Europabio and Partners Biorefinery Feasibility Study
Europabio and Partners Biorefinery Feasibility Study
Europabio and Partners Biorefinery Feasibility Study
The climate challenge The EU has set an ambitious target to reduce GHG emissions and oil dependency The key to achieve this goal is to establish a biobased economy that focuses on replacing oil in all applications including plastics, chemicals and other materials Europe is well positioned to spearhead the development of a new bioeconomy1 with world leading companies in the biochemical industry and strong agricultural industry However, the EU risks falling behind the US, Brazil and China as the development of the bioindustry is facing a major barrier due to the lack of demonstration facilities to mature technologies and commercialization It is urgent for Europe to capture the economic and environmental benefits arising from its research investments There is a gap in demonstration scale second generation biorefineries focusing on the production of high value products like chemicals, materials and fibres The industry is willing to invest but lacks public funding support to realize projects The bioindustry has come together to promote this goal (e.g. via EuropaBio)3 The ambition is to see at least two lignocellulosic demonstration scale integrated biorefineries within the following value chains: Biological enzymatic conversion of agricultural residue, hard wood and energy crops into C5 and C6 sugars and ultimately chemicals, materials and energy. The investment would be approx. 25-50 million2 per biorefinery Thermochemical conversion of wood and black liquor into chemicals, materials, fibres and energy. The investment would be approx. 150-200 million2 per biorefinery
Europe has great potential but risks falling behind Gap for demonstration biorefineries focusing on non-energy
1. Defined as an economy that does not base itself on oil but on renewable biomass. This includes bioenergy, biomaterials, chemicals, etc. 2. Rough estimate for new demo biorefinery the size of 10 tons of dry biomass per day for biochemical and 100 tons per day for thermochemical 3. However, the group present is mostly focusing on biochemical conversion as there are few representatives of the forest based sector. This group is therefore keener to support a biochemical conversion facility.
Start dialogue for FP8, PPP or a tailored European Biorefinery Initiative (EBI)
Agenda
1. Vision 2. Design and cost 3. Funding options 4. Location analysis 5. Governance models 6. Implications and implementation plan Annex A: Back ups
The world is facing many severe challenges Threat of climate change and environmental degradation
that 2nd generation biofuels can help to address Address climate change through emission reductions (GHG potential of -60% to -100%) No competition with food security (e.g. 1st generation crops) Stimulation of economic growth in agricultural and biochemical industries (green growth), with economic potential estimates of $300-400 billion1
1. McKinsey growth scenario for WEF, ADL Green Boom scenario Source: World Economic Forum, McKinsey
Europe is well positioned to exploit the bio-opportunity, but risks falling behind other countries
Europe is well positioned to spearhead development of a 2nd generation bioeconomy. Sophisticated agricultural sector with large availability of feedstock Strong network of biochemical clusters Strong commitment to GHG reduction Dominant market position in key technologies and inputs (e.g. Enzymes, biotechnology) Strong commitment to stimulation of EU R&D agenda in general and the knowledge-based bioeconomy in specific but risks falling behind Brazil, China and the US Brazil, China and the US invest heavily in biorefineries from an economic and global security perspective A substantial part of their funding is directed at closing the gap between research and commercial application Strong progress on first generation biofuels High ambitions and targets for the replacement of fossil transportation fuels Government support (e.g. through public technology grants) and tax credits Large-scale investments in biorefineries, often with participation of EU based companies implying a substantial risk for Europe losing the knowledge it has invested in building through research However, they are mostly focused on biofuels and less on other products leaving an attractive niche for Europe
Note: By 2020, the EU expects 20 percent of its power to come from renewables, part of which will have to be delivered by power derived from biomass. Additionally, 10 percent of all transportation fuels should come from renewable sources, which will require a substantial increase in penetration of bio fuels 5
Brazil, China and the US are making significant public investments in bringing biorefineries to commercial scale
US High targets for the replacement of fossil transportation fuels Wide range of support schemes including grants, tax credits, loan guarantees, etc Focus: bioethanol Public support last 5 years: ~ 1.2 billion EU High targets for the replacement of fossil transportation fuels Focus: biodiesel/ biochemicals Public support last 5 years1: ~ 200 million
BRAZIL World leading first generation biofuel production Some commercial 2G bagasse refineries in operation Aggressive government growth targets for bioethanol by 2025
CHINA Large-scale investment in biorefineries Plan to substitute 20% of crude oil imports by 2020 Target of 1.7bgy ethanol by 2010
1. Estimated funds provided by FP6 and FP7 to biorefinery-related projects Source: US Department of Energy, EU, World Economic Forum, Bio-economy.net
For example the US has multiple support mechanisms for the biorefinery industry focusing on demonstration and commercial application
US approach to biorefineries Mainly for solving national security issue of foreign oil dependency Focused on biofuels and bioethanol in particular Started under Bush administration and continued under current Support programs boosted with the Economic Recovery Act or 2010 granting USD 564 million to biorefinery projects Program (start year) Renewable Fuel Standard Description Goal to produce 36 billion gallons of biofuels by 2022 Act to favour biobased products over alternatives in public procurement Cataloguing and labelling products based on biorefinery ingredients Lucrative support for farmers to transition to energy crops USD 2-300 million per year support to 2nd generation biorefineries (mainly demo) Loan guarantee to finance commercial scale biorefineries Government institution US gov Dep. Agriculture
Low High
Demand
Bio-preferred procurement (2002) Bio-preferred labelling (2002) Biomass Crop Assistance Program (2008) Biomass Program
Dep. Agriculture
Dep. Agriculture
Dep. Energy
Supply
Dep. Energy
Dep. Agriculture
IRS
IRS
* Impact to date some programs have only been starting slowly and are therefore not showing too much impact yet Source: interview with BIO; Dalberg analysis
Overcoming the gap from research to funding (called the valley of death) requires co-investments from public and private stakeholders
Governments
Financing, technology, ideas
Markets
Number of projects
Demonstration
Deployment
Diffusion
Graphics: Mercer
2nd generation biorefineries align with EU priorities, but demonstration-scale biorefineries are needed to overcome the valley of death
Strong alignment with EU core priorities. The EU has defined three ambitions for 2020, which are linked to the biobased economy and 2nd generation biorefineries: 1. Smart growth: developing an economy based on knowledge and innovation but interventions need to be targeted, and aligned with other initiatives There is much research related to 2nd generation biorefineries in Europe (see next slide) However, there is a valley of death between early stage research and commercialization that requires intervention, especially outside the biofuel space (sustainable chemicals, biomaterials and fibres) This project is a feasibility study to investigate the opportunities to promote demonstration scale integrated lignocellulosic biorefineries in Europe This report lays out the vision, technical value chains and capital investments required as well as the funding options, implications on governance and implementation paths
2.
