IEA T 42 : BIOREFINERY
Meeting March 3rd 2010 - Lestrem
Christophe Rupp-Dahlem Programs Director Vegetal-Based Chemistry / ROQUETTE President of the French Association for the Vegetal-Based Chemistry (www.chimieduvegetal.com) [email protected]
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 1 AGENDA
14h - 14h30 : Roquette Introduction : general, innovation strategy
14h30 - 16h30 : Tour plant (maize starch, glucose, sorbitol)
16h30 - 17h00 : Conclusion
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 2 THE ROQUETTE GROUP TODAY
One of the leading global producers of starch products : ¾ Number 2 in Europe ; In the Top 4 in the world ¾ World leading producer of polyols and gluconates ¾ 18 factories around the world including the most important cereal based biorefinery in Europe located in Lestrem (F)
4 Agricultural Raw Materials : Corn Wheat Starch potatoes Pea
Our business from harvest to starch and starch derivatives
Turnover of 2,5 billion €
250 research contracts by year with universities and private partners worldwide. An active portfolio of more than 150 patents
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 3 Our mission From raw materials … …to Roquette products • Production of starches
CO Corn RN S TEEP GERM Wheat SO LUBL FI ES BER V EGE GLUT Potato TATI EN W ON B ATER RAN
GL UTEN Corn SO Pea LUBL starch ES PULP
P Wheat ROT EINS FIBE starch R e l n b o u i l t P Potato starch o c n ROT S a EI r io NS f t c a r e f s t o n Pea l a o u i F l t starch l c n e i n a e C r o f t i o t r c P a r f DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 4 Our mission
• Corn starch plant Corn
Corn Steep Steeping (solubles)
Germ Grinding Corn germ meal Corn Feed Screening (fiber)
Gluten (protein) Separation
Refining
STARCH Raw material for our complete range of products
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 5 Our mission
• Wheat starch plant Wheat
Bran Milling
Kneading Gluten
Washing
Fibers and gums Screening Solubles Refining
STARCH Raw material for our complete range of products
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 6 Our mission • Potato starch plant
Potato
Rasping
Vegetation Separation water Solubles Proteins
Pulp Screening Refining
STARCH Raw material for our complete range of products
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 7 Our mission
• Pea starch plant PEAS
External Mill fibers
Separation/ STARCH Refining
Internal fibers Separation
Solubles
PROTEIN
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 8 CURRENT INTEGRATED PROCESSES - GLOBAL SYNOPTIC
Starch molecule STARCH = thousands of linked glucose Native starch Drying molecules
Modification Hydrolysis Enzymes Modified starches : Dextrins, Pregelatinized, Ethers-esters, Cationics, others
Hydrolized products : Dextrose Malto-dextrins Glucose syrups Hydrolysates
Biotechnology Hydrogenation
Fermentation Hydrogenated products : & Biocatalysis products : Hydrogenated Polyols : Sorbitol, Mannitol, New building blocks, organic Glucose syrups Isosorbide, Maltitol, Xylitol, acids…
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 9 Our products
Sales by product line
Co-products Native starch
18% 10% Fermentation products Modified starch 2% 13%
Polyols 26% 19% 12% Liquid sugars Dry sugars
ProcessingProcessing naturenature’’ss productsproducts……
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 10 Our applications
1% 12% 9% 49% 14%
15% in volume …… adaptedadapted toto thethe needsneeds ofof industryindustry
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 11 Our applications • Paper – Corrugated cardboard
Human Food 1% 12%
9% 49% 14% by volume
Paper - Corrugated cardboard15%
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 12 Our applications • Pharmacy - Cosmetology
Pharmacy - Cosmetology
1% 12%
9% 49% 14% Human food 15% Paper – Corrugated cardboard
by volume
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 13 Our applications • Chemistry – Bio-Industry
Pharmacy - Cosmetology 1% 12% Chemistry – Bio-industry 9% Human food 49% 14% Paper - Corrugated cardboard 15%
