Advantages of Decentralized Bioethanol Production at Biogas Plant Sites

4th European Bioethanol Technology Meeting Advantages of Decentralized Bioethanol Production at Biogas Plant Sites C. Lanzerstorfer, A. Jäger Upper A...
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4th European Bioethanol Technology Meeting

Advantages of Decentralized Bioethanol Production at Biogas Plant Sites C. Lanzerstorfer, A. Jäger Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

Outline Introduction Biogas Plants Economic Situation of Biogas Plants Results Process Integration for Biogas and Bioethanol Plants Economic Results Outlook Future Research in this Field at FH Oberösterreich

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Biogas Plant Characteristics Mature technology for bio-energy production Potential for optimization (reduction of residence time, pretreatment of substrates, use of lignocelluloses) Competitive on small/medium scale Sustainability of local plants (short ways of transport) Robust operation – can be taught with reasonable amount of training to farmers

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Biogas Plant Statistics Number of plants in Austria

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Biogas Plant Flow diagram

Off-gas Electric power

Thermal energy (hot water)

Cogenerator Biogas

Biomass Digester Digested manure

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Biogas Plant Profitability Costs Biomass, harvesting, digestate spreading Maintenance, insurance, labour 13 years, 6% interest rate

Revenues Available el. power and heat after subtraction of consumption and demand of biogas plant

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Biogas Plant Profitability 705 k€ max. Revenues (100% heat utilization)

?

545 k€ Revenues for el. power

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Biogas Plant Profitability

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Biogas Plant Profitability

Off-gas Electric power

Thermal energy (hot water)

Cogenerator Biogas

Biomass Digester Digested manure

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Integrated Biogas - Bioethanol Plant Advantages Thermal energy from biogas plant can be utilized in bioethanol plant for fermentation and distillation All of stillage from the bioethanol production can be fed into the biogas plant as a substitute for renewable biomass Thermal energy

Biogas Plant

Bioethanol Plant Stillage

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Process Integration Proposed solutions in literature1

55% Reduction in power generation of BG-plant

1

Senn, T.: Die Produktion von Bioethanol als Treibstoff unter dem Aspekt der Energie-, Kosten- und Ökobilanz. Tagungsband Fachtagung Regenerative Kraftstoffe, Stuttgart 2003, 87-98 (2003) Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Process Integration Improved Integration Hot water from cogeneration unit is used for heating in fermentation Steam for distillation is produced from hot off-gas from cogeneration unit Produced bioethanol grade 92% (dehydration external 2) Size of bioethanol plant is determined with respect to maximum utilization of the available thermal energy from the biogas plant (no use of biogas or external fuel for heating purposes)

2

Wetter, C., Brügging, E. and Doetkotte, F.: Machbarkeitsstudie zur Absolutierung von Bioethanol aus landwirtschaftlichen Brennereien. Fachhochschule Münster, Steinfurt (2005) Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Process Integration Off-gas Bioethanol

Steam

Distillation

Stillage Off-gas

Thermal energy (hot water)

Fermentation

Electric power Hot water

Cogenerator Biogas

Digester Biomass

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

Digested manure

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Process Integration Digestion Experiments (VDI 4630)

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Process Integration Digestion Experiments (VDI 4630)

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Process Integration Digestion Experiments (VDI 4630)

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Integrated Biogas - Bioethanol Plant Plant Data Biogas plant:

500 kWel

(existing)

Substrate: renewable biomass (maize silage, CCM and some pig manure); renewable biomass partly replaced by stillage Bioethanol plant:

500 m³/a bioethanol

(virtual)

sized with respect to maximum utilization of the available thermal energy from the biogas plant; limiting parameter is the amount of steam produced from hot off-gas for distillation bioethanol 92% Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Integrated Biogas - Bioethanol Plant Energy Balance

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

page 18

Integrated Biogas - Bioethanol Plant Profitability Calculation No cross-calculation costs for stillage and heat El. power consumption of bioethanol plant within operation costs of plant

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

page 19

Integrated Biogas - Bioethanol Plant Profitability 640 k€ max. Revenues (100% heat utilization*) 545 k€ Revenues for el. power

?

* 100% of remaining heat Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Integrated Biogas - Bioethanol Plant Profitability Costs Biomass, harvesting Maintenance, insurance, labour, el. power 10 years, 6% interest rate

Revenues Bioethanol

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

page 21

Integrated Biogas - Bioethanol Plant Profitability

Min. required price for Bioethanol (92%): 0,80 € /l

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

?

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Integrated Biogas - Bioethanol Plant Total Economics Min. required price for bioethanol (92%): 0,60 € /l BIoethanol

940 k€

100% heat utilization

640 k€

Revenues for el. power

?

545 k€

Min. required price for bioethanol (92%) without additional heat utilization: 0,80 € /l Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Summary Integrated Biogas - Bioethanol Plants Break even can be calculated depending on substrate costs Costs for bio-energy production are comparable low for local/regional plants Central dehydration plants are necessary Demonstration plant required to convince authorities and local investors/producers

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Outlook Bioethanol „2nd“Generation – Utilization of Straw Thermo-mechanical pretreatment of straw (steam explosion) Enzyme production on pretreated straw (30°C) Hydrolysis of pretreated straw (50°C) Fermentation to ethanol

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Outlook

Future

Thank You for Your Attention ! Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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Outlook

Upper Austria Univ. of Applied Sciences, Faculty of Engineering and Environment Science

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