Bionic - From Biomass To Energy

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Bionic presentation describing exemplary the interaction between african biomass production and bionic's microfuel technology. Auguist 2012, English Version

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Bionic - From Biomass To Energy

  1. 1. BIO-CHAR FOR EUROPEAN POWER-PLANTS BIO-CHAR AND BIO-OIL PRODUCTION FOR EUROPEAN POWER PLANTS via microfuel biomass depolymerisation using sustainable feedstock from Bionic Palm plantations in Africa by Bionic Group of companies Bionic Palm Ltd c/o Bionic Laboratories GmbH PO Box 14916 GP D- 64521 Gross-Gerau, Germany Accra, Ghana www.bionic-world.net www.bionic-palm.com info@bionic-lab.de© Revision 22, Mar 2012, patents pending © 2012 by Bionic 1
  2. 2. TABLE OF CONTENTS 1. Bio-Char for European Power-Plants 23. Bionic in Ghana 2. Table of Contents 24. Testfarm in 2010 3. Substitution of fossile Energy 25. Environment & Resources 4. EU targets for renewable Energies 26. Continuous soil Improvement 5. From Biomass to Energy 27. Decreasing CO² Footprint 6. Energy content of Biochar / Biooil 28. Zero waste internal Cycles 7. The System 29. Social Responsibility & Environment 8. Microfuel Process 30. Local Social Responsibility & Equity 9. Mass Balance 31. Affordable energy - the basis of public prosperity 10.Free Bio-Coal for European power plants 32. Bionic„s lasting engagment in Africa 11.Principal Process Flow 33. Strategic Path forward 12.Petro Unit 34. A true Win-Win situation 13.Power Generation 35. Experience 14.Bio Oil 36. Technical Standards 15.Bio Char 37. Recent Projects 16.Plant Design (1.000 TPD capacity) 38. Thank you for your attention 17.Plant Layout 18.Modular Design Abbreviations: MWDP microwave depolymerisation 19.Calculation Overview TCDP thermo catalytic depolymerisation 20.Detailed Sample Calculation TPD tons per day MGY mega gallons per year 21. Comparing of Costs REDD reducing emissions from reforestration 22. Bionic in Ghana ASTM american society for testing of materials HDS hydrosulphurisation CDM clean development mechnism ATEX athmosphere explosive 2
  3. 3. SUBSTITUTION OF FOSSILE ENERGY• Electricity from fossile oil and coal generates the largest CO2 emissions worldwide.• Instead of waiting for new technologies, present power production can be easily converted to prevent fossile CO2 emission by using CO2 neutral biomass instead.• However, conventional biomass, such as woodchips, straw or biomass pellets, requires enourmous investment in new incineration and filter technologies for a biomass fuel of substantially lower energy content.• A viable alternative offers the use of biochar from the Bionic microfuel process.• The Bionic microwave depolymerisation process MWDP uses conventional biomass, converts the volatile components into usable fuels which cover the costs of the complete process and additionally produces a dry, CO2 neutral biochar with similar calorific values as fossile coal.• Building on African biomass waste or fast growing biomass plantations allows economic support for developing countries and real cost savings at the same time.
