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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
<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 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
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
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 7; 2002-07-10 page 7; 2007-04-27
Definition Definition
Reaction
MF 1618 KW
Equipment Checks
Ethylen NH3
4400 KW
Best Practice
Khlwasser
Process Modeling
Pinch Technology
pinch point
TEMPERATURE
Implementation Implementation
HEATER
Sustainability Sustainability
min cooling demand
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
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
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 10; 2002-07-10 page 10; 2007-04-27
Evaluation
R NH2 + 2 COCl2
R NCO + 4 HCl
Old Design
Phosgene 100 Parts
New Design
Phosgene 30 Parts Solvent 20 Parts
Amine
Amine Isocyanate
Isocyanate
Reaktion Reaction
Phosgene
Distillation
Phosgene
Reaktion Reaction
Distillation
Cl2
+ +
H2 + +
H2
O2 H 2O
2H+ 2Cl
-
HCl
HCl
HCl
H 2O
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
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
2nd generation:
Bioethanol (lignocellulosic biomass) Synthetic Biofuels Biodiesel (Hydrotreated Biodiesel)
EU Biofuel Vision
2005 2010 2020
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 16; 2002-07-10 page 16; 2007-04-27
Transesterification
Glycerol separation
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
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 18; 2002-07-10 page 18; 2007-04-27
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
Heterogeneous catalysis
- e.g. Pd/Pt/C (EP 1681337)
Diesel
Technical realization
- Neste Oil NExBTL
NExBTLHydrierung
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
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 22; 2002-07-10 page 22; 2007-04-27
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
<Occasion or Subject> 2007 AIChE Spring Meeting Author (internally with department name) Dr. Leimkuehler Page 24; 2002-07-10 page 24; 2007-04-27
[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
<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
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
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