toward a bio-based economy: biochemical platform for fuels ... · dr. dirk e. maier professor and...
TRANSCRIPT
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Toward a Bio-based Economy: Biochemical Platform for Fuels, Chemicals and Feed from Renewable Resources
Praveen V. Vadlani
Grain Science and Industry Department
Kansas State University
Manhattan, KS 66502
USA
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Oil
Crops
Solvents
Molded parts
Refining Chemistry & Chemical Engineering
Biomass Biological Engineering
Current Feedstocks
New Feedstocks
Fuels
Fibers
Serving the Marketplace: A Bio-Based Economy
Source: www.dupont.com
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Motivations for Bioeconomy
• Environmental quality – Local and regional (air quality,
solid waste disposal)
– Global climate change
• National security – Reduced reliance on foreign fuel
sources
• Rural development – Rural economies are not thriving
in many parts of the world
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KANSAS
• Located in the middle of the United States
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KANSAS
• Economy:
–Agriculture
–Aviation
–Oil and Gas
– Service Sector
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Kansas Agriculture
#1 Wheat Producing State
#1 Wheat Flour Producing State
#1 Grain Sorghum Producing State
#2 Cattle in Feedlots and Slaughter
#3 Land in Farms
#5 Cash Receipts from Farm Sales
#6 Exports of Farm Products
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Manhattan, Kansas
• 2 ½ hours west of Kansas City
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Manhattan, Kansas • Located in the Flint Hills of Kansas which consists of
limestone rock and prairie grass.
• Population of approximately 60,000, including students.
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Kansas State University
• Beautiful campus with limestone buildings
• 23,300 students
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College of Agriculture Our College is one of Nine at K-State:
• Agriculture
• Architecture, Planning and Design
• Arts and Sciences
• Business
• Education
• Engineering
• Human Ecology
• Technology and Aviation
• Veterinary Medicine
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College of Agriculture
• 2,536 Agricultural students in total
• 2,087 Undergraduate students
• 449 Graduate students
• Partnering with businesses small and large (ADM, Cargill, John Deere, Rabobank) to provide real projects, internships, and jobs to our students
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Special Targeted Programs
• Bioprocessing and Industrial Value-Added Program
• Sorghum Improvement Center
• Wheat Genetic and Genomic Resource Center
• National Plant Diagnostic Network
• National Agriculture Bio-security Center
• International Grains Program
• International Meat and Livestock Program
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Department of
Grain Science & Industry - A Brief Overview
Dr. Dirk E. Maier Professor and Head
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KSU Grain Science & Industry Faculty
August 2009
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GSI North Complex on Kimball Ave
(View from top of East Stadium.)
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Unique Departmental Programs
• Bioprocessing & Industrial Value Added Program
• “To develop bioprocessing technology and utilize agricultural-based materials to produce higher-value food, feed, and industrial uses products for economic development.”
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Bioprocessing Lab
Value-Added Products: Biomaterials, Biopolymers, Enzymes, Biofuels,
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Bioprocessing
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Fermentation from Latin verb ‘ fervere’ - action of yeast on fruit extracts Louis Pasteur – Father of Fermentation – ‘life without air’ Different types of fermentation by specific microorganisms Pure culture – Pure Product Bioprocessing – Integration of Biochemistry, Microbiology, Engineering principles Application of microbial means in an industrial process to produce specific products
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The Fuel Ethanol Process
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Break down starch to dissolved sugars
(Enzymes convert starch to simple sugar)
Fermentation of sugar to produce ethanol
(Yeast converts glucose into ethanol)
Purify ethanol to a concentrated form
(Distillation)
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FUEL ETHANOL INDUSTRY
Whole Corn Hammer Mill Slurry Tank
Jet Cooker
Steam
Fresh Water &
4 Recycled
Water Sources
Liquefaction
Enzymes
Mash Cooling
CO2
Beer
190 Proof
Ethanol
Syrup
Condensate
Evaporator
Thin
Stillage
DDGS Final
Product
5% Gasoline
200 Proof
Ethanol
Wet Grain
Whole
Stillage
Alcohol
Dehydration 200 Proof
Denatured
Ethanol Final
Product
Rotary Dryer
Distillation
System
Centrifuge
Continuous
Fermentation
Source: MGPI, Atchison, Kansas
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A Bushel of Corn is 25kg (56lbs)
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Sugars 17 kg
Ethanol 8.1 kg(93% efficiency)
Wet Corn 25 kg
Starch 15.3 kg
DDG 7.6 kg
CO2 7.7 kg(93% efficiency)
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ETHANOL – COST OF PRODUCTION
El e c t r i c i t y
4 . 1%
Fue l s
16 . 8 %
Wa st e ma na ge me nt
0 . 4 %
Wa t e r
0 . 1%
Enz y me s
2 . 4 %
Ye a st
0 . 4 %
Che mi c a l s
1. 9 %
De na t ur a nt
4 . 6 %
M a i nt e na nc e
4 . 0 %