  4. 4. EU TARGETS FOR RENEWABLE ENERGIES growth of biomass requirement for power generation inside EU. Progression 27 [ Twhel ] ~ 1.960 11,5% 320 15% agricultural 1030 75% Wood 70  High energy content  Low ash  High availability need for biopellet feedstock requires ImportAvailable 2010 8 ~ 550 Biofuels 70Max pellet capacity 610 6 Heat 400Required ImportExpansion 126 Power 80 10% Biowaste 140 2005 2020 2020estimated for 2020 Mio t. 4
  5. 5. FROM BIOMASS TO ENERGY Bionicbiomass plantations biomass preprocessing drying, grinding and pelletizing Microfuel process usable light oil similar to Diesel ( D2 ) CO2 neutral water power generation soil amendment (tera preta) high calorific Biochar 5
  6. 6. ENERGY CONTENT OF BIOCHAR / BIOOIL Unit Wood Pellets Bionic Bionic Anthraci Char Oil te MJ/kg 14,4 19,9 26,8 42,2 30,0 Bionic kWh/kg 4,0 5,5 7,4 11,7 8,3 H2O 50,0 % 15,6% 3,4% < 0,1% < CO2 neutral neutral neutral neutral 10,0% 949 g/kWh Bionic Char and Bionic Oil has significant higher calorific value and better quality than conventional pyrolysis or torrefication products 6
  7. 7. THE SYSTEM• The Bionic Group provides full service management for plantations in Ghana and other West African countries for foreign clients.• Sustainable biomass feedstock, such as Jathropha, Bamboo, Castor or Eucalyptus will grow under controlled and secure conditions and will be available for harvest 3-5 times faster than compareable sources in Europe.• Programs against climate change like reforestration (REDD) can be integrated.• After preparation (grinding and pelletizing) the feedstock will be processed in Bionic„s microwave depolymerisation system for conversion into • light oil, usable for power generation in local market and • biochar, usable in European power plants (500 TPD) • Quality of the light oils complies with ASTM D975 D-2 Diesel • Quality of the biochar compares to anthracite charcoal, but is CO2 neutral• Revenues from oil sales cover all costs for feedstock farming and processing 7
  8. 8. MICROFUEL PROCESS The proprietery microfuel system has beendeveloped by the Bionic Group since 2001 and modulated microwave radiation is one of the leading catalytic cracking technologies in the world. (patents pending) Biomass Lignine light oil zeolith catalyst Hydrogen Cellulosis biochar Biomass, containing most Lignine and The complete process isCellulosis, is converted by the combination of a combined in a single zeolithic catalyst and modulated microwave high-tech reactor systemradiation to oil and biochar in a single reactor. with a capacity of up to 80 TPD Feedstock. 8
  9. 9. MASS BALANCE pre-processing conversion output Microfuel MF 480 B Gas 420 kg3.000 kg/h ofdry biomass pellets ~ 14,0% Oil 990 kg ~33,0% Char 1.470 kg 600 kW (el) ~49,0% 750 kW (therm) 600 kW (el) 250 kW (therm)for pre-processing of Water 120 kg feedstock ~ 12-17% of oil output used ~4,0%300 kW (el) for internal power350 kW (therm) production Heat 1.500 kW CHPfor post-processing ~ 500 kW @ 90 Cof bio-oil (through energy recovery) Material flow per hour per reactor 9
  10. 10. BIO-COAL FOR EUROPEAN POWER PLANTSSYNTHETIC FUEL/ LOCAL GREEN ELECTRICITY FROM A500HA PLANTATIONlocal markets 1 x MF480B 500 ha ++ reactors 121 BPD Diesel OR 143 BPD BIOCRUDE 3 t per day 4 Ton per day For fuel available for local conversion electricity production in IFGT yielding 3.2 100 ton p.a. / ha MWH 1.5 T per day fast growing banagrass Bio-char Export to Europe CO2 neutral power generation from high calorific bio-char 10
