Supporting the Transformation of Forest Industry to Biorefineries and Bioeconomy IEA Joint Biorefinery Workshop, May 16th 2017, Gothenburg, Sweden Eric Soucy Director, Industrial Systems Opmizaon CanmetENERGY © Her Majesty the Queen in Right of Canada, as Represented by the Minister of Natural Resources Canada, 2017 1 CanmetENERGY Three Scientific Laboratories across Canada CanmetENERGY is the principal Areas of FoCus: performer of federal non- § Buildings energy efficiency nuclear energy science & § Industrial processes technology (S&T): § Integraon of renewable & § Fossil fuels (oil sands and heavy distributed energy oil processing; Oght oil and gas); resources § Energy efficiency and improved § RETScreen Internaonal industrial processes; § Clean electricity; Varennes § Buildings and CommuniOes; and § Bioenergy and renewables. Areas of FoCus: § Oil sands & heavy oil processes § Tight oil & gas Areas of FoCus: § Oil spill recovery & § Buildings & Communies response § Industrial processes § Clean fossil fuels Devon § Bioenergy § Renewables OWawa 2 3 3 4 4 CanmetENERGY-Varennes Industrial Systems Optimization (ISO) Program SYSTEM ANALYSIS SOFTWARE SERVICES Research INTEGRATION EXPLORE TRAINING Identify heat recovery Discover the power of Attend workshops with opportunties in your data to improve world class experts Knowledge plant operation Knowledg Industrial e Transfer projects COGEN I-BIOREF KNOWLEDGE Maximize revenues Access to publications Evaluate biorefinery from cogeneration and industrial case strategies systems studies 5 Process Optimization in Pulp and Paper Industry Approach Combining Several Systems Analysis Tools Innovation Through Integrated Solutions 6 Process Optimization in Pulp and Paper Industry Advanced Data Analytics § Valuable process knowledge is hidden in historical database v Large amount of data is available in mills v Difficult to fully understand the links and interacOons between data § Data analyOc techniques can help extract this knowledge v StasOcal analysis to explain process variability and improve operaon v StasOcal models to maintain performance over Ome 7 Process Optimization in Pulp and Paper Industry Utility Systems Most cogeneraon systems are not used in an opOmal way 8 Process Optimization in Pulp and Paper Industry Utility Systems (cont’d) COGEN A detailed model of the utility system is used and the optimal steam path that minimizes the total operating cost is determined: optimize existing system and maximize economic benefits from steam savings è Benefits will be maximized year-round by considering contractual, operaonal and environmental constraints on different Ome periods 9 Forest - Pulp and Paper Industry Context § Pulp and paper industry is in an on-going transformaon to increase profitability: § Lower producHon costs à Energy efficiency projects, reduce cost of GHG emissions, reduce losses, improve operaons § Increase annual revenues à Install new turbines and produce addiOonal "green" power § Diversify producon à Change product grade; Add biorefinery technologies Opmizing energy integraon is essenal to reduce operang costs, lower GHG emissions, add new revenues and prepare pulp and paper mills for the low-carbon economy. Pulp mills are perfect host site for biorefinery technology integraon! 10 Optimizing Existing Assets in Pulp & Paper mills: FPInnovations – CanmetENERGY Successful Partnership Resolute Ganeau Canfor Taylor Resolute Alma West Fraser QRP Resolute St-Felicien Kruger Corner $50M+ in savings/revenues Brook West Fraser Cariboo Port Hawkesbury Paper Domtar Kamloops AV Cell Nakawic Zellstoff Celgar Castlegar Resolute Thunder Bay Kruger Brompronville 11 Forest Biorefinery R&D Program § Objectives v Develop updated biorefinery and bioenergy technology map, as well as current and emerging market trends of bioenergy, biofuels, biochemicals, and biomaterials v Develop systems engineering models and decision-making tools to evaluate the most promising biorefinery products/technologies that, when optimally integrated to an existing industrial site, will result in radically improved economic performance and environmental footprint v Develop state-of-the-art retrofit and design solutions to enable the transformation of traditional forest markets through incremental implementation of biorefineries 12 Biorefinery Focus Areas Bioplastics Bioenergy Biofuels Biochemicals Biocomposites • Technological • Markets • Markets • Markets intelligence • Rich-Sugar streams • Tannins • Bioenergy • Data analysis La Tuque • Biobutanol • Lignin-based polyols • Cogeneration • Organic acids • Carbon fiber CFS, BELT, UQTR, NRC, CRIBIQ, Forest CFS, FPInnovaHons, FPInnovaHons, CÉPROCQ, CRIBIQ, UQTR, COOPs, Domtar, Enerlab, pulp and paper mills PolyteChnique Montréal, Forestry COOPs Pure Lignin Environment Université Laval, VTT TeChnology Ltd., Arbiom 13 I-BIOREF: A Biorefinery Pre-Feasibility Analysis Software 14 I-BIOREF: Why such tool? q How can a company succeed in idenfying a strategy to enter the bioeconomy that is robust for future market scenarios, and at the same Ome, yields high margins? q What are the benefits of integrang a biorefinery technology into an exisOng mill? q In an integrated biorefinery, what are the impacts on the exisng mill? q Under what condiOons does a biorefinery project becomes economically and environmentally viable? Make the analysis easier, faster and… cheaper ! 