Sustainable growth: promoting a more efficient, greener and more competitive economy
Inclusive growth: fostering a highemployment economy delivering social and territorial cohesion
3.
Funding mechanisms
NER300
FP6 - FP7
EuroBioRef BioCoup SupraBio Leibniz Inst fuer Agrartechnik Icelandic biorefinery BioBase Europe CPI
EIBI
SupraBio Research projects Belgium (>20) Finland (>50) France (>20) Germany (>10) Sweden (>10)
Europe
Icelandic biomass Biorefinery Ireland BioMCN Nuon Europe BioHub Rotterdam Brensbach Abengoa Roquette/DSM Innventia
Sud Chemie
National funding (e.g. FNR - Germany, Nordic Energy Research, BOF - Belgium, BBSRC -UK, etc.)
BE Basic Inbicon
Company
Procethol 2G
DTU/BioGas Sekab
Sud Chemie
Inbicon Biogasol NSE Biofuels BioAmber Solvay Bio T-Fuel FMS Chemrec ARD Biodemo GoBioGas BPS
TMO
Research
Pilot
Demonstration
Europe is still far from a biobased economy despite the number of initiatives and funding mechanisms: Most facilities focus on biofuels Most funding is for research activities, rather than demonstration facilities
Establishing a strong biobased economy in Europe would have significant impact on the environment and oil dependency
Less petroleum used in the production of plastic from natural feedstock (corn) Less emissions in the production of propanediol from natural resources
Industrial biotechnology will bring environmental advantages to a number of industries (e.g. plastic production, textile, pulp and paper production industries, biofuels, etc.) Despite the early-stage technology, biotechnology already shows environmental benefits when compared to business as usual processes based on oilderived chemicals
Source: EuropaBio
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Building a strong biobased economy in Europe will create both revenues and jobs directly and indirectly Next to direct jobs, a biobased economy will also increase farmer income and improve economic activity in developing rural regions
Note: The numbers of biorefineries are determined by the ability of each region or member state within the EU27 to supply bioproducts. Jobs in the chart represent the total man-years of employment between 2010 and 2020, not the number of jobs in 2020 alone. Included jobs are in management, operation and construction of the biorefineries. Revenues are per year Source: Bloomberg
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Agenda
1. Vision 2. Design and cost 3. Funding options 4. Location analysis 5. Governance models 6. Implications and implementation plan Annex A: Back ups
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1. For a new biological enzymatic biorefinery the size of 10 tons of dry biomass per day the capital investment required will be in the range of 25-50 million. For a new thermochemical facility at 100 tons per day the capital investment is likely to be 150-200 million. If feasible to build on existing facilities investments required will drop substantially
14
point towards at least two pilot scale refineries To test both the biochemical and thermochemical value chains, it will be necessary to establish at least two specialized facilities As the demonstration scale facilities will be firstof-a-kind, and relatively small, they will be more expensive per unit produced than later facilities Building on existing facilities will lower capital investment required significantly
Nice to have
150-200 million
Nice to have
NB: The biochemical conversion does not include facilities for on-site enzyme production Source: Capex survey, technological survey, team analysis
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BACK UP
7-12 million
5-25 million
10-15 million
Total cost 150-200 million
Thermochemical integrated biorefinery on wood, 100 tons of dry biomass per day
Storage Crushing Thermal treatment Syngas Fibre Ashes & impurities Synthesis Destillation
Conversion of stillage + +
~ 30 million
70-100 million
40-70 million
Source: Capital Investment survey among experts, interview with Andritz, analysis of existing biorefineries
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Examples Co-locate with complementary industrial facilities Pulp & paper production Heat & power Agricultural processing, e.g. mills, first generation biorefineries, etc.
Synergies achieved Savings on capital infrastructure such as: Silos for feedstock storage Boilers Power plants Waste water treatment facility Access to feedstock supply Reduction in Capex (almost no investment needed except modifications to existing plant) Reduction in time to start testing operations Leverage skilled staff and experience build
Reduction of Capex needed Savings of 20-80% of new capex cost depending on level of synergies
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Agenda
1. Vision 2. Design and cost 3. Funding options 4. Location analysis 5. Governance models 6. Implications and implementation plan Annex A: Back ups
19
The European Industrial Bioenergy Initiative (EIBI) is the best option in the short-term. A tailored bioindustry initiative (EBI) would be better in the long-term. FP8 or PPP funding in the long-term are potential long-term options as well
The EIBI is already underway and is likely to open up funding before 2014. Although primary focus is on bioenergy, there is funding space for the biochemicals and materials
A tailored bioindustry initiative (EBI), the FP8 and PPP require changes to current programs and the outcome is uncertain A tailored bioindustry initiative build on the model of the EIBI would be a new initiative and as such the success is depending on broad support Previous PPPs (called JTI) have been deemed bureaucratic and are not likely to continue. The EC asks for input to redesign the PPP facility Using FP8 for biorefinery investment would require an expansion of funding eligibility from research to Capex investment
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Scarcity of resources
Urgency
Allow industry co-funding across the value chain to pool resources and expertise
Focus on short-term options as well as long-term
Long-term ownership
Source: Interviews with steering group members, steering group meetings, Dalberg analysis
21
Sub criteria
Evaluation Does the funding option enable demonstration at the right scale and of the desired technologies and products? Does the funding option make it possible to accommodate the different conversion technologies highlighted in this group? When will the grant realistically be awarded and what is the length of the process?