by volume
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 14 Our applications • Animal nutrition
Pharmacy - Cosmetology
1% 12% Chemistry - Bio-industry 9% 49% 14%
Human food 15% Paper - Corrugated cardboard
by volume Animal nutrition
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 15 Roquette Frères France
• Corn starch (native and modified) • Wheat starch (native and modified) • Sugars (liquid and dry) • Polyols
Head office of the group and main production site DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 16 Innovation at ROQUETTE
Î Transforming innovative ideas into new, sustainable and competitive products
TARGET : being a major leader in the future bio-based economy with integrated biorefineries
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 17 Two Axes for the Programs of Innovation
VEGETAL BASED From integrated biorefineries NUTRITION and to generate new business CHEMISTRY with partners HEALTH
New monomers and new Ind. Functional Biotech processes. ingredients
New functionalized natural polymers
Microalgae Pea
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 18 Hubs for Innovation
Dedicated task-force to speed up the time to market for innovative new products
New Industrial Biotechnology & Hubs Center
Illustration of new expertises : New WB processes Agro-materials Microalgae
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 19 DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 20 ALGOHUB™ Program
Biodiversity Production
Supernatants Microalgae Biomass Microalgae Extracts
Animal Human Purified Production Nutrition Products cosmetics and pharma • Health • Omega-3 actives and ingr • Aquaculture Supplements • Eggs •Pigments • Ingredients • Antioxydants Recombinant • Anti-pathogens Proteins • Anti-inflammatories • Anti-Alzheimer • Enzymes • New functionalities
Concentrated & integrated Industry : ALGOHUB™ Program
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 21 ALGOHUB™ Program
Setubio Valorisation de la biodiversité
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 22 Biorefinery : A New Example For Sustainable Development
The refinery based on fossil resources Source Transformation Products Downstream process
Refining Chemical Oilfields & Formulation Transformation Cracking
Native Oil Naphta Monomers & polymers End Product The biorefinery based on renewable resources (cereals) Source Transformation Products Upstream process
Biotech Chemical Agricultural Starch Trans- Trans- Formulation fields production formation formation
Maize/Wheat Glucose Monomers & polymers End Product
Leading role of biotechnology Shared role between biotechnology and chemistry Leading role of chemistry
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 23 New Biorefineries : An Example of the Circular Economy
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 24 The New Cereal Based Biorefinery
New platform chemicals PROGRAM
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 25 PROGRAM
The Concept Definitions MeeM ting the needs of the present without compromising the ability of future generations to meet their own needs. ProcessingP starch and using chemical, biological and physical means to refined value added end-products for use in food and non-food applications.
PROCESSES : White Biotech (W.B.) Plant Based Chemistry Products with new W.B. processes New Chemical Products for Commodities, Specialties and Fine Chemical Markets Biopolymers
RRB3 – Ghent – June 4th 2007 10 The BioHub ® PROGRAM
Substitutes for petchem
Current products New products with new WB processes
Ö Biosolvents : Dimethyl Isosorbide Ö Active ingredients : Ö Bioplasticisers : Isosorbide diesters L-Methionine Ö Biolubricants : Isosorbide diesters Ö Chemical intermediates : Ö Biofluxing agents : Dimethyl Isosorbide Bio Succinic Acid Ö Biopolymers : Isosorbide Bio Glycolic Acid Ö Biocomplexing agents
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 27 An Example of a Biohub® Platform : Isosorbide a Sustainable Diol For Chemicals And Polymers
H
