Periodic Reporting for period 3 - IMPRESS (Integration of efficient downstreaM PRocessEs for Sugars and Sugar alcohols)
Periodo di rendicontazione: 2022-09-01 al 2024-02-29
The objective of the IMPRESS project was to demonstrate a new hybrid biorefinery process for the first time, integrating disruptive upstream and downstream technologies developed by the project partners. The first main objective of the project was to develop and upscale separation and purification methods for the upstream process and modular downstream processes. The second main objective was to enhance the knowledge in the related technologies and their benefits to their operations and open new market opportunities based on the integrations. This was to be supported by the education modules for lifelong education development.
The IMPRESS project achieved its main objectives above, with the successful demonstration of the novel IMPRESS process routes from lignocellulose-based 2nd generation biomass to produce new high-value-added products and chemicals and of the technology integrations between upstream and downstream processes. An educational platform “The Future of Biorefining” of the project was generated. The project produced seven products via novel production routes as well as novel biobased feedstocks, like xylitol, CMF, fodder yeast, bio-based ultra-pure monoethylene glycol (MEG) and monopropylene glycol (MPG) and lignin-derived activated carbon and nanospheres. The integration of technologies such as Dawn, Ray, and Xylitol turned out to be the preferred IMPRESS concept from an economic perspective. The project resulted in larger than originally targeted CAPEX and OPEX savings when compared to the bio-based state-of-the-art production; compared with fossil-based MEG production, all the bio-based routes display higher capital and manufacturing cost.
The LCA study provided initial environmental results for the IMPRESS products, which will support the technology and product owners to further develop and optimize their processes.
The IMPRESS project resulted in 4 patent applications, 9 scientific publications, 10 non-scientific publications and 6 innovation radars and 7 reported as KER's. In addition, the project results have been presented in numerous conferences, workshops and seminars to academic and industrial audiences as well as to the general public.
The IMPRESS project achieved its main objectives above, with the successful demonstration of the novel IMPRESS process routes from lignocellulose-based 2nd generation biomass to produce new high-value-added products and chemicals and of the technology integrations between upstream and downstream processes. An educational platform “The Future of Biorefining” of the project was generated. The project produced seven products via novel production routes as well as novel biobased feedstocks, like xylitol, CMF, fodder yeast, bio-based ultra-pure monoethylene glycol (MEG) and monopropylene glycol (MPG) and lignin-derived activated carbon and nanospheres. The integration of technologies such as Dawn, Ray, and Xylitol turned out to be the preferred IMPRESS concept from an economic perspective. The project resulted in larger than originally targeted CAPEX and OPEX savings when compared to the bio-based state-of-the-art production; compared with fossil-based MEG production, all the bio-based routes display higher capital and manufacturing cost.
The LCA study provided initial environmental results for the IMPRESS products, which will support the technology and product owners to further develop and optimize their processes.
The IMPRESS project resulted in 4 patent applications, 9 scientific publications, 10 non-scientific publications and 6 innovation radars and 7 reported as KER's. In addition, the project results have been presented in numerous conferences, workshops and seminars to academic and industrial audiences as well as to the general public.
The IMPRESS project achieved its main goals and specific objectives, without major deviations - demonstrating a new hybrid biorefinery process, integrating disruptive upstream and downstream technologies developed by the partners.
The key outcomes within the main processing and product streams of IMPRESS are as follows:
Lignin streams were produced by Avantium Dawn TechnologyTM Demonstration Plant and supplied to partners to produce activated carbon and lignin nanoparticles by Aalto.
The purity of the Dawn sugars was improved by Lenntech to make them useful for partners, e.g. glycols conversion by Ray TechnologyTM and fermentation technologies of Vogelbusch.
The glycols were produced in Avantium's Ray TechnologyTM Demonstration Plant. Purification of MEG/MPG via advanced distillation was implemented by Sulzer Chemtech and further optimization with layer melt crystallization by Aalto and Sulzer Chemtech.
Knauer developed the purification of various products by Simulated Moving Bed (SMB) technology.
Ircelyon developed novel absorption separation processes based on new functional metal organic frameworks (MOF).
PDC developed conceptual process designs (CPD) and techno-economic assessments (TEA) for the IMPRESS concept. They also identified and implemented integration benefits in those designs and assessments.
Sphera, with the help of consortium partners, executed a thorough LCA study to identify environmental hotspots in the IMPRESS unit operations and to compare the environmental performance of the IMPRESS products with the current incumbent alternative production routes (both fossil and biobased).
With Xamk´s lead, the consortium developed an online learning platform “the Future of Biorefining” with the educational material of the project.