Fit
Technological match
Timing
Feasibility
How much additional funding needs to be raised, and from which sources? Does the funding option require additional public or private partners and how much involvement is required from the partners?
22
The majority of current funding comes from member states Loans from the EIB have not yet been available (high risk profile), even after RSFF
Grants
1%
Art. 185 initiatives National research entities such as FNR (Germany), Nordic Energy Research, BOF (Belgium), BBSRC (UK), etc. Loans and loan guarantees
86%
European Investment Bank Public loans Risk Sharing Finance Facility (under EIB)
None to date
This split of funding sources stresses the need to include member states in the strategic considerations for funding options
Funding for high risk research, development and innovation Risk shared with EC through capital cushion of 2 billion
TBC
1. Main funding source for current biorefinery research projects. Percent counted as number of projects not percent of total funding. Source: Star-Colibri D2.3 - Preliminary report on the global mapping of research projects and industrial biorefinery initiative s
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Majority of consortia members Location needs to be within located in one country or a few country or at border bordering countries Project focus need to be aligned Involvement from multiple local with: stakeholders (e.g. farmers, local Local resources (feedstock universities, local governments, available and prominent local national private sector, etc.) industry) Local political priorities (e.g. Example: Bio Base Europe Energy targets, research agenda, policies for regional and industrial development etc.) Members of consortia from several EU countries Often including research partners from countries involved Example: SupraBio project (launched under EC call for sustainable biorefineries) Location less determined, but regional development priorities could play a role Project focus need to match existing priorities and mechanisms The EU does not support research or demonstration of 1st generation biorefinery
EU funding
Funding options
Timing of grant Program/facility CPI, BE-Basic, BioBase Europe, ARD, etc. European Industrial Bioenergy Initiative (EIBI) Tailored European Biorefinery Initiative (EBI) Options to use
High Low
Work with/build on existing facility with potential support from FP7 call Establish consortia to answer EIBI call for demo facility Engage EC to include this initiative under the European Strategy for Bioeconomy Invoke a member state to support a biorefinery project Engage in FP8 dialogue to help define early FP8 call for demo biorefineries Help design new PPP instruments Form coalition to apply in 2014
Structural funds
FP8 call for biorefineries focused on non-fuels Long term (2015-) PPP for demo biorefineries focused on non-fuels NER300 Article 185
Establish consortia for next NER300 call Invoke national research support to form partnership Invoke national research institutions to establish joint call
25
Establish private consortia, define project and negotiate with existing facilities Apply to relevant FP7 call (if any)1. Alliance with existing facility enables to apply to small calls
Funding mandate but no funds allocated yet Member states allocation based on interest generated by EOIs Public funding for up to 50% of capex Expected size of grants2: 10-20 million for demo plants
Establish dialogue with EIBI to integrate this groups ambitions and co-funding options Partner with biofuels companies and member states for integrated biorefinery project Ensure member states support to proposed project and consortia as soon as possible Apply to EIBI Expressions of Interest and Calls
1. There might be an FP7 call to allow for targeted adjustments but not for building of new facilities 2. Typical size of grants allocated per project Source: Dalberg analysis, EU
26
BACK UP
Partner with member states, ETPs, industry and other stakeholders to rally for a tailored European Biorefinery Initiative (EBI) Inclusion of a tailored EBI under the European Strategy for Bioeconomy Ensure member states support to proposed project and consortia as soon as possible Apply to EBI Expressions of Interest and Calls
EU funds granted by member states or ~ 350 billion total regions Average size of grants: Aimed at resolving structural economic 200.000 (Interregio IV) and social problems Interreg funds most likely funding option
Partner with public institutions to develop a biorefinery project aligned with structural funds goals (convergence, competitiveness and employment, territorial cooperation) and matching an interregional cooperation Obtain member states support for the project
Form a private consortia and develop a common position in the biorefinery field Communicate common position to member states and EC through ETPs, Star-Colibri and individual reach out to member states
PPP between EC and private partners During FP7, the EC established PPPs through JTIs and other mechanisms New PPP structures are expected for 2014
Funds not allocated until the establishment of a PPP Funds pooled from FP8 and member state contributions
Help design new PPP program Establish a private sector consortia willing to commit funds (historically, at least 50% in the case of JTIs and other PPPs) Convince EC and ETP to establish biorefinery PPP
Join NER300
Article 185
Form alliance with member states willing to invest human and financial resources on a common research program and to apply for Art 185 to EC
Public sector instrument only, no direct private sector involvement EC mechanism to coordinate national research programmes Funding: from member states (at least 67%) and EC
Form alliance with at least 5 member states willing to launch a transnational research call and to negotiate with EC for financial support under the EraNet Plus supporting scheme
1. First round with a funding mandate of up to 3 billion was closed for applications early 2011 Source: Dalberg analysis, EU
30
Main Production focus: bioenergy Requires all stakeholders to implications Requires international consortia pool funding and design in Urgency to create project committee consortia, decide biorefinery Likely to require international vision and location EU consortia