La bor
4 . 1%
Admi ni st r a t i v e
c ost s
2 . 8 %
Ot he r c ost s
0 . 4 %
De p' n
12 . 0 %
Fe e dst oc k
4 6 . 1%
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Major Components In Lignocellulosic Biomass
Lignin
Hemicellulose
Cellulose
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Bioethanol production from different biomass sources
Forage sorghum (Sorghum bicolor),
Switchgrass (Panicum virgatum),
Miscanthus (Miscanthus giganteus)
wheat straw (Triticum aestivum)
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Using Corn in Modified Corn Processing – David Johnston
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Carotenoids in Animal Feed
• Anti-oxidants, enhance immune response in ruminants (Yang & Tume 1993)
• Precursors of Vitamin-A (van de Berg et al 2000)
• Reduce mastitis in cows (Chew 1995)
• Improve keeping quality of milk and meat (Noizere et al 2006)
• Improve reproductive efficiency (Hurley & Doane 1989, Chew 1993)
• β-carotene enhances color of flesh (salmon & trout) and egg yolk
• Fish feed-total carotenoids 30-120mg/kg (Venugopal 2009)
astaxanthin 40-70mg/kg (Decker 2000)
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Carotenoids
• Astaxanthin – Natural $7,000-15,000/kg
– Synthetic $2,000/kg
• β-carotene (Caswell & Zilberman 2000)
– Natural $1,000-2,000/kg
– Synthetic $400-800/kg
• Carotenoid supplementation to animal feed is expensive
• Natural product preferred
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Red yeasts fermentation • Monoculture
Phaffia rhodozyma (PR) Astaxanthin & β-carotene producer Sporobolomyces roseus (SR) β-carotene producer only
• Samples centrifuged, pellet freeze dried
• Carotenoids extracted • HPLC • MALDI/TOF MS confirmation
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PR SR
Seed flask
SR
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Lab scale fermentation
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Carotenoid-enriched DDGS
Ananda N, Vadlani PV (2010) Journal of Agricultural and Food Chemistry 58 (24): 12585–12591 Ananda N, Vadlani PV (2010) Journal of Industrial Microbiology and Biotechnology 37(11): 1183-1192
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Soybean Fiber and Oligosaccharides Bioconversion
Soybean Oligosaccharides • Sucrose 2.5 - 8.2% • Raffinose 0.1 – 0.9% • Stachyose 1.4 – 4.1% Soybean Hull • 8 – 10% of soybean (dry basis) • Hull is made of 75% non-starch carbohydrates • 12% pectin
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Project Advantages
• Bioconversion of under-valued soluble carbohydrates to high-value protein
• Removal of oligosaccharides – decreases flatulence and abdominal discomfort, and increases nutritive value of animal feed
• Bioconversion of soy hulls (fiber) to protein
• Microbial bioprocessing of soybean meal and hull - better sulfur amino acid profile and additional nutrients (vitamin B12)
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Production of succinic acid
• A. succiniproducens
• A. succinogenes
• E. coli
– succinic acid minor fermentation product (~7.8% of total)
• Deletion of ldh
• overexpression of PEPC/ malic enzyme or PYC
• Deletion of ldh and pfl
– NZN111
• Deletion of ldh/pfl/ptsG
– APF111
Non-recombinant microorganisms :
Metabolically Engineered E. coli:
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Engineered Ecoli for Succinic Acid
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SBS550MG (pHL413)
Succinic acid produced from 20g/L (~110 moles) of glucose
E. coli Wild Type
succinate
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Feedstocks Technologies Markets
Residues:
Ag, MSW
Commodity: Corn, oil seed
Herbaceous: Switchgrass
Woody: Poplar,willow
Bio-Chemical
Hydrolysis Fermentation Biocataysis
Thermo-Chemical Combustion Gasification/Pyrolysis Chemistry/Catalysis Separations Tech.
Final Products
Electricity
Fuels
Chemicals Plastics
Heat/Steam
Intermediary
Products
Methanol
Biosynthesis gas
Hydrogen
Organic Acids
Ethanol
Biorefinery
Source: bioenergy.ornl.gov/02workshop/paster.ppt
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S
p
e
c
i a
l
t
y
C
h
e
m
i c
a
l s
Process for Converting Starch to Biochemicals
Cu
rre
nt
Pro
ce
ss
Fermentation
Corn
Tapioca
Wheat
Water
Liquefaction Saccharification
Jet Cooker
110°C, 5-8min.
95° C
, 90m
in.
Jet Cooker
120°C, 5-8min.
60° C
, 36-7
2 h
rs.
Sta
rch
Ta
nk
Glucose
Sta
rch S
epara
tion
Purification
Ion Exchange
Cabin
Fructose Fuel Alcohol
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Bioresource Refining
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Conclusions
• Enzymes and microbial systems will play a vital role in the new industrial biotechnology
• Cost of enzymes and dosage requirements will dictate the economics of commodity chemicals
• Efficient microbial systems essential for high product yield and concentration
• Integrated Biocatalysis & Fermentation– for ethanol and beyond
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• Integrated Biorefineries– broader product mix, cost efficiencies and for sustainability
• Integration will involve – physical, biochemical and thermo-chemical platforms
• Strategic partnership with established chemical and/or oil companies is essential
• Raw materials cost should become marginal
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Acknowledgments
• USDA (CSREES Award# 2004-33610-14308) and FAS Program
• NSF (BES 0420840)
• Grain Science and Industry Department, KSU
• MeadWestvaco Corporation
• Graduate Students, Bioprocessing Lab, BIVAP
• Center for Sustainable Energy, KSU
• Kansas Soybean Commission