The key outcomes within the main processing and product streams of IMPRESS are as follows:
Lignin streams were produced by Avantium Dawn TechnologyTM Demonstration Plant and supplied to partners to produce activated carbon and lignin nanoparticles by Aalto.
The purity of the Dawn sugars was improved by Lenntech to make them useful for partners, e.g. glycols conversion by Ray TechnologyTM and fermentation technologies of Vogelbusch.
The glycols were produced in Avantium's Ray TechnologyTM Demonstration Plant. Purification of MEG/MPG via advanced distillation was implemented by Sulzer Chemtech and further optimization with layer melt crystallization by Aalto and Sulzer Chemtech.
Knauer developed the purification of various products by Simulated Moving Bed (SMB) technology.
Ircelyon developed novel absorption separation processes based on new functional metal organic frameworks (MOF).
PDC developed conceptual process designs (CPD) and techno-economic assessments (TEA) for the IMPRESS concept. They also identified and implemented integration benefits in those designs and assessments.
Sphera, with the help of consortium partners, executed a thorough LCA study to identify environmental hotspots in the IMPRESS unit operations and to compare the environmental performance of the IMPRESS products with the current incumbent alternative production routes (both fossil and biobased).
With Xamk´s lead, the consortium developed an online learning platform “the Future of Biorefining” with the educational material of the project.
Expected results and state at the end of the project:
IMPRESS process routes and technology integrations were investigated. The integration of technologies such as Dawn, Ray, and Xylitol turned out to be the preferred novel IMPRESS concept from an economic perspective. The project resulted in larger than originally targeted CAPEX and OPEX savings when compared to the bio-based state-of-the-art production; compared with fossil-based MEG production, all the bio-based routes display higher capital and manufacturing cost.
• Dawn Technology™ will enter in Engineering, Procurement and Construction (EPC) phase: Techno-economic considerations generated more information for the process scope. Additional experimental work was done, and technology is ready for implementation at the Dawn Technology demonstration plant.
• Avantium is advancing towards the next phase of engineering the commercial demonstration plant: the development of the Process Design Package (PDP) for the Ray Flagship Plant and focusing on establishing a strategic partnership to jointly invest and develop the commercialization of Ray TechnologyTM.
• Different hemicellulose derived sugar streams were provided to Vogelbusch for proving biomass fermentation. Know-how about the fermentation of different hemicellulose hydrolysates was developed successfully, and batch and fed-batch fermentation technologies were advanced.
• Different hemicellulose-derived sugar streams were provided to Vogelbusch for proving xylitol fermentation. The key process steps of fermentation were carried out. A process simulation for a production plan was prepared. Vogelbusch will use the data to offer engineering and design work for xylitol plants.
• Lenntech made good progress with the filtration experiments, leading to a refined approach to bringing filtration technology to a pilot scale, as a part of the IMPRESS process. These will inform decisions on feasibility and design of an industrial-scale plant.
• Knauer's SMB process exploited by Knauer showed sufficient progress towards purifying of Xylitol from Vogelbusch's fermentation process.
IMPRESS process routes and technology integrations were investigated. The integration of technologies such as Dawn, Ray, and Xylitol turned out to be the preferred novel IMPRESS concept from an economic perspective. The project resulted in larger than originally targeted CAPEX and OPEX savings when compared to the bio-based state-of-the-art production; compared with fossil-based MEG production, all the bio-based routes display higher capital and manufacturing cost.
• Dawn Technology™ will enter in Engineering, Procurement and Construction (EPC) phase: Techno-economic considerations generated more information for the process scope. Additional experimental work was done, and technology is ready for implementation at the Dawn Technology demonstration plant.
• Avantium is advancing towards the next phase of engineering the commercial demonstration plant: the development of the Process Design Package (PDP) for the Ray Flagship Plant and focusing on establishing a strategic partnership to jointly invest and develop the commercialization of Ray TechnologyTM.
• Different hemicellulose derived sugar streams were provided to Vogelbusch for proving biomass fermentation. Know-how about the fermentation of different hemicellulose hydrolysates was developed successfully, and batch and fed-batch fermentation technologies were advanced.
• Different hemicellulose-derived sugar streams were provided to Vogelbusch for proving xylitol fermentation. The key process steps of fermentation were carried out. A process simulation for a production plan was prepared. Vogelbusch will use the data to offer engineering and design work for xylitol plants.
• Lenntech made good progress with the filtration experiments, leading to a refined approach to bringing filtration technology to a pilot scale, as a part of the IMPRESS process. These will inform decisions on feasibility and design of an industrial-scale plant.
• Knauer's SMB process exploited by Knauer showed sufficient progress towards purifying of Xylitol from Vogelbusch's fermentation process.