InfraLeuna GmbH

Greenchem Conference, Lund City Hall, 8-9 November 2010
Industrial Biotechnology - a platform for sustainable growth in Sweden
Industrial biotechnology at the Leuna chemical site
Dr. Markus Wolperdinger
InfraLeuna GmbH, Leuna, Germany
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www.infraleuna.de
The chemical site Leuna is a modern and highly
integrated location for chemical manufacturing
• Located close to the cities of Berlin, Halle and Leipzig
• Over 90 years of tradition in chemical manufacturing
• More than € 5.5 bn of investment since 1990
• One of the largest chemical sites in Germany (approx. 13 km²)
• 100+ companies on-site
• Employs approx. 9.000 people
• Annual turnover € 7,5 bn
• Approx. 12 m tons of goods handled annually
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www.infraleuna.de
Leuna main
entrance
with office
building and
City of Leuna
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www.infraleuna.de
More than 100 companies are located in Leuna
1 ADDINOL Lube Oil GmbH
2 Agro Service Nord Produktion Leuna GmbH
3 ARKEMA GmbH
4 BASF Leuna GmbH
5 BAUFELD-CHEMIE GmbH
6 Quadrimex Sulfur Chemicals GmbH & Co. KG
7 Minakem Leuna GmbH
8 DOMO Caproleuna GmbH
9 Dow Olefinverbund GmbH
10 envia THERM GmbH
11 FP-Pigments GmbH
12 Hexion Specialty Chemicals Forest Products GmbH
13 Hexion Specialty Chemicals Leuna GmbH
14 InfraLeuna GmbH
15 Innospec Leuna GmbH
16 Kartogroup Deutschland GmbH
17 KataLeuna GmbH Catalysts
18 Leuna Carboxylation Plant GmbH
19 LEUNA-Harze GmbH
20 LEUNA-TENSIDE GmbH
21 Linde AG
22 Mitteldeutsche Sanierungs- und Entsorgungsges. mbH
23 MVV TREA Leuna GmbH
24 Quinn Chemicals GmbH
25 Evonik Industries AG
26 TAMINCO Germany GmbH
27 TOTAL Raffinerie Mitteldeutschland GmbH
28 WAX Umweltschutz GmbH
29 Xentrys Leuna GmbH
N
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www.infraleuna.de
Approximately € 11.5 bn have been invested in the
chemical triangle in Eastern Germany since 1990
Pipeline
RostockBöhlen
Naphtha
LPG
(€ 0.5 bn)
(€ 3 bn)
Schkopau
- Polymers
- EDC, PVC
- Ethylene derivatives
Piesteritz
- Urea, ammonia,
nitric acid
Ammonia
Urea
Ethylene
Propylene
Butadiene
Aromatics
(€ 1.5 bn)
Gases
Hydrogen,
Gases
(€ 5.5 bn)
Pipeline
Rostock-Schwedt
Bitterfeld / Wolfen
Bitterfeld / Wolfen
- Chlorine
- Chlorine
- Inorganic chemicals
- Inorganic chemicals
- Quartz crystal glass
- Quartz crystal glass
Hydrogen
Gases
Chlorine
Leuna
(€ 1 bn)
Böhlen
- Cracker
- Aniline
Ethylene
- Refinery
- Polymers
- Basic chemicals
- Catalysts
- Glues, amines ...
Crude
Refinery products
Hartmannsdorf
- Tank farm
Refinery products
Stade
- Port
- Cavern
Ethylene / Propylene
"Druschba"crude pipeline
Litvinov
- Cracker
- Petrochemicals
Teutschenthal
- Cavern
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Natural
gas
< 5 kt/y
> 5 to 10 kt/y
> 10 to 50 kt/y
> 50 to 100 kt/y
> 100 to 200 kt/y
> 200 to 500 kt/y
> 500 to 1000 kt/y
> 1000 to 2000 kt/y
> 2000 kt/y
Pipeline transportation
Rail transportation
www.infraleuna.de
Vision: Leuna develops from a petro- to a bio- and petrochemically integrated site
Crude oil
Catalysts
Natural Gas
H2
H2S
NaHS
Glues
DMF
Formaldehyde
Amines
Refinery
Ethanol
Butanol
etc.