Industry-driven initiative and Advantages Only funding window opened EIBIs biorefinery vision partially best option to pool funding aligned to bioindustrys needs Could be shaped to match (size, technologies) scope tightly (e.g. Urgency can foster dialogue Biochemicals and biomaterials and speed up decision making production) Joining the initiative is likely a Can result in good longer term better option than competing relation between industry and for the same funding public institutions with positive spin-offs
Challenges 70% bioenergy output Need to partner with bioenergy stakeholders Value chains predefined Some level of national/regional confinement to obtain member state support
Allows for 2-3 competing consortia No immediate geographical dependency Could be shaped to match scope tightly (e.g. Biochemicals and biomaterials production)
Tailored initiative would match scope tightly Attractive timing: European Strategy for Bioeconomy to be decided over the next few months
Uncertain bet as PPP facility Uncertain if the FP8 will currently in flux prioritize development and Uncertain size of funding make funding available for Long term option unlikely to Capex see public funding before 2015 May turn out very research Alignment on technical design, focused location and governance might Long term option unlikely to be challenging in joint see public funding before consortia of diverging interests 2015 in the most optimistic and competitors scenario Getting several DGs to align priorities and pool funding involves greater political risk
Will compete with EIBI for EC and member state funding Political will: member states support difficult to obtain (especially given the existence of EIBI already) Alignment on industry needs will require consensus from very different stakeholders
31
High Low
Negotiations can start Additional funding: funds needed to join as soon as a private existing facility consortium defines Additional partners: entity governing the demonstration project existing facility
Fit: EIBI can accommodate different conversion technologies and products Bioenergy needs to be 70% of output measured on energy content (including heat and power)
Feasibility: Additional funding: at least 50% from private sector Additional partners: at least 3 member states and 2 companies from different EU countries
Medium/High
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High Low
Medium/High
Additional funding: partially funded by private sector Additional partners: member states, ETPs, industries, research institutions, etc.
Fit:
Feasibility:
Medium
Allows for testing different conversion technologies and products Timing varies according to national priorities. Once national decision is taken, funds are allocated under certified expenditures
Additional funding: generally co-financing with own member state resources Additional partners: member state cofinancing the project and granting the structural funds
33
High Low
Medium/High
Feasibility Additional funding: partially funded by private sector Additional partners: likely EC and member states
Medium/High
Note: timing estimated according to past examples, expert insights or Dalberg research Source: Dalberg analysis
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High Low
Additional funding at least 50% from private sector Additional partners: none
Article 185
Feasibility: Additional funding: at least 50% from member states Additional partners: member states and EC Feasibility: Additional funding: at least 67% from member states Additional partners: member states and EC
Medium/Low
Fit: Focused on research (no support of demonstration) Funds allocated in the long-term (expected later than 2014)
Medium/Low
Note: timing estimated according to past examples, expert insights or Dalberg research Source: Dalberg analysis
35
These funds could influence the biorefinery economics and feasibility but cannot contribute to cover the capital investments required
Agenda
1. Vision 2. Design and cost 3. Funding options 4. Location analysis 5. Governance models 6. Implications and implementation plan Annex A: Back ups
37
Decision 1:
Decision 2 (if decided to build a new facility) Funding mechanism Feedstock, technical route, output What needs to be tested
Decision 3:
Decision Criteria:
Availability of time and financial resources Project match with existing facilities
Open funding windows Member states support Consortias private interests, state of the art of the technology, key areas to test
Economic synergies Operability, access to talent pool and expertise Feasibility to join the cluster (regulation, capacity, etc.)
Existence of local feedstock market close to cluster Degree of industrialization of agriculture/forest processing Crops/forest residues yields Access to transportation network Selection of key clusters offering the best colocation synergies, feedstock availability and transportation costs
38
Decision outcome:
The specific location will be a function of the funding strategy applied High-level region defined by type of funding, output and feedstock focus and member states involvement Specific location defined by co-location synergies, feedstock availability and transportation costs to end users These criteria are unnecessary if the consortia decides to build on existing facilities to leverage knowledge and minimize funding needs
39
40
Feedstock cost, transportation costs, synergies from co-location and funding High importance and regulation are key factors for the location decision Low importance
% of final product value 60 25-40 40
Key variables for location decision
10-35 5-10
20 0
Feedstock cost1
10-30
5-10 Transportation and logistics Proximity to end users Accessibility to transport infrastructure
Capital costs
Function of geography
Cost of Total Capex energy/utilities/water Plant capacity/ and other operating technological costs scope Cost of labour/ construction materials
Function of co-location
Function of funding options and local regulation 1. Feedstock: lignocellulosic material. 2. Other operating costs: electricity, water, waste disposal, etc. 3. Other fixed costs: real estate leases, maintenance, etc. Note: these graphs are an approximation for illustrative purpose only. The exact breakdown will depend on the final value of the product Source: National Renewable Energy Laboratory, Expert interviews, Dalberg analysis
41
Relative importance
1 Synergies from colocation
Higher importance for a demonstration plant due to significant Capex savings Additionally, positive impact on the plants operability through shared staff, access to talent pool and expertise, etc.
