BioMCN - new bio-methanol producer in Holland
Closed down methanol plant turned into the world's largest biofuels production plant
On the northern coast of the Netherlands a few driven entrepreneurs transformed a closed down methanol factory into the world’s largest second generation biofuels production unit in less than three years. By changing the feedstock into crude glycerine and applying a patented evaporating technique, the end-product is now a bio-methanol chemically identical to methanol but with an environmentally friendly profile.
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– The demand for biofuels is constantly increasing in the world, says BioMCN CEO Rob Voncken. We considered it a great market opportunity to use an existing, idle methanol plant to produce an alternative green product.
And right they were. With the major parts of the technology already in place BioMCN were able to start up a pilot plant after only one year and their first large production unit a year later. Today, three years after the acquisition of the plant, BioMCN is the world’s largest supplier of second generation biofuels with a capacity of up to 200 000 tonnes per year. So unique that the King and Queen of Sweden visited the plant last year together with the Queen of Holland.
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Crude glycerine replacing natural gas
The traditional method for producing methanol involves the use of natural gas, a feedstock not only non-renewable but in Europe also increasingly scarce and expensive. BioMCN developed and patented a vaporisation process that instead uses crude glycerine, a residue from biodiesel production, as feedstock. Crude glycerine is available in large quantities and the prices are periodically very low.
Spot purchases of two feedstocks
To minimize the risk and maximize the opportunities for bio-methanol BioMCN decided to also re-start the production of methanol with natural gas as feedstock. The glycerine pipe was therefore added as a tie-in on the existing natural gas pipe-line. They now do spot purchases for either natural gas or crude glycerine, running the plant on the cheapest feedstock for the time being.
– This is how we develop our future, Rob Voncken explains. Our methanol production puts us in the market and helps us learning on the job. It also gives us a fixed cost contribution and reduces the development and investment costs. When bio-methanol is more established as a product and as the demand increases we will be able to deliver as much as 800 000 tonnes bio-methanol per year.
Carbon dioxide can be a new feedstock
That will be possible when the second idle plant that was acquired is started-up and yet another two units have been built. It is in the plan for the near future. But these enthusiastic and creative entrepreneurs are also looking at alternative feedstocks for their product, such as cellulosic biomass, algae or even carbon dioxide.
– The US Army is already using carbon dioxide as energy feedstock in their submarines, says Mr Voncken. There is a lot of research going on about converting carbon dioxide extracted from the atmosphere into bio-methanol and we are looking at that possibility as well!
So our enemy can become our friend! With some clever chemistry there seems to be no limit to new biofuels processes.
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A patented vaporisation process
So how does the BioMCN process work? Eelco Dekker, Marketing and Business Developer, walks me through the 50 000 square meter grounds pointing out the different stages of the process.
Situated on the coastline most of the crude glycerine is transported to BioMCN by ship from biodiesel plants in Europe.
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Parts come by train or truck. When applicable the vessels are loaded with methanol on their return journey to optimize logistics and minimize emissions.
First the liquid crude glycerine is purified in a vacuum distiller and converted into gas by heating and evaporation. This method is patented by BioMCN and I am not allowed to take pictures of that unit. The purified glycerine, now in gas form, is fed into the old methanol steam reformer where it is split into synthesis gas, so called syngas.
– Since glycerine decomposes very similar to natural gas almost no changes had to be made to the steam reformer, says Mr Dekker pointing at the steam tower.
Wherever I look there is activity going on. Bio-methanol is flowing in pipes around us, new pipes are being constructed. The plants are from the 70’s and need some fixing up here and there. In the background I hear some noise from the second, idle methanol plant eagerly waiting for its turn to be started up. Next year hopefully.
Syngas - an intermediate phase
Once split into syngas the process that follows is the same whether you are producing methanol or bio-methanol. It is the origin of the gas stream that differs. The syngas is purified, cooled and compressed and fed into a synthesis reactor where it reacts to form bio-methanol. Next the bio-methanol is purified by distillation and stored.
We pass a biogas production unit where the organic by-products from the process are fermented and turned into green electricity. All of the by-products are reused. Salt is sold as road salt and the left over purified water… well, it is returned to its origin, adding to the cleanliness of the North Sea!
Using the full energy potential of the glycerine
Glycerine is used in different pharmaceutical products, such as toothpaste and soaps, however there is a big surplus on the market. The good thing about converting glycerine to bio-methanol is that the full energy potential of the glycerine can be utilised. When used as a fuel, it reduces carbon dioxide emissions by 70% (well-to-wheel) compared to regular gasoline.
As a fuel, bio-methanol can either be blended with petrol, or used as a feedstock for other green fuels. Another great benefit is that it can be used in similar engine and fuel systems to those found in today's cars. It can be stored, transported and sold in much the same way as petrol and diesel.
Bio-methanol can also be used as a chemical building block for a range of future biofuels, for example bio-MTBE, bio-DME, bio-hydrogen and synthetic biofuels.
An entrepreneurial team
– It is nice to be the first ones to develop a new market, says Mr Voncken, who saw the position as CEO as an entrepreneurial challenge. We are continually developing new applications, in alliance with other innovative companies and research institutes.
Mr Voncken and Mr Dekker make a great team, having worked together in three different companies over the years. All together BioMCN employs 90 operators, engineers, technicians and administrative personnel, and recruitment is still going on.
– I spend most of my time visiting new customers, legislators and governmental officers, says Mr Dekker. I was looking for a position in a field that needed a lot of development, and I surely found it!
One of few methanol producers in Europe
Eelco Dekker focuses a lot on making European environmental legislation understandable for future customers for them to see the necessity and the value of switching to a green component. BioMCN is one of the few methanol producers in Europe since production units have only survived in areas where natural gas is cheap, such as South America and the Middle East. The demand for methanol is hence sufficient but when it comes to bio-methanol the awareness of its greatness is yet to come. In future years Mr Dekker believes that bio-methanol will be an indispensable element in the transportation fuel industry.
For the time being, most of the bio-methanol is sold as a component of octane boosters in ordinary gasoline, such as methyl tert-buthyl ether (MTBE). By switching from ordinary methanol to bio-methanol these producers significantly reduce their carbon footprints.
– Our company is about making a contribution to the necessary changes in the fuels market, concludes Mr Dekker. I strongly believe in the future of biofuels and am enjoying this challenging position more and more as I see the market develop and the attitudes towards the environment improve day by day.
Text & photos: Elisabeth Kempemo, Logos Kommunikation