Hydrogenperoxide
S8
Propylene
N2
CO
Surfactants
Bio-oils
-surfactants
Methanol
Epichlorohydrin
Fine
Chemicals
Plasticdispersions
Complex
Chemicals
EVACopolymers,
Additives
PACompounds
PA 6 / PA 6.6
H2
BioEthylen
Glycerin
Resins
PE-Wax
O2
O2
CO2
Caprolactam,
Polyamide 6,
Fiber
production
Air
separation
plant
Methanol
Lubricants
LDPE
H2
Methanol
MMA
H2
Steamreformer
Ethylene
Ammonia
CO2
„BioRefinery“
EBS
Aromatics
Enzymes
Proteins
etc.
New Investors
Powerplant
Sugar, Starch, Cellulose, Hemicellulose, Lignin, Algae, etc.
INFRASTRUCTURE
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www.infraleuna.de
The transfer of petrochemical-based manufacturing into
petrochemical- and renewable-based manufacturing
comes along with a number of challenges
• Feedstock availability and
logistics
• Feedstock pretreatment
• Feedstock utilization
• Process development &
Challenges !
scale-up
• Integration in value chains
• Manufacturing costs & price
• Commercial competitiveness
• Consumer acceptance
© Pictures: www.tecson.de, InfraLeuna GmbH, FhG
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www.infraleuna.de
…the feedstock utilization challenge
• Integration in existing
manufacturing
environments, e.g., for
food- and feed
production, pulp&paper
industry, utilization of
waste- and sidestreams. (Step 1)
Biomass
Food
&
Feed
Chemistry
Energy
Fertilizer
• Utilization of „non-food“
biomass in Bioreferies,
integrated in chemical,
energy and fuel
production. (Step 2)
Successive, multiple utilization necessary
Sources: JSW Consulting
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www.infraleuna.de
…the process-development and scale-up challenge
Feedstock
Conditioning
Value generation
Special materials, media
Fatty acid products
Vegetables oils and fats
Sugary feedstock
Starch-containing
feedstock
Cellulosic feedstock
Lignocellulose
feedstock
Aquatic biomass
Products*
Direct
sugarification
Multi-stage
sugarification
Production
of valueadded
chemicals
by
biocatalysis
and
fermentation
Processing, Fractioning
Optimization
Cultivation,
growth
Chem. building blocks
Aromatic compounds
Conversion
of valueadded
materials
via physical,
chemical
and
biocatalytical
approaches
Separation
of valueadded
products
and
purification
Olefin building blocks
Industrial Enzymes
Gases, H2, CO, CO2
Complex chemicals
Residue treatment
Others…
Gases, e.g. CO2
* Selected examples
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www.infraleuna.de
The integration of biotechnological, chemical,
and thermo-chemical processes is essential
Renewable Resources
Conditioning
Pre-treatment
Hydrolysis
Extraction
Biotechnological
Transformation
Chemical
Transformation
Separation
Purification
Chemical Building Blocks: C1, C2, C3, C4, C6 - Cn
Quelle: Hirth, IGB
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www.infraleuna.de
InfraLeuna spearheads German drive for alternative feedstocks
Germany gears up for biotech future
22 June 2009 00:00 [Source: ICB]
With €50m funding in place and start-up scheduled for 2011, the white biotech research center at the Leuna chemical
site looks set to be a major force in Europe's alternative feedstock innovation drive
Consultant's corner
John Stokoe/Euro Swiss Research
ACCESS TO scale-up facilities is crucial for utilization of renewable feedstocks for the chemical industry of the future.
