1. Copernicus Institute Research Institute for Sustainable Development and Innovation WP 2/3 Technical and economic characteristics and environmental assessment of BREW case study products

2. Copernicus Institute Research Institute for Sustainable Development and Innovation Progress track WP 2/3 Kickoff (Apr 03): Product preselection, data collection methodology, LCA methodology Plenary 1 (Sep 03): Product list finalised, data received from companies, generic approach proposed by DSM/Shell Plenary 2 (Jan 04): Product trees developed for key platform chemicals, BREWtool developed as tool for standardised LCI and product value calcs Plenary 3 (May 04): Preliminary results based on company data. Choice of feedstocks finalised. Background data issues discussed. Plenary 4 (Sep 04): LCIs for 3 sugar feedstock types. Uncertainty analysis for dextrose. Environmental and economic comparison of selected petchem and bio- based feedstocks and end products. Sensitivity cases for energy recovery/waste management. Generic background data, specific company data for bioprocess Parallel path Generic bioprocess design

3. Copernicus Institute Research Institute for Sustainable Development and Innovation - Continuous biotechnological processes -Waste biomass and water recycling -Energy integration -Technologically advanced workup Emerging bulk, bio-based, biotech industry

4. Copernicus Institute Research Institute for Sustainable Development and Innovation Scope of presentation Case ‘TODAY’ Company data Industry technology reviews (SRI) Generic process design Case ‘TOMORROW‘ (2010) Generic process design

5. Copernicus Institute Research Institute for Sustainable Development and Innovation System Boundaries for BREW products

6. Copernicus Institute Research Institute for Sustainable Development and Innovation Feedstocks (fermentation substrates) Benchmark for ‘TODAY’

7. Copernicus Institute Research Institute for Sustainable Development and Innovation Sensitivity analysis on feedstock: dextrose from corn

8. Copernicus Institute Research Institute for Sustainable Development and Innovation Sensitivity: dextrose from corn

9. Copernicus Institute Research Institute for Sustainable Development and Innovation Assumptions for dextrose from corn -Corn production in US - Industry current best practice corn wet milling - Dextrose 32% dry solids. For higher % ds there will be additional energy inputs to evaporate water Integrated facility for dextrose production and biorefinery (allows delivery of fairly dilute sugar solution) - Allocation by mass (small difference for price-basis allocation)

10. Copernicus Institute Research Institute for Sustainable Development and Innovation Commercialised today: lactic acid & PLA ref: Cargill Dow (SRI process)

11. Copernicus Institute Research Institute for Sustainable Development and Innovation Lactic acid and PLA via dextrose from corn

12. Copernicus Institute Research Institute for Sustainable Development and Innovation Lactic acid and PLA via dextrose from corn

13. Copernicus Institute Research Institute for Sustainable Development and Innovation Lactic acid and PLA via dextrose from corn

14. Copernicus Institute Research Institute for Sustainable Development and Innovation Lactic acid and PLA via dextrose from corn

15. Copernicus Institute Research Institute for Sustainable Development and Innovation Lactic acid and PLA via dextrose from corn

16. Copernicus Institute Research Institute for Sustainable Development and Innovation Near future commercialisation (<2010): Succinic acid (SRI design) Design capacity: 75 k t.p.a. >> First medium-scale plant being built. Market for products still under development. ref: SRI

17. Copernicus Institute Research Institute for Sustainable Development and Innovation Longer-term commercialisation (<2020): bio-Hydrogen Photofermentation (A&F) Design capacity: 0.45 k t.p.a >>Factor 100 + higher for bulk commodity status ref: A&F

18. Copernicus Institute Research Institute for Sustainable Development and Innovation Longer-term commercialisation (<2020): Splitting of fats/oils using enzymes 2010?

