pulp and Paper
Canada, June 2006
51
The biorefinery in New York Woody
Biomass into Commercial Ethanol
A partnership among Researchers and Industry

• Vision - Core Competencies
• Development of fast-growing wood species
• Efficient pre-treatment/separation of woody
  biomass into three biorefinery process streams
  cellulose, hemicelluloses, and lignin
• Creation of value added portfolio of fuels,
  chemicals and bio-materials.

T.E. Amidon. The biorefinery in New York. J. Pulp
and Paper Canada, June 2006
52
The biorefinery in New York
The Scope and Economic Sense

• The first wood-based biorefinery in the region
• - Cellulose for Pulp/paper fibre needs
• Hemicelluloses/extractives for ethanol/chemicals
• Lignin for energy

Wood burning has marginal economics but
Biorefinery adds significant value Cost of wood
40-80 /dry ton (Price of extractives Sugars
0.07/lb, Acetic acid0.30/lb) Value of
extractives _at_15 extraction efficiency 44/dry
ton
T.E. Amidon. The biorefinery in New York. J. Pulp
and Paper Canada, June 2006
53
Tembec Temiscaming, QC Highlights-Integrated
biorefinery

FSC certified forestry feedstock
Bioenergy, biomaterials, bioproducts
Specialty cellulose pulp
Lumber Residues
Chemical/biological Transformation of Waste
Streams
Modified lignin, ethanol, anaerobic biogas
Cost Incentives
Whole wood-lumber 150/bone dry ton Forest/agri
residues (bark, saw dust) 40-90/ton
L. Magdzinski. Tembec Temiscaming integrated
biorefinery. J. Pulp and Paper Canada, June 2006
54
Kraft pulp mill Integrated Fibre Biorefinery
CASE STUDY (Basis
1.0 ton Oven Dry mass)
Scenario 1 Products Transportation fluids
Ethanol and diesel fuel Scenario 2 Products
Kraft pulp and wood fuel Scenario 3 Products
Alkaline pulp, ethanol, diesel fuel Scenario 4
Products Alkaline pulp, Poly Itaconic acid,
polyurethane, diesel fuel
A. Van Heiningen. Concerting a kraft mill into an
integrated forest biorefinery. J. Pulp and Paper
Canada, June 2006
55
Bio-degradability Analysis
Selected results after 5.5 month trials
56
(No Transcript)
57
(No Transcript)
58
(No Transcript)