The idea to produce today's chemicals, as well as new ones replacing those that are not cost and eco-efficient from renewable
resources with the help of industrial biotechnology seems to be quite appealing to a majority of players in the chemical
industry. This idea, combined with the concept of lowering greenhouse gas emissions and being sustainable at the same time
makes renewable resources even more appealing to all stakeholders.
Consumers seem to embrace "green" products as well, and would adopt them readily if they were available at competitive
prices and made from materials that are not used for the food or feed chain.
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www.infraleuna.de
At the Fraunhofer Process Center in Leuna state-of-the-art
facilities and equipment will be available to all participants
Biotransformation
and Bioprocessdevelopment
Bioprocessund Bioproductevaluation
Chemical-Biotechnological Process Center - CBP
Productprocessing and
Process integration
Industrial
Biotechnology
within
Fraunhofer
Bioproductmanufacture and
-characterization
Feedstock
selection and conditioning
Processsimulation and
automating
Lab
Lab II
Enzyme
screening, design
& optimization
Pilot-scale
1L
10 m³
Scale-up and process development
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Chemical site
Leuna
www.infraleuna.de
The new Fraunhofer Process Center - CBP in Leuna
Technical area
with modular units
Utilities
Media
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
> 8.000 m² total space
25 to 10.000 l process volume
Flexible USP & DSP Anlagen
Feedstock flexibility
Integrative processes
5+ individual modules
Extension capacity
Offices/Laboratory
Offices
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The implementation of the CBP follows a multifunctional,
modular approach
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4
1
2
3
7
4 5
6
1:
Innovative enzyme processes
4:
Microalgae, greenhouse, DSP
2:
Lignocellulose-based biorefinery
5:
Bio-Ethylene and biogas
3:
Innovative fermentation processes
6:
Office, utilities and storage
7:
Extension space
Linde-KCA-Dresden GmbH
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The CBP is fully integrated in the site infrastructure
Drinking-/Fresh
water plant
cCe Culture and
congress center
City of
Leuna
City of
access to the
Spergau Direct
railroad system of
Deutsche Bahn (DB)
Main entrance for
passenger cars
(Gate 1)
Power generation
Railroad
shunting
yard
Office building
Central waste water
treatment plant
CBP
Main roa
highway d B91 Æ direct
ac
s A38, A
14 und A cess to
9 (ca.3 k
m)
N
Main entrance for trucks
(Gate 6)
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www.infraleuna.de
Several projects have been initiated by Fraunhofer
Lignocellulose-Biorefinery
Lignocellulose-Biorefinery IIII
Integrated
Integrated Bioproduktion
Bioproduktion
Enzymes
Enzymes as
as Catalysts
Catalysts
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www.infraleuna.de
At the Leuna chemical site, the integration of
industrial biotech into chemical manufacturing is
under-way
• Fraunhofer -owned and -operated Process-Center - CBP
operational in 2012
• Laboratory- to pilot-scale process dimensions
• State-of-the art technologies and equipment: feedstockpretreatment, conversion, down-stream processing
• Reduction of scale-up time and capital spending
• Integration of activities into chemical manufacturing network
• Subsidies for subsequent investments available
• Nucleus and “role model” for industrial biotech activities
• Open to all interested parties
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www.infraleuna.de
Contact us to learn more about the Fraunhofer
CBP and the chemical site Leuna
Dr. Markus Wolperdinger
Director Industrial Biotechnology
Tel: +49 (0) 3461 / 43 3083
Fax: +49 (0) 3461 / 43 42 90
Email: [email protected]
InfraLeuna GmbH
Am Haupttor
D-06237 Leuna
www.infraleuna.de
Mr. Martin Naundorf
VP Site Development
Tel.: 03461 / 43 41 67
Fax: 03461 / 43 42 90
Email: [email protected]
Prof. Dr. Thomas Hirth
Fraunhofer-Institut für Grenzflächen- und
Bioverfahrenstechnik IGB Stuttgart
Tel: +49 (0) 711-9704401
FAX: +49 (0) 711-9704006
Email: [email protected]
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www.infraleuna.de