3 Feedstock cost
Lower importance for a demonstration plant given the limited feedstock required As a result, a demonstration facility will have bigger flexibility to feedstock availability than a commercial plant (where this is the paramount variable)
4 Transportation cost
Lower importance for a demonstration scale plant, given the limited output sold in the market
42
Co-location generates synergies for the biorefinery by reducing Capex up to 90% and Opex up to 15%
Synergies from co-location arise along the value chain: Upstream, through proximity to agriculture processing facilities and paper pulp mills Midstream, through integration into existing industrial complexes Downstream, through proximity to end users
Funding and regulation and regulatory environment impact Capex and Opex through: Different EU priority regions Availability of local co-funding Local tax credits and waste water regimes
Feedstock costs are 25-40% of the COGS The key driver for feedstock cost is its availability in the biorefinery surroundings The availability of agriculture residues depends on crop production, yield and degree of development of the infrastructure to collect residues In the case of forest residues, feedstock availability is a function of wood and wood residues production Transportation costs to end users are 5-10% of the COGS Transportation costs are mostly driven by: Access to good transport infrastructure Distance from the biorefinery to customers (e.g. chemical, biotech, pharma and plastic industries)
Cost of feedstock
43
1. Co-location with existing facilities generates synergies along the value chain
Synergy description Feedstock collection Upstream Feedstock reception and pretreatments Surrounding cereal cooperatives supply more stable quantities of agriculture residues Proximity to cereal/sugar beet processing facilities provides cheaper feedstock because of low transportation costs Integration of forest-based biorefineries with paper pulp mills ensures feedstock availability and minimizes capex and operational costs
Biomass degradation
Availability of experienced staff and access to good talent pool in the region Proximity to heat/power factories Allows the biorefinery to generate heat/energy through combustion of waste products Obtains heat/energy from other plants in the industrial complex (those with a positive energy balance ) Proximity to certain factories (e.g. Sugar beet refineries) can provide input for the biorefinery such as water, CO2 or sucrose Integration into an industrial complex can provide waste water and other effluent treatment facilities Synergies from tailored in-the-field R&D
Biomass treatment
Reduced energy costs (Opex) Savings in boilers, CHP plants, etc. (Capex)
Midstream
Biomass treatment
Output refining
Proximity to end users (e.g. biofuel buyers) and other companies using biorefinery output as a production factor (e.g. chemical, pharma, plastic industries, etc.)
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1,0
1,0
1,0
1,0
1,0
0,9
0,9
0,9
0,9
0,5
0,0 Ger Den Ire Ita Bel Pol Hun Fra Aus
The exact co-location decision will need to consider synergies arising from each cluster, however Northern Europe seems to present a stronger starting point with well established clusters of the relevant industries
1. Data for 2009. Size measured in number of employees, according to European Cluster Observatory (ECO) methodology 2. According to the Star Ratings of the European Cluster Observatory. Data for 2009. Calculated as the average of biotech, plastic, pharma and chemical clusters ratings Source: Eurostat, Biorefinery, European Cluster Observatory (ECO)
45
1. The paper pulp industry in Scandinavia has the biggest co-location potential for forest-based biorefineries
High paper pulp production areas
Integration with paper pulp mills provides feedstock supply (black liquor) to biorefineries
Integration (through additional modules to a paper pulp mill facility) reduces Capex substantially
Examples estimate the cost of adding biorefinery facilities to an existing pulp and paper plant to be only 25% of the capex required to build a new plant of same capacity
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Upstream synergies
Midstream synergies
Downstream synergies
Feedstock supply (wheat and glucose) from wheat silos and wheat biorefinery
Energy and steam provided by cogeneration facilities Water supplied by sugar beet biorefinery
Minimum transportation costs to end users (BioDemo - biotechnology industrial plant in the cluster)
Unknown
Processum (Sweden) Black liquor supply from integration to paper pulp mill Energy, steam provided by cluster facilities Minimum transportation costs to end users (companies producing ethanol and ethanol derivatives present in the cluster) Unknown
Wheat straw collection infrastructure available from co-location with heat and power generation
TBD
Unknown
47
Co-location generates synergies for the biorefinery by reducing Capex up to 90% and Opex up to 15%
Synergies from co-location arise along the value chain: Upstream, through proximity to agriculture processing facilities and paper pulp mills Midstream, through integration into existing industrial complexes Downstream, through proximity to end users
Funding and regulation and regulatory environment impact Capex and Opex through: Different EU priority regions Availability of local co-funding Local tax credits and waste water regimes
Feedstock costs are 25-40% of the COGS The key driver for feedstock cost is its availability in the biorefinery surroundings The availability of agriculture residues depends on crop production, yield and degree of development of the infrastructure to collect residues In the case of forest residues, feedstock availability is a function of wood and wood residues production Transportation costs to end users are 5-10% of the COGS Transportation costs are mostly driven by: Access to good transport infrastructure Distance from the biorefinery to customers (e.g. chemical, biotech, pharma and plastic industries)
Cost of feedstock
48
External financial support is key for the economic sustainability of the biorefinery Most EU biorefinery related projects are funded by member states through national funds EU biorefinery landscape is very diverse given the different national supporting schemes Scandinavia, Benelux, France and Germany are leading this industry in terms of number of biorefinery related projects Despite greater availability of EU structural funds, Eastern Europe is still lagging behind Nations with strong biorefinery activity offer advantages beyond financial support (upstream, midstream and downstream synergies)
72 59 49 40 34
11 5
Fin
Fra
Ger
Net
Swe
UK
Pol
Hun
Co-location generates synergies for the biorefinery by reducing Capex up to 90% and Opex up to 15%
Synergies from co-location arise along the value chain: Upstream, through proximity to agriculture processing facilities and paper pulp mills Midstream, through integration into existing industrial complexes Downstream, through proximity to end users
Funding and regulation and regulatory environment impact Capex and Opex through: Different EU priority regions Availability of local co-funding Local tax credits and waste water regimes
Feedstock costs are 25-40% of the COGS The key driver for feedstock cost is its availability in the biorefinery surroundings The availability of agriculture residues depends on crop production, yield and degree of development of the infrastructure to collect residues In the case of forest residues, feedstock availability is a function of wood and wood residues production Transportation costs to end users are 5-10% of the COGS Transportation costs are mostly driven by: Access to good transport infrastructure Distance from the biorefinery to customers (e.g. chemical, biotech, pharma and plastic industries)