CH2 OH – (CHOH)4 –C (glucose) O Hydrogenation
CH2 OH – (CHOH)4 –CH2OH (sorbitol)
Isosorbide Isosorbide Derivatives for polymers O R-C (isosorbide) COOH – (CH2)n – COOH OH Diacids or other chemicals Fatty Acids
O OCH3 O C O O Polyesters R PEIT O O O Polyurethanes OC OCH3 Isosorbide Di-Esters Polycarbonates R Di Methyl Isosorbide « PVC plasticisers « sustainable co-solvent and fluxing Others polymers Personal & Oral care» agent»
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 28 Illustration of the Isosorbide Platform : Polysorb® ID 37 - New 100% Bio-Based Plasticizer
Î Polysorb® ID 37 is a blend of diesters obtained from esterification of Isosorbide with fatty acid
Î It’s synthesized by 9 fatty acid (vegetal based) 9 and isosorbide coming from dehydratation of sorbitol
Cereals (corn, wheat) Plants
Starch Oil (vegetal) Sorbitol
Fatty Acid (vegetal) Isosorbide
Isosorbide diester (IDE) : Polysorb® ID 37
► 100 % Bio-Based and Plasticizing Effect comparable to Phthalate Plasticizers
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 29 An Example of Bio-Based Building Block : Succinic Acid a Sustainable Di-acid for Chemicals And Polymers
H
Glucose CH2 OH – (CHOH)4 –C O Fermentation CO2
Succinic Acid Succinic Derivatives Succinic Acid for polymers COOH – (CH2)2 – COOH
Î Joint development with + Isosorbide or BDO , …
HO
BDO (1,4 Butanediol) OH Green Polyesters like PIS O (Polyisosorbide succinate) THF (Tetrahydrofuran) PBS (Polybutylene succinate) GBL O O (GammaButyrolactone)
Succinate esters
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 30 Bio-Sucinnic Acid As Monomer for Renewable Materials/Products
starch Enzymatic glucose hydrogenation sorbitol dehydration isosorbide hydrolysis
PolySuccinic-Isosorbide Enzymatic succinic starch glucose hydrolysis Fermentation acid
Enzymatic succinic PolyButylene-Succinate starch glucose Fermentation hydrogenation butanediol hydrolysis acid
CO2 neutral product cycle Bio-renewable Renewable Feedstock (bio) processes performance materials
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 31 DSM – ROQUETTE Partnership for Bio-Succinic Acid
Biodegradable Polymers (e.g. PBS, PSI)
Renewable Bio-SA Existing large-volume Feedstock Fermentation products like BDO
RQ-DSM Bio-SA derivatives Alliance
Industrial partners
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 32 D,L and L-METHIONINE Project : Production Diagrams
Oil Cracking Propylene Acroleine AMTP D-L Methionine products
Methanol Methyl HCN Mercaptan H2S Ammoniac Natural gas Salts
Cereals Starch Glucose L-Methionine
KT 700 = g 2008 €/k rket = 4 d ma Worl 2008 price
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 33 The BioHub® Program
Institut des Molécules et de la Matière Condensée de Lille (IMMCL)
To create new value chains through industrial innovation !
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 34 BIOHUB® PROGRAM : Main Figures
Î Global cost of the Programme = € 90 mio. (6 years )
Î Aids from the French Industrial Innovation Agency : € 42 mio. (€ 22 mio. as subsidy and € 20 mio. as reimbursable loans)
Î Industrial investments = € 700 mio. (starting after 2010)
Î Expected volumes and surfaces = 1.3 mio. tons corn or 150 000 ha
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 35 Many companies with very different backgrounds have started to engage in the biorefineries concept
NOT COMPLETE • Chemicals
• Agro Industries
• Biotech
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem Source Mc Kinsey 36 Chemical and Agro Industrial players have started to form partnerships to build biorefineries
Some Emblematic Examples
Announced Product Agro Industries Chemicals Volume kt Timeline
Ethylene/VCM 360 VCM (from ethanol) 2010
Ethylene Brazil 350 2011 (from ethanol)
Ethylene 200 2009 (from ethanol)
Succinic acid Europe Demo plant End of (from starch) 2009
USA 1,3- propanediol 45 Operational
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 37 Building the Foundation for a Sustainable World
THANK YOU
DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 38