19. Copernicus Institute Research Institute for Sustainable Development and Innovation Product value breakdown for BBBs with commercialisation (1) today, (2) in near future (<2010) and (3) longer term (<2020)

20. Copernicus Institute Research Institute for Sustainable Development and Innovation Thought exercise – common scaling for case ‘TODAY’ - Plant size scaleup: I 2 /I 1 = (C 2 /C 1 ) 2/3, C2 = 200 k t.p.a. BUT - ISBL in this case LINEAR since scale-up will be just a matter of replication - OSBL: power 2/3 rule? Ensure: Offsites include CHP plant or other energy recovery/waste management options for biomass waste from process (basis NREL investment figs) - Fixed + variable direct: linear

21. Copernicus Institute Research Institute for Sustainable Development and Innovation BREWtool results - key

22. Copernicus Institute Research Institute for Sustainable Development and Innovation NREU

23. Copernicus Institute Research Institute for Sustainable Development and Innovation GHG

24. Copernicus Institute Research Institute for Sustainable Development and Innovation Land use

25. Copernicus Institute Research Institute for Sustainable Development and Innovation Product value

26. Copernicus Institute Research Institute for Sustainable Development and Innovation END

27. Copernicus Institute Research Institute for Sustainable Development and Innovation Additional slides (methodology)

28. Copernicus Institute Research Institute for Sustainable Development and Innovation BREWtool: data structure

29. Copernicus Institute Research Institute for Sustainable Development and Innovation Production cost and Product value calculations (~ SRI methodology)

30. Copernicus Institute Research Institute for Sustainable Development and Innovation Energy recovery from post- consumer waste (1) incineration Post- consumer waste Calorific value, 100 GJ HHV MSW incinerator with energy recovery Electricity to grid 12 GJ Heat export 12 GJ Primary energy avoided η=38.0% 1 31.6 GJ η=76.9% 15.6 GJ 47.2 GJ 1 Weighted according to EU electricity mix; assume same mix for avoided electricity. Final Energy produced ~ 50 GJ

31. Copernicus Institute Research Institute for Sustainable Development and Innovation Post- consumer waste Calorific value, 100 GJ HHV Anaerobic digester Electricity to grid 8.8 GJ Heat export 4.1 GJ Primary energy avoided η=38.0% 1 23.2 GJ η=76.9% 5.3 GJ 28.5 GJ 1 Weighted according to EU electricity mix; assume same mix for avoided electricity. Final Energy produced ~ 30 GJ Biogas- fueled CHP plant Biogas, 37 GJ Energy recovery from post- consumer waste (2) digestion

32. Copernicus Institute Research Institute for Sustainable Development and Innovation Energy recovery from post-consumer waste (2) digestion REFERENCES Calc composition of organic waste from digestion + CHP process for a plant in Germany described in De Mes et al. 2003, p.77: fruit + veg: 26 kt/y; of which organics: 35% park wastes: 4 kt/y; of which organics: 70% Avg organics 30%, Total organics: 11.9 kt/y Composition organics: assume avg. carbohydrate CnH2nOn: 17 GJ HHV/t For the Vagron plant described in De Mes et al. 2003, p.100 (process shown on this slide), Assume same composition for OWF as above, i.e. 30% of total mass waste. Ref organic fractions: Provincie Antwerpen, 1999: Onderzoek naar de mogelijke toepassing van nieuwe afvalverwerkingsteknieken in de provincie Antwerpen. Eindrapport. http://www.gomesanet.be/nederlands/publicaties/afvalsverwerking/19mei99.pdf Refs Vagron process: De Mes, T.Z.D., Stams, A.J.M., Reith, J.H. and Zeeman, G (2003): Methane production by anaerobic digestion of wastewater and solid wastes, in: Reith, J.H., Wijffels, R.H., Barten, H. (eds): Bio-methane and Bio-hydrogen - Status and Perspectives of biological methane and hydrogen production. Dutch Biological Hydrogen Foundation 200, c/o ECN, Petten, the Netherlands. pp. 58-102. Vagron plant in Groningen: http://www.vagron.nl/html/uk/vagron4.htm Clarifies that Vagron is also treating GFT. The biowaste above refers to the organic wet fraction (OWF). Assume same composition of OWF as for the German plant. Calc. organic dm = 303 kg/1000 kg biowaste