Cost of feedstock
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3. Feedstock availability
Given the high transportation costs, the availability of feedstock in biorefinery surroundings is key However, a demonstration scale facility is much more flexible with regards to feedstock availability than a commercial one (given the different feedstock needs) Feedstock availability depends on the existence of feedstock markets in the region Feedstock markets tend to be relatively local as it is rarely viable to transport feedstock like agricultural residue more than 100 km The price for agricultural residues is lower in unorganized markets but the infrastructure cost is likely to be higher Currently, only some countries have an organized market for these residues (e.g. Denmark straw market, result of utilities obligation to produce a share of their energy from straw)
However, the market for agricultural residues is likely to become more commoditized and transparent in the near term, given the increasing demand from biorefinery-related projects
As many European member states do not currently have an organized market, the best proxies to measure feedstock availability are the regional crop production and yields
51
10 9 8 7 6 5 4 3 2 1 0
T/ha
Regions with high production and high yields offer a better feedstock availability and minimize supply costs Feedstock costs will be relevant for the biorefinery in order to provide the best simulation possible of these costs at a commercial scale
Note: Data for 2007 distributed according to NUTS 2 classification (territorial units for statistics at the EU level). Cereal as defined by Eurostat (wheat, corn, barley and other cereals). Average yields per year from 2005 2010 Source: Expert interviews, Eurostat, Dalberg analysis
52
80 70
75,4 61,6
60
10
53,4
8,3
5,6
50 40
30
2,8
1,8 1,6
20 10 0
Swe Ger Fra Fin Pol
0
Swe Fin Fra Aus Spa Lat Ger Est UK
The wood industry is highly concentrated in Sweden, Finland, Germany and France The production of wood residues could potentially be doubled but there is no current financially viable infrastructure for the collection of fellings, roots, branches etc. from the forestry sites
1.Wood residues: miscellaneous wood residues, those which have not been reduced to small pieces. They consist principally of industrial residues 2.Wood: Wood in the rough, in its natural state as felled, or otherwise harvested, with or without bark, round, split, roughly squared or other forms (e.g. roots, stumps, burls, etc.). All wood obtained from removals Source: FAOStat, UNECE, METLA, Dalberg analysis
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Co-location generates synergies for the biorefinery by reducing Capex up to 90% and Opex up to 15%
Synergies from co-location arise along the value chain: Upstream, through proximity to agriculture processing facilities and paper pulp mills Midstream, through integration into existing industrial complexes Downstream, through proximity to end users
Funding and regulation and regulatory environment impact Capex and Opex through: Different EU priority regions Availability of local co-funding Local tax credits and waste water regimes
Feedstock costs are 25-40% of the COGS The key driver for feedstock cost is its availability in the biorefinery surroundings The availability of agriculture residues depends on crop production, yield and degree of development of the infrastructure to collect residues In the case of forest residues, feedstock availability is a function of wood and wood residues production Transportation costs to end users are 5-10% of the COGS Transportation costs are mostly driven by: Access to good transport infrastructure Distance from the biorefinery to customers (e.g. chemical, biotech, pharma and plastic industries)
Cost of feedstock
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4. Transportation costs are minimized through good infrastructure and proximity to customers
Accessibility1 to transportation infrastructure
High potential
Concentration of potential end users (Revenues of chemical, rubber and plastic industry2) Billion 178 180
160 140 120 100 80 60 40 20 0 92 79 56 50 40 33 15 15 126
Ger
Fra
UK
Ita
Net
Spa
Bel
Ire
Pol Swe
The cost of transportation to customers depends on distance and cost/quality of transport infrastructure Benelux, northern France, Germany and southern England have the best access to transport infrastructure Potential customers in the chemical, rubber and plastic industries are mostly concentrated in Germany, France and the UK
1. Accessibility (as defined by ESPON): combines level of economic activity in a certain region with the effort, time, distance and cost needed to reach that area 2. Data for 2007. Includes revenues generated by the manufacturing of chemicals, rubber and plastics industries Source: ESPON Project 1.2.1, European Monitoring Center on Change, Eurostat, Dalberg analysis
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Highest values
Funding options Biorefinery landscape4 Medium High Low Low Low High Low High High High Medium Medium Low Medium Low Low Low Low High Medium Medium Low Low Low High High High
Cereal production yields (t/ha)1 6.1 9.6 4.1 1.2 4.8 6.0 2.7 3.4 7.0 6.7 3.7 4.9 7.2 4.9 2.8 2.9 5.7 0.0 8.3 3.2 2.8 2.9 4.2 5.5 3.0 4.8 7.1
Wood production (Million m3)2 19.1 4.8 5.6 0.0 16.8 2.7 5.0 50.4 53.4 61.6 1.5 5.6 2.5 8.3 11.4 5.8 0.3 0.0 1.1 33.8 10.4 14.0 8.7 2.9 15.4 75.4 8.6
1. Average national production 2005-2010 2. Wood: Wood in the rough, in its natural state as felled, or otherwise harvested, with or without bark, round, split, roughly squared or other forms (e.g. roots, stumps, burls, etc.). All wood obtained from removals 3. According to Star Ratings of European Cluster Observatory (2009). Average ratings for EU biotech, plastic, pharma and chemicals industry. Shows clusters specialized critical mass to develop positive spill-overs and linkages (based on three main criteria: cluster size, specialization and focus) 4. Based on number of biorefinery related projects, according to Star Colibri database. Includes private, public and EU funded projects
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Wood biorefining in Scandinavian forests Sweden, Finland, Norway Score: High potential synergies across value chain (pulp mills, bioclusters, customers) Good access to biorefinery expertise and talent pool
Score: High EU support Limited national support Few ongoing projects Score: Extensive agricultural area Low cereal yields Score: Medium distance to customers Good access to transport network Low fit region for biorefinery Likely EU support and lower Capex and Opex Limited synergy and national support
Score: Limited EU support High national/regional support Dense biorefinery landscape Score High feedstock availability (black liquor) from integration with pulp mills Score: Proximity to customers Good access to transport network High fit region for forest residues demonstration biorefinery High synergy possibilities and likely national support
Transportation cost
Overall potential
In the long-term, other regions could become attractive (e.g. Eastern Europe), as particularly feed stock availability develops. This will be of higher importance for a full scale commercial biorefinery.