  11. 11. PRINCIPAL PROCESS FLOW Pre-process Reactor Condensation/Disti llation Distillation output column conveyor Rotor feeder fuel output Dryer fuel tank output screw ATEX Kat 3 Zone 22 T1 Shredder Rotor feeder Decagon Silo condensers Rotor feeder hydrotreating system OUT Rotor Big Bag security vent Vacuum Pelletizer fluid catalyst mixer circlesystem steam out PI Rotor feeder IN cooling 80 °C water 25°C separation tank inertgas water out uncondensable Silo output togenerator 50°C input conveyor Air IN thermal nitrogen 1 2010/10/18 12 Overview singleUnit oil No Date Rev Description Sheet: 01 generator pressure tank nitrogen nitrogen mf480 exhaust gases for exhaust gas tank generator Prozess Flow Diagram of : 01 heat- Classification: Draft Reviewed: gas in exchanger ProjectID : DrawingNo: 17/10 Rev. : (c)2010by BFT Bionic Fuel Technologies AG,Germany 11
  12. 12. PETRO UNIT propane atm. destillation gaswasher butane nafta nafta Alkyl reformer gasfuel HDS jet A-1 HDS diesel / cracker blender visbreaker blender HS vac. destillation sulphur 12
  13. 13. BIO OIL Upgraded Bio-oil produced by the microfuel process matches the ASTM specifications in most cases for transportation and generator low sulphur fuels. Blending with additives like cetane enhancers and hydrotreatment increases the energy content and quality parameters.Bio-Oil Analyticscomparing to ASTM specifications for low-sulphur fuel Parameter Method Unit eucalyptus wood chips Specification ASTM D975 1-D S500Flash point ASTM D 93 / DIN 2719 °C 56,5 52,5 min 38Kin. Viscosity (40 °C) ASTM D 445 / DIN 3104 mm2/s 1,126 1,319 1.1 - 2.4Lubricity HFRR 60°C ASTM D 6079 µm 389 357 max 520Ash content ASTM D 482 / DIN 6245 % (m/m) < 0,005 < 0,005 max 0.01Sulfur content ASTM ASTM D 2622 % mass 0,044 0,007 max 0,05Density (15 °C) ASTM D 1298 kg/m3 832,9 852,6 820 - 845Distillation temp ASTM D 86 correlation °C 204,4 368,8 max 288Cetane index ASTM D 976 - 40,1 40,3 min 40Nitrogen content ASTM D 4629 mg/kg 2500 177 no specificationCooper strip corrosion ASTM D 130 Corr Degree 1A 1A max No 3PAH content (Aromates) ASTM D 1319 / DIN 12916 % (m/m) na 0,9 max 35Cloud point ASTM D 2500 / DIN 23015 °C -16 -16 < 35°CCFPP ASTM D 6371 / DIN 116 °C -49 -55 < - 20 °C for winter gasoilCalorific value, lower ASTM D 240 DIN 51900 J/g 39797 37158 -Calorific value, upper ASTM D 130 / DIN 51900 J/g 42053 39684 - need to be adjusted by additives 13
  14. 14. BIO CHAR The microfuel process increases the calorific value of the charcoal significant and allows to use it either as an soil enhancer or for burning purposes. Analytical Results for charcoal Feedstock Eucalypthus Wood Chips content Unit raw material char raw material char Ho wf kJ/kg 18720 24380 19970 26885 Hu wf kJ/kg 17530 23990 18870 26485 Cl wf Mass.-% 0,11 0,05 0,01 0,08 Cr Mass.-% 0,15 0,04 0,14 0,032 C wf Mass.-% 49,0 61,1 50,9 72,9 F wf Mass.-% < 0,005 < 0,003 < 0,005 0,009 H wf Mass.-% 5,8 2,3 5,9 2,2 H2O Mass.-% 16,5 4,4 15,6 3,4 K2O Mass.-% 14,96 5,68 10,13 3,85 MgO Mass.-% 6,08 2,09 9,8 4,01 Mn Mass.-% 0,21 0,06 0,17 0,02 N wf Mass.-% 0,8 1,3 0,2 0,9 O wf. Mass.-% 42,15 11,27 41,99 8,99 P wf Mass.-% 0,065 0,275 0,007 0,111 Pb wf Mass.-% 0,0022 0,0073 < 0,0005 0,0392 SiO2 Mass.-% 13,5 40,2 14 30,5 14
  15. 15. POWER GENERATION BY STEAM TURBINES 15
  16. 16. A 5 MW GAS TURBINE UNIT pre-processing conversion output 4.000 kg/h of banagrass Electricity: 42.500 MW/year for sale250 kW (el) 300 C exhaust500 kW (therm)for pre- heatprocessing of 600 C clean airfeedstock for cogen Fertilizer ash 16
  17. 17. GAS TURBINE PROCES ACTUAL IFGT TURBINE 17
  18. 18. GASIFICATION UNIT AT ORDOS / CHINA 18
  19. 19. MF 480 B IN COMBINATION WITH 5 MW IFGT pre-processing conversion output 3.000 kg/h of Microfuel MF 480 Dry banagrass Gas 420 kg pellets B ~14% for internal proces Bio-Oil 990 ~ 33,0% kg 800 kW (el) 750 kW (therm) 600 kW (el) 420 kg gas ~49,0% 250 kW (therm) for burning Char 1.470 kg4.000 kg/h of chamber<12% banagrasspellets ~4% Water 120 kg 27.200 MW/year for local electricity 5 Mwh Turbine Unit 300 C exhaust heat 300 kW (el) 600 C clean air for 350 kW (therm) of which ~ 1.8Mwh for internal cogen for post- proces at cost price of ~ $ 0,07 kwh processing of bio-oil Material flow per hour and reactor Fertilizer ash 19
