Mastering Technological Complexity

Interdisciplinary. Integral. Innovative.

Innovations For A Sustainable Future

Dr. H.J.Leimkhler
BTS - Your partner for projects in the chemical and pharmaceutical industry

The Long-term View of CPI Feedstock and Energy Availability

Our tasks for the next decades:

Secure reliable energy and feedstock supply for the CPI at reasonable costs
- Enhance the efficiency of our processes - Decrease petroleum dependency - Develop a second supplier for energy and raw materials
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 2; 2002-07-10 page 2; 2007-04-27

Topics

Short introduction Energy Savings: Enhance Energy Efficiency

- The Energy Audit

Biofuels: Release the Petroleum Market

- Development of Economic Biodiesel Processes

The Second Supplier: Renewable Feedstock

- Challenge for Research

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 3; 2002-07-10 page 3; 2007-04-27

Bayer - Management Holding Structure

Holding Company
Group Management Board
Corporate Center

Bayer AG

Business Areas
Bayer HealthCare Bayer CropScience Bayer MaterialScience

Service Areas
Bayer Business Services Bayer Technology Services Bayer Industry Services

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 4; 2002-07-10 page 4; 2007-04-27

The Bayer Group

Bayer Facts and Figures 2006
106,000 employees worldwide 430 companies 5,000 products Sales: EUR 29 billion EBIT: EUR 2.8 billion Net income: EUR 1.7 billion R&D expenses: EUR 2.3 billion Capital expenditures: EUR 1.7 billion

Bayer Objectives
Leader in research and technology Continuous growth of expertise in the manufacture of high-quality and environmentally compatible products
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 5; 2002-07-10 page 5; 2007-04-27

Enhanced Energy Efficiency in the EU chemical industry

The Energy intensity* in the EU chemical industry has decreased

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 6; 2002-07-10 page 6; 2007-04-27

How to enhance energy efficiency

Quick Energy Check
- Quick Check of production plants - Potential energy savings: 5 % of total consumption

Comprehensive Energy Audit

- Systematic Analysis of production processes - Potential energy savings: 10 % of total consumption

Development of Integrated Processes

- Disruptive change of production process - Potential energy savings: 30 - 50 % of total consumption

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 7; 2002-07-10 page 7; 2007-04-27

Energy Check and Energy Audit

Energy Audit ...
applies a wide range of state-of-the-art methods and tools in a systematic approach brings together the experience of plant managers, operators and experts saves 5 to 10 % of total energy consumption and costs (several references) detects additional ideas for process improvements
Data Analysis (Six Sigma, Data Mining) Energy Distribution (Sankey Diagram)

Definition Definition
Reaction

MF 1618 KW

Equipment Checks
Ethylen NH3

4400 KW

Best Practice
Khlwasser

Analysis Analysis Optimization Optimization Assessment Assessment

iC5

Benchmarking Utility Checks

Process Modeling

Pinch Technology
pinch point
TEMPERATURE

min heating demand

Performance Monitoring Energy Management

Implementation Implementation
HEATER

Sustainability Sustainability
min cooling demand

heat integration possible

ENTHALPY

Energy audits up to 10% energy savings with reasonable effort Energy audits up to 10% energy savings with reasonable effort
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 8; 2002-07-10 page 8; 2007-04-27

Comprehensive Energy Audit: An Example (1)

Project Background A polymer production site strongly integrated process High process-dependent energy consumption Mostly continuous mode of operation Evaluation of energy generation, steam, cooling water, refrigeration Objective: Complex-wide optimization of energy consumption and costs
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 9; 2002-07-10 page 9; 2007-04-27

Comprehensive Energy Audit: An Example (2)

Project Data and Results
Duration: 1 Year
40 % Analysis 30 % Optimization 30 % Evaluation

12 of the steps without investments Total savings: 7 - 10 % (energy consumption and costs) Site complies with regional Kyoto Protocol regulations Bayer Technology Services manages and implements the project

85 identified steps
30 steps from Pinch Analyses 25 steps from brainstorming 30 steps from expert assessments