Source: Dalberg analysis
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Agenda
1. Vision 2. Design and cost 3. Funding options 4. Location analysis 5. Governance models 6. Implications and implementation plan Annex A: Back ups
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Ownership
Access
Open access. IP property of entities Open access renting the facility Preferential access to partners Management team Advisory board Ghent Bio Energy Valley, Bio Park Terneuzen, Dutch and Belgian Governments TBC TBC
Governance bodies/model
Key stakeholders British Government Industry players Mainly customers of facility Advisory role contributing expertise and customer flow ~100% public (British Government)
Delft University, Research institutions, DSM, Purac, other Private funding In kind contribution (skills, staff, etc.)
Role/ contribution of private partners Capex funding source Opex funding model
Source:
100% public (Interregio IV, Dutch 30% public (Dutch national and national and regional governments, regional funds) Flanders government) 70% private
Mostly fees from research and Fees from research and innovation ... innovation projects renting the facility projects renting the facility Public grants
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Agenda
1. Vision 2. Design and cost 3. Funding options 4. Location analysis 5. Governance models 6. Implications and implementation plan Annex A: Back ups
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The setup and timelines for FP8 and PPP are uncertain.
The project structure and responsibilities will be different between the FP8/EIBI and the PPP setup The PPP will require joint project governance and technical design decisions among all stakeholders The EIBI and FP8 will require joint industry coalition to promote the prioritization of non-fuel biorefineries but will enable several project consortia to test competing technologies All funding mechanisms require at least 50% private sector co-funding, which would require a private sector coinvestment of up to 125 million depending on scope and ambition
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EIBI group EC, member states, Industry research and industry stakeholders Biofuel producers Max 50% public Min 50% private consortia Likely to require public research institutions Max 50% public Min 50% private consortia
Member states, supporting EU projects with the biggest national interest EU may contribute top up funding through ERA Net Plus Overall EIBI Detailed private consortia PPP consortium
Overall the initiative coalition of ETPs, member states and industry Detailed private consortia TBD Choice to build on existing facilities Member state support TBD
Optimal conditions to minimize TBD cost (see location analysis) Potentially EU priority regions Potentially EU priority regions Public-private governance Private governance, but likely to require some public access Private consortia, unlikely to be open facilities
To be decided by consortia PPP consortia Could accommodate open facility Could accommodate open if consortia agrees facility if consortia agrees
TBD
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Next step
Tailored EBI
FP8
Existing
PPP
New
Existing
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Use of the EIBI Is your desired project feasible within window or set up own the technical parameters? initiative: EBI Do you believe it will be easier to collaborate than compete for funding?
Preparation of decision will require an urgent dialogue with EIBI to prepare groundwork Positive EIBI decision commits the industry to aggressive time-scale, requiring implicit agreement by companies on competitive coalition approach The decision to go for an own program (EBI) also requires immediate action and strong collaboration with ETPs and other stakeholders
Is it attractive to pool investments with A collaborative approach will require this group? Coalitions between companies to drive design and Do you believe that you can align on a provide application assistance feasible and satisfactory technical EuropaBio as trusted broker and liaison with EU design and scope by collaboration? A competitive approach will require ETPs and industry to coordinate technical design process and drive proposal submission Companies to work in committee towards consensus designs
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Strategic partnerships can ensure sound economics, steady supply of biomass and expertise but too many stakeholders may challenge the decision power of the consortia
FP8 aligns with a competitive approach, whereas PPP follows a collaborative approach, with significant implications for roles & responsibilities
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Support in creation of coalitions Application assistance Trusted broker between / within coalitions
Support to prepare submissions (standard requirements, non-technical components) Support to prepare submissions (standard requirements, non-technical components) Exchange of non-sensitive information between coalitions / companies
Facilitation of design
Facilitation of meetings and consensus building across companies on technical design, financial design and location
Submission of proposal
Creation of coalitions
Partnering with companies that are closely aligned on technical design / location / operating model Preparation and submission of the proposals (together with partners and support from bioindustry coordinator)
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Compilation of industrys needs and arguments Structure these needs around a Strategic Research Agenda Support EC in defining future funding mechanisms (EIBI, FP8, etc.) Support EC in the actual fund allocations (calls)
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Refinement / changes to strategy document Approval of strategy Definition of roles & responsibilities of key stakeholders Mapping of financial implications / budgets Finalization of timelines Approval of implementation plan Location TBD Communication of strategy
Implementation
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Agenda
1. Vision 2. Design and cost 3. Funding options 4. Location analysis 5. Governance models 6. Implications and implementation plan Annex A: Back ups
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BACK UP BASED ON 9 RESPONSES Essential to test both thermochemical and biological in same plant (Number of responses) 6 2 No Not essential, But if possible
3
2 0
4 Yes No
I am indifferent
Biological Enzymatic Steam explosion Gasification Biological Acidic Combustion Anaerobic fermentation Pyrolysis Chemical conversion (catalytic) Waste water treatment