  20. 20. PLANT DESIGN (1.000 TPD CAPACITY) 20
  21. 21. SINGLE MF 480 UNIT 21
  22. 22. PLANT LAYOUT 22
  23. 23. MODULAR DESIGN 23
  24. 24. CALCULATION OVERVIEW Input Capacity 1.000 ton per day / 10.000 ha plantages Investment ~ 300 MM Euro Annual total costs ~ 78 MM Euro Annual revenue from oil ~ 85 MM Euro Annual financial gains ~ 7 MM Euro Remaining biochar for free 500 tons per day Comparable value in Europe ~ 35 MM Euro p.a. 24
  25. 25. DETAILED SAMPLE CALCULATION Biochar to Europe from Bionic plantations in AfricaFeedstock 1000 tpd BiomassProduction 330 tpd Oil D2 800,00 € to 264.000,00 € 320 d 84.480.000,00 € 500 tpd Char - € to - € 320 d - € 84.480.000,00 €Investment reactors 12 reactors 6.900.000,00 € 82.800.000,00 € preprocessing 12 lines 5.500.000,00 € 66.000.000,00 € postprocessing 3 lines 12.000.000,00 € 36.000.000,00 € 184.800.000,00 €farming trucks 150 units 110.000,00 € 16.500.000,00 € harvesting 12 units 1.100.000,00 € 13.200.000,00 € pruning 12 lines 440.000,00 € 5.280.000,00 € misc 10 1.000.000,00 € 10.000.000,00 € 44.980.000,00 €cultivation of land preparation 10.000,00 ha 1.500,00 € 15.000.000,00 € seedlings 10.000,00 ha 1.000,00 € 10.000.000,00 € fertilizers 10.000,00 ha 500,00 € 5.000.000,00 € misc 10.000,00 ha 1.000,00 € 10.000.000,00 € 40.000.000,00 €Total Investment 269.780.000,00 € depreciation 12,00 years 22.481.666,67 € interest 4,50% p.a. 12.140.100,00 € annual capital costs 34.621.766,67 €Annual costs capital cost 34.621.766,67 € staff 350 employees 500,00 € 2.100.000,00 € recultivation 10000 ha p.a. 1.200,00 € 12.000.000,00 € fuel 2500 to p.a. 800,00 € 2.000.000,00 € catalyst 1600 to p.a. 4.400,00 € 7.040.000,00 € maintenance 6% average 229.780.000,00 € 13.786.800,00 € lease of land 10000 ha p.a. 200,00 € 2.000.000,00 € misc 1.500.000,00 € 1.500.000,00 € management 2.500.000,00 € 2.500.000,00 € 77.548.566,67 € Revenue 6.931.433,33 € 25
  26. 26. COMPARING OF COSTS comparing to traditonal fossile char Fossile Char from Canada or Australia 500 free border 220,00 € 320,00 d 35.200.000,00 € 500 CO2 zertificates 13,00 € 320,00 € d 2.080.000,00 € Total 37.280.000,00 € Biochar from Africa 500 to - € 320,00 € d - € 500 to transport 40,00 € 320,00 € d - 6.400.000,00 € ./. revenue 6.931.433,33 € Total 531.433,33 € savings per year 36.748.566,67 € 26
  27. 27. BIONIC IN GHANA• Bionic Palm Limited (BPL) is registered in Ghana as a 100% subsidiary of Bionic Fuel Oil Trading Ltd, Singapore (BFOT) since 2007.• BPL and BFOT are core members of the Bionic Group of Companies.• BPL is well integrated in Ghana‟s plant oil sector through strong local partners.• Ghana is the prime emerging economy in West Africa, politically stable with strong international ties to Europe and North America.• Ghana‟s strong economic development helped attaining the status of a mid income country in November 2010• Ghana offers favorable terms for foreign investment.• Ghana is positioning itself successfully for its role as “Gateway to West Africa”.• At least 80% of Ghana‟s arable land is currently unused. 27
  28. 28. TESTFARM IN 2010 28
  29. 29. ENVIRONMENT & RESOURCESIntegrated farming concept Eucalypthus, Miscanthus(elephant gras) e.g. Jatropha double hedge Bamboo , Castor are possible energy crops Change of agricultural crop on a regular basis reduces Natural pollination decrease of nutrients in through bees soil like in a monocropping changing crops Hedge roots stabilize soil Zero waste approach and prevent erosion fertilizer soil improvement any wasteValue food and energy products Harvested biomass from fields biomass press cake biochar Jatropha Seeds Food and honey for local markets Oil extraction Jatropha oil Synthetic Fuel Local soap production Biojetfuel Biochemicals Biochar and more 29