35 to 50 steps are feasible 25 steps are economical and will be implemented

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 10; 2002-07-10 page 10; 2007-04-27

Development of Integrated Processes

Preliminary process concept

Basis: Chemistry Kinetics Experimental work

Evaluation

The best solution: Economic Process concept

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 11; 2002-07-10 page 11; 2007-04-27

Example: Isocyanate production

R NH2 + 2 COCl2

R NCO + 4 HCl

Old Design
Phosgene 100 Parts

New Design
Phosgene 30 Parts Solvent 20 Parts

Solvent 100 Parts

Amine

Amine Isocyanate

Isocyanate

Reaktion Reaction
Phosgene

Distillation
Phosgene

Reaktion Reaction

Distillation

Energy Savings: 40%

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 12; 2002-07-10 page 12; 2007-04-27

Example: Chlorine Recycling with Oxygen depolarized cathode (ODC)

Classical Diaphragm Process Cl2 H2 Oxygen depolarized cathode Cl2 O2

Cl2
+ +

H2 + +

Cl2 2H+ 2Cl

-

H2

O2 H 2O

2H+ 2Cl
-

HCl

HCl

HCl

H 2O

Cell voltage: 2.4 V Energy Consumption: 2.5 MWh / t Cl2

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 13; 2002-07-10 page 13; 2007-04-27

Cell voltage: 1.5 V Energy Consumption: 1.8 MWh / t Cl2

Energy Savings: 30%

Preliminary Result
Enhanced energy efficiency of our processes is the most profitable way to decrease our petroleum dependency We can reduce the energy consumption of most chemical processes by 10% with relatively small effort (Energy Audit) Further energy efficiency enhancement (up to 50%) by the development of new integrated processes is possible

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 14; 2002-07-10 page 14; 2007-04-27

The Role of Renewable Energy

7% of total energy generation in the European Union in 2004 is renewable 4% is based on biomass EU targets for renewable energy
- 12% in 2010 - 20% in 2020
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 15; 2002-07-10 page 15; 2007-04-27
Source: European Environmental Agency, 2006

1600 1400 M illion tonnes of oil equivalents 1200

Renewables

1000 800 600 400 200 0

Nuclear
Coal and lignite
Gas
Oil

90

91

93

96

97

98

01

92

02

94

95

99

00

19

19

19

19

19

19

19

19

19

20

19

20

20

20

20

03

04

The European Union Biofuel Vision

1st generation:
Improving present processes for Bioethanol (starch and sugar crops) Bio-ETBE Biodiesel Contribution of chemical industry: Process development Construction and operation of plants

2nd generation:
Bioethanol (lignocellulosic biomass) Synthetic Biofuels Biodiesel (Hydrotreated Biodiesel)

EU Biofuel Vision
2005 2010 2020

Integrated bio-refining complexes

2050

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 16; 2002-07-10 page 16; 2007-04-27

1st generation Biodiesel Conventional process layout

Transesterification reaction
Homogeneous alkaline catalyst (e.g. KOH) Separation of byproduct glycerol Neutralization of remaining catalyst Washing for salt removal Drying to remove wash water

Vegetable oil Pretreatment

MeOH Cat

Extensive downstream processing

-

Transesterification
Glycerol separation

Large amount of waste water generated Technological challenge

Process simplification Replace washing process Avoid salt formation

Washing Drying Biodiesel

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 17; 2002-07-10 page 17; 2007-04-27

Process development Heterogeneous Catalysis

Methanol Veg. oil Methanol-Recycle

Transester.

Separation

Neutralisation

Washing

BiodieselDrying

Biodiesel

GlycerolSeparation

Potential Challenges

Strongly simplified downstream processing Simplified Unit Operations Byproduct salt-free glycerol Typical heterogeneous catalysts only active at high Temperatures & pressures - e.g. ZnO/Al2O3 230C, 50bar (20 min)
(Bournay et al., Catal. Today 105(2006), 190)

Neutralisation

GlycerolDrying

Glycerol

Development of heterogeneous catalysts for conditions comparable to homogeneous process

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 18; 2002-07-10 page 18; 2007-04-27