15 Approach Market assessment and Computer Modeling, technological intelligence Simulation & Optimization of Integrated and Standalone § Mapping of resources Biorefineries utilization in pulp and paper Modeling, algorithms mills development, simulation, and experiments § Data on available biomass § Experiments and competitive pricing strategy • Extractives • Pre-treatment/fractionation § Market data on bioenergy, • Detoxification of cellulosic biochemicals and hydrolysates biomaterials • Sugar extraction and § Critical review of Canadian fermentation • Lignin recovery from black bioenergy and biorefinery liquor demonstration projects • Full characterization of lignin § Extensive technological properties from various intelligence on biorefinery sources (up to 90 samples) Outputs: processes and innovations § ASPEN Plus® Modeling § Prefeasibility scenarios for integrated and • Pre-treatment/fractionation standalone biorefineries • Lignin recovery • Sugar extraction and § Industrial case studies fermentation § Guidelines, engineering rules and expert tips • Separation/purification for designing and implementing biorefineries § Multi-criteria analysis § Knowledge, know-how and technology transfer • Technical performance • Economic viability • Environmental footprint • Risk assessment 16 I-BIOREF: Multi-Criteria Analysis § Technical performance criteria § Modeling and simulaon on v UOlity and chemical consumpOon Aspen Plus® v Impacts on the uOlity and chemical v Pretreatment and fracOonaon of consumpOon of the exisOng mill lignocellulosic biomass: Sugar § Economic viability criteria recovery yield and energy requirements v Does the project meet the v Integrated system for diversified profitability thresholds? bioproducts porholio v Under which circumstances does it become profitable/unprofitable? § Experimentaon § CompeOveness criteria v Recovery of bioacOve extracOves v Pretreatment of lignocellulosic v Access to biomass biomass v Performance in a volale market v FracOonaon of lignin § Environmental footprint criteria v Lignin funcOonaliOes and colour v Environmental impacts (LCA) v Fermentaon of mixed sugars model v Energy and GHG intensiOes and sugar stream extracted from lignocellulosic biomass 17 I-BIOREF Software: What it does? q Comprehensive mass and energy balance, and chemical balance q I-BIOREF supports decision-makers in selecting viable biorefinery q 6 economic metrics (PBP, IRR, NPV, ROCE, ROI, solutions EBIDTA) q I-BIOREF evaluates the benefits of integrating commercially q 2 competitiveness metrics (CAB, RTMU) available biorefinery processes v Competitive access to biomass q I-BIOREF provides several criteria to assess the biorefinery project v Resistance to market uncertainties from different perspectives q 17 LCA-based metrics q I-BIOREF performs sensitivity analysis to evaluate the impacts on resources utilization v Mid-point impact category (carcinogens, respiratory inorganics, land occupation, etc.) v Damage category (climate change, human health, ecosystem quality, etc.) q Pulp and paper processes: Kraft and TMP q Biomass pretreatment processes: Steam explosion; Liquid hot water; Acid hydrolysis; Alkaline hydrolysis; Instant controlled pressure; Organosolv; Torrefaction q Pre-extraction processes Supercritical fluids (e. g. CO2); Hot water;, Enzymatic q Lignin recovery processes: LignoBoostTM; LignoForceTM q Sugar streams conversion processes: Detoxification; Fermentation; Separation/Purification q Thermochemical processes: Gasification; Pyrolysis; Catalysis I-BIOREF is not a process simulaon soware! 18 Forest - Pulp and Paper Industry Concluding Remarks § Process opOmizaon is key to design highly-efficient Biorefinery pulp mills § Leveraging on exisOng assets is key in supporOng the transformaon § In retrofit situaons, steam and water savings of 10 to 20% are possible cost- effecvely. Increased power generaon is also typical § Develop a long term vision for implemenng energy saving projeCts and robust biorefinery teChnologies: v Permits a gradual implementaon that miOgate the implicaon of short-term modificaons over long-term high impact soluOons v Analysis of biorefinery pathways for integraon at exisOng mills v Analysis