  30. 30. CONTINUOUS SOIL IMPROVEMENTBy improving soil all climate advantagesof tropical farming can be used:• 5 time faster growth of bio mass• up to 4 planting seasons under irrigation Growing more valuable food between hedges Growing maize and other grains between hedges Soil stabilization by reforesting Eroded savanna soil The continuous improvement of land from eroded soil to valuable farmland instead of radical change of land use saves resources and preserves the environment 30
  31. 31. DECREASING CO² FOOTPRINTRaising the amount of plants the CO²absorption volume will be increased fromthe first moment of farming Growing high value foods between hedges  Organic fertilizer, bio-char Significantly positive overall CO² balance Growing maize and other grains between hedges  Low till farming Soil stabilization by reforesting  Low impact clearing Eroded savanna soil depleted through unsustainable farming 31
  32. 32. ZERO WASTE INTERNAL CYCLES Energy Crops Jatropha Seeds Waste Biomass Biomass from plantages Microfuel plant Oil extraction Continuous fertilization and soil improvement 5% Biochar Press Cake Power Generation Export Export 32
  33. 33. SOCIAL RESPONSIBILITY & ENVIRONMENT Poverty reduction Integrated Domestic workforce Product Mix Zero waste approach National food security Low impact farming En eso & Building up a sustainable methods nv sou national food production uit ity vir ur Innovative tropical Re iro rc on al farming concept Eq sibil sp Soci nm ces nm y en en Healthy economy Carbon negative t t& Improving national footprint Re trade balance Sequestration of biochar Economic Prosperity & Continuity Economic Sustainability Production of bio-char & bio-oil Postive cash flows generated by Production of high calorific bio-char and selling maize and Jatropha oil bio-oil under sustainable conditions 33
  34. 34. LOCAL SOCIAL RESPONSIBILITY & EQUITY International markets Improved trade balance Fully local Import ExportBetter living conditions value chainfor local population - + More jobs Increased prosperity Supply of health servicesImprove level of training and education on the jobSocial innovation through Satisfy domestic food spillover effects demand with domestic production  Raising food security  Reducing food imports Poverty Reduction National Food Security Healthy Economy 34
  35. 35. AFFORDABLE ENERGY - THE BASIS OF PUBLIC PROSPERITYPublic prosperity requires economic growth, which in turn requires sufficient energy availability. Raising production requires more automation Increasing energy demands from machines and mechanization More production requires more goods to be moved Increasing energy demands of logistic operations from production sites to markets More economic growth requires more people to be Increasing energy demands of public transportation moved from home to work More personal prosperity raises private Increasing energy demands of private transportation expectations on quality of life Increasing energy for private housekeepingWithout enough affordable energy national economic growth is highly limited. The right sources of energy must be found for each national economy. Energy Energy fromSolar energy Wind energy Water energy based on biomass fossil fuelsTo expensive at this time Favorable, but requires Favorable, but requires High and unstable pricesfor emerging countries, back up source of energy appropriate rivers, cannot at world markets, A clearcannot be used for allnational energy demands depending on weather. Not sufficient for all be used for all national energy demands continually increasing prices in the future option for national energy demands the future 35