Process development Integrated separation

Integrated continuous separation of reaction products
- Distillation Biodiesel, Methanol recycle - Liquid-liquid separation Glycerol - Equilibrium shift complete conversion in 1 stage

Heterogeneous catalyst High reaction temperature (above boiling point of Biodiesel) Methanol
- High reaction rates - Distillation of reaction products
MeOH, Biodiesel, partial condensation Glycerol gas Reactor liquid
Transesterif. reactor phase separation

Biodiesel Glycerol
phase separation

Veg. oil
Wang et al., CN 1710026A
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 19; 2002-07-10 page 19; 2007-04-27

2nd Generation Hydrotreatment of animal fat

Hydration of oils/fats
- Main product: Biodiesel C12...C22 - By-product: fuel gas (propane)
Source: Neste Oil

Heterogeneous catalysis
- e.g. Pd/Pt/C (EP 1681337)
Diesel

Technical realization
- Neste Oil NExBTL

Animal fat / Vegetable oil

NExBTLHydrierung

Cost advantage of feedstock

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 20; 2002-07-10 page 20; 2007-04-27

Preliminary Result
Biofuels can substitute petroleum / natural gas in the energy market The portion of biofuels in this market will increase We are working on economic processes for the production of biofuels

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 21; 2002-07-10 page 21; 2007-04-27

Renewable Feedstock in the Chemical Industry

10% of feedstock in the German Chemical Industry is renewable

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 22; 2002-07-10 page 22; 2007-04-27

Example: Bayer Material Science (BMS) Renewable Feedstocks Worldwide 2005

ca. 50 different renewable feedstocks purchased

Feedstock
Glycerin Sugar Castor oil Soya bean products Various

% by weight
50 22 11 4 13

Examples of use
polyol, adhesives polyol coatings coatings, polyol polyol, coatings

BMS uses renewable resources where nature has produced unique structures which are technically advantageous and economically viable and bring added value to our customers
1: Not including Wolff Walsrode an HC starck <Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 23; 2002-07-10 page 23; 2007-04-27

Polyurethane insulation in refrigerators

Polyol and isocyanate used to manufacture PU foam insulation Sugar used as one raw material in the polyol manufacture

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 24; 2002-07-10 page 24; 2007-04-27

Glycerin from Biodiesel as Raw Material for propylene oxide

Increasing biodiesel demand leads to high glycerin quantities (2006: 5 Mio. t) Price decline expected Glycerin is an attractive feedstock for PO Additional research and process development necessary

1st Step: Hydrogenation

OH

2nd Step: Dehydration

OH

[CAT]
HO
OH

OH

[CAT]

HO

HO

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 25; 2002-07-10 page 25; 2007-04-27

Research Activities on Renewable Feedstock

Biorefinery on lignocellulose basis
- Disintegration of wood (beech, poplar) - separation of the compounds lignin, cellulose, hemicellulose and others - Usage of wood compounds as feedstock for intermediates production

Research project, German industry consortium

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 26; 2002-07-10 page 26; 2007-04-27

Preliminary Result
Renewable feedstock is used mainly in
coatings adhesives surfactants lubricants polyurethanes

Additional research is necessary to boost the use of renewable feedstock in the CPI

<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 27; 2002-07-10 page 27; 2007-04-27

EU funded research in the 7th framework

Funding period: 2007-2013

Relevant for CPI projects (biotechnology, nanotechnology, energy, environment) : 9650 MM for 7 years
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 28; 2002-07-10 page 28; 2007-04-27

Summary
Enhanced energy efficiency of our processes is most profitable way to decrease our petroleum dependency; the methods are available Biofuels can substitute petroleum / natural gas in the energy market; the CPI participates with the development and operation of economic processes Renewable feedstock is a challenge for process development; research on this topic is an investment in the future
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 29; 2002-07-10 page 29; 2007-04-27

Mastering Technological Complexity

Interdisciplinary. Integral. Innovative.

Thank you for your attention

BTS - Your partner for projects in the chemical and pharmaceutical industry

Thanks to Prof. L. Mleczko, BTS Dr.D. Harrison, BMS Dr. H. Rast, BTS