9 4 4 2 2 2 2 1 1
2 0
2 0
>10
10
50
100
>100
Comment: Depends on what needs to be tested. Gasification will require high volume while other technologies can be tested at smaller scale
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BACK UP BASED ON 9 RESPONSES Essential to test several feedstock in same plant (Number of responses)
8
Energy crops
Whole crop
Yes
No
Additional feedstock to test (Number of responses) Forest resources Energy crops Agricultural residue First generation sugar crops Municipal waste Algae Food/oils
1 1 3 3 4 5 6
Funding model EIBI estimates total Capex for the 14 projects to be ~ 2.6 billion There are no funds allocated to these projects at present Project funding will be 50-50 public-private Most EIBIs public funds will come from member states Member states will decide the amount of funding granted, based on project descriptions (EOIs) and national interests Most national funding will be linked to specific projects EC might provide minor funds to incentivize cooperation across member states (under ERA Net Plus, still to be confirmed by EC) Private funding will cover (at least) 50% of the Capex of the project
1. Measured as energy content (including heat and power) over total plants output Source: EIBI, Interviews
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FP7 calls Calls are not public in advance. The EC defines and launches new calls several times per year Funds allocated to each call depend on type of projects funded and available budgets When defining new calls, the EC consults member states, industrial associations and other interest groups FP7 calls can support up to 30% of demonstration projects and up to 50% of research projects Funds for each call vary depending on the nature of the project Calls generally have intense competition. Strong research consortia with a balanced EU geographical presence have a competitive advantage
Timing Several times per year during FP7 Call definition generally takes place 6-9 months prior to the launch of the call Several times per year during FP7 1-2 years before the program starts
Entities involved Negotiation: European Commission, member states Approval: European Commission
European Commission
Negotiation: European Commission, European Council, member states, private sector, interest groups and other stakeholders
European Council
NER300 focus areas The NER300 is structured around Carbon Capture and Storage (CCS) and Innovative renewable energy technology The Renewable Energy Technology category includes: 1. Bioenergy: lignocellulose, household waste or algae to electricity or biofuels 2. Concentrated solar power 3. Photovoltaics 4. Geothermal 5. Wind 6. Ocean 7. Hydropower 8. Smartgrids
Lignocellulose to intermediate solid, liquid or slurry bioenergy carriers via torrefaction with capacity 40 kt/y of the final product
Lignocellulose to Synthetic Natural Gas or synthesis gas and/or to power via gasification with capacity 40 million normal cubic metres per year (MNm 3 /y) of the final product or 100 GWh/y of electricity Lignocellulose to biofuels or bioliquids and/or to power including via directly heated gasification with capacity 15 million litres per year (Ml/y) of the final product or 100 GWh/y of electricity. Production of Synthetic Natural Gas is excluded under this subcategory Lignocellulosic raw material, such as black liquor and/or products from pyrolysis or torrefaction, via entrained flow gasification to any biofuels with capacity 40 Ml/y of the final product Lignocellulose to electricity with 48 % efficiency based on lower heating value (50% moisture) with capacity 40 MWe or higher Lignocellulose to ethanol and higher alcohols via chemical and biological processes with capacity 40 Ml/y of the final product Lignocellulose and/or household waste to biogas, biofuels or bioliquids via chemical and biological processes with capacity 6 MNm 3 /y of Methane or 10 Ml/y of the final product Algae and/or micro-organisms to biofuels or bioliquids via biological and/or chemical processes with capacity 40 Ml/y of the final product
78 Source: NER300
Governance model Private public partnership Management team: strategy and day-to-day operations Advisory board: PPP members and other stakeholders (e.g. university of Ghent)
Funding model Capex ~ 21 million to date, almost 100% publicly funded Structural funds (Interreg IV): ~ 6 million Belgium (Flanders) and the Netherlands (government and provinces): ~ 15 million Opex: Covered through fees from research and innovation projects
CPI facilities
Development lab 1000 L pilot facility 10.000 L demonstration facility Plug & play reconfigurable set up based on: Fermentation Chemical processing Extraction Pyrolysis and gasification facility (in progress)
Funding model
Capex: ~ 70 million to date Almost 100% publicly funded (mainly British government through different pots)
Opex: Mainly covered through project activity Currently no core funding, but some public grants to help market failures Aim for Opex mix of 1/3 public, 1/3 private and 1/3 public-private consortia Projects range from 1000 to several hundred thousand Pounds
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BE-Basic
About BE Basic Research and innovation center Facility not operational yet Open access to private sector and research players Preferential access to BE-Basic partners (universities, research institutions and the private sector) Governance model Private public partnership between universities, research institutes and 24 companies PPP owns the facility and manages the strategy and day-to-day operations PPP coordinator: Delft University of Technology
BE Basic facilities
Integrated second generation biorefinery, modular setup, pilot scale Feedstock: agricultural waste and non food crops Technologies: biological conversion Output: biofuels, bioplastics and other bioproducts
Funding model
Publicly and privately funded: Dutch public funds (Government and provinces), EU, universities, private sector Capex Research program (flagships): 120 million Pilot facility: 100 million Subsidies from regional funds and local bodies: 30 million
81 Source: BE-Basic
Funding model
Demonstration facility Technology description: Feedstock: agricultural crops and lignocellulosic material Technologies: biological conversion, extraction and purification Output: organic acids, diols, etc. Capacity: 2,500 tones per year
Publicly and privately funded: 21 million European Regional Development Funds: 2.5 million Dpartement de la Marne: 1.25 million Rgion Champagne-Ardenne: 1.25 million Private (ARD and banks): 16 million
82 Source: ARD