  36. 36. BIONIC‘S LASTING ENGAGMENT IN AFRICA• The Bionic Group has dedicated major portions of its future royalty income to philanthropic activities. Development Support for the African people plays a key role in that context.• At Bionic we believe in accelerating human development through sustainable business projects that create a lasting change for as many people as possible. This applies to the local community level as much as to the national and regional levels.• Bionic Palm has been living up to those standards in Ghana since 2007. We are working on completely new models to drive innovative agricultural and bioenergy sectors adapted to African requirements.• Bionic Palm currently operates a 150ha testfarm developing an approach that reclaims formerly depleted and eroded soils for agricultural use. The concept combines food and fuel at a 70/30 ratio, as Africans need both, food and energy.• In the same context Bionic Palm runs development programs for better seeds for the region and a Jatropha breeding program that aims to bring non-toxic Jatropha hybrids to the market at least doubling current yields at the same time 36
  37. 37. STRATEGIC PATH FORWARD Phase 5 Productio Plantations Biooil & Biochar 2015 n Phase 4 Managed Funds for Green Third Party Green 2013 BPL Plantations Finance Venture Investment Phase 3 Plantation Agri 2012 Consulting & Support Management Services Phase 2 Agri Agriculture 2011 Agriculture Logistics Processing Marketing & Trading Phase 1 Commercial Farming Test Breeding Program 2009 Food & Fuel Farming Jatropha and FoodFoundation 2007-2009 Innovative Knowledge & Technology Base 37
  38. 38. A TRUE WIN-WIN SITUATION Europe AfricaSignificant reduction of carbon footprint Production of a biofuel from localfor coal fired power-plants resourcesIndependence from fossile feedstock Reduced import cost, increased exportsIndependence from market Creation of hundreds of lasting jobs fordevelopments local workforceStable prices for several years Improvement in food securityUse of African climate situation for Poverty reductionfaster growth of feedstockSignificant cheaper prices than fossile Technology transfercoal, even cheaper than new processesusing wood pelletsImproved competitiveness at a lower Supporting REDD & CDM projectsrisk 38
  39. 39. EXPERIENCE Bionic, a group of companies Market approach since 2004 Several laboratory reactors in market Demonstration plant established in 2008 Modified Systems available for municipal waste, plastics, tyres and decontamination of hazardous soil Bionic Palm Ltd., Ghana Market approach since 2007 150 ha test plantation, 5.000 ha roll out in preparation Research for African food and fuel farming World leading Jatropha breeding program Smeral Brno a.s., Czech Republic Experience in mechanical construction and manufacturing since 1861 600 employees working on large scale manufacturing projects Acts as general manufacturer and contractor for the Bionic Group Process validation Bionics microfuel Technology has been validated in 2010 on a client„s request Report is available upon request 39
  40. 40. TECHNICAL STANDARDSBionic„s microfuel System complies to the following technical Standards: DIN EN ISO 9001 ASME Div 01, Div 02 (AIA TÜV, Germany) CE conformative declaration ATEX 94/9/EU explosive protection directive Maschinenrichtlinie (machinery directive) 2006/42/EU- manufactured by SMERAL a.s., BRNO, Czeck Republik 40
  41. 41. THANK YOU FOR YOUR ATTENTION @: info@bionic-world.de 41

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