Post on 19-Jul-2018
Industrial Biocatalysts for the biobasedeconomy
Biorefinery development & Biocatalysis
Dr Pauline TeunissenRenewable Resources and BiorefineriesSeptember, 69, 2006York
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Genencor Division at a glance
Ø History traced to 1982
Ø May 2005: Danisco–Genencor Division:
responsible for production, innovation,
marketing and sales of industrial enzymes.
Ø 8 Bioproducts manufacturing sites; ~4 million litersof capacity
Ø Approximately 1200 Employees Worldwide
Develops and produces enzymes forindustrial applications
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Genencor & Danisco = stronger than ever
Strong financial base for investing further:
§in our innovation, applications and manufacturing capabilities
§in improved and new products
§in improving the economies of scale
We will continue to be a strong player in the industryand a reliable supplier of costeffective performance ingredients.
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Genencor’s Products In Everyday Life
Innovative and Cost EffectiveCatalysts for Many MajorIndustrial Segments
§ Cleaning§ Textiles§ Starch Processing
§ Fuel Ethanol§ Brewing§ Leather§ Baking§ Pulp and Paper§ Food and Specialties
§ Biomass (coming soon)
Delivering on thePromise ofBiotechnology forOver a Decade!
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CellFactory
Fuels
Chemicals
Polymers
Specialties
Enzymes
Glucose
MixedSugars
Sucrose
Sugar CaneBeet
Starch Grains
Lignocellulose
The BioRefinery
CoProducts
BioRefinery
Upgraded CoProducts
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Enzymes for Fuel Ethanol Production
Enzyme§ Liquefying enzymes
§ Saccharifyingenzymes
§ Protein hydrolyzingenzymes
§ Viscosity reductionenzymes
§ Granular starchhydrolyzing enzymes
Purpose§ Thermostable alpha
amylases for liquefaction ofstarch at high temperatures
§ Glucoamylases and blendsfor hydrolysis of starch toglucose
§ Proteases for improvedfermentation efficiency
§ Multicomponent enzymesfor wheat, barley & rye
§ Alphaamylase andglucoamylase blend forprocessing of uncookedstarch
Product nameSPEZYME® XTRASPEZYME® HPA
GZYME ® 480FERMENZYME ® L400
GC 106FERMGEN
OPTIMASH ® (wheat,rye and barley)
STARGEN ® 001
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crop
GroundCorn/Starch
Saccharification
EtOHFermentation
Water / Heat
Saccharification
EtOHFermentation
Distillation
EtOH
DDG’s
Grain
Granular Starch Hydrolysis
The Opportunity:Potential to Transform the Ethanol Industry• No Cook• Fewer Process Steps• Fewer Side Reactions
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What are the potential benefits ofSTARGEN ® to the Ethanol Industry ?
Energy saving Elimination of jet cooking
Saving on the operational cost Labor, time, chemicals
Value added byproduct (DDGS) Higher protein content
Carbon conversion efficiency Higher yield
Reduction of yeast growth inhibitors High glucose, Maillard products, etc.
Reduction in byproducts formation
(Reduction in osmotic stress) Glycerol, organic acids, etc.
Saving on the capital cost Capacity increase/new plant
Capacity increase High density fermentation higher alcohol yield
Process Simplification Reductions in unit operations
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Enzymatic Drilling of Granular Starch
Granular Starch
Granular Starch +STARGEN ® 001,2hr
Granular Starch +STARGEN ® 001,4 hr
Granular Starch
+STARGEN, 8hr
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Comparison of different alpha amylases withglucoamylase under yeast fermentation forEthanol
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0 20 40 60 80Hours
% V
/V E
toh
A.Kawachi AA
LT75
FRED
ETHYL
FA
Control
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STARGEN®001 application
§Pretreatment: Acid protease, OPTIMASH ® enzyme, acidamylase, 120 min at pH 3.6, wheat (appr. 55ºC), rye (52ºC)
§Fermentation: addition of STARGEN ® 001, 32ºC
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crop
GroundCorn/Starch
Saccharification
EtOHFermentation
Water / Heat
Distillation
EtOH
DDG’s
Grain
Waste
Starch
Oil
Fiber
Protein
The Grain Milling Process
Need: Better Enzymes andProcesses for the GrainProcessing Industry
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Technology is being brought to bear onthe issues
§ Low Energy Milling of Biofeedstocks tosugars and other components for furtherprocessing
§ Efficient Bioconversion of Mixed Sugars toProducts
§ Efficient Utilization of Byproducts§ Optimized extraction of value§ Cost Allocation§ Bioprocess integration
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Wood chips
Switchgrass
SugarcaneCottonwoods
Corn
Paper
Sources of Cellulosic Biomass
Miscanthus
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crop
EtOH
PreTreatment
Saccharification
EtOHFermentation Distillation
Grain
Co
Prod
uct
Unk
now
n Va
lue
Waste
The DOE Cellulosic Biomass SubContract
Why Cellulosic Biomass:•Plentiful, and Potentially Low Cost•Could be Financially Competitive•Potential Synergies with ConventionalProcessing Technologies
The Challenge:1 billion bushel/yr Corn productionyields 25 million dry tons of Cornstover which could potentiallyproduce >2.5 billion gal EtOH peryear
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Cellulase cost was THE major bottleneck incellulosic biomass conversion
The Barrier – yr 2000
Evolution of Enzyme Cost
0
1
2
3
4
5
6
7
2000 2005
Etha
nol,
$/ga
l
Operating Costs + DeprecEnzymesOther RawsFeedstock
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Advanced Cellulase Development Program
Project Structure and Funding§ U.S. Department of Energy (DOE) funded >$15
million over a 4year period beginning in June 2000§ Subcontract through the National Renewable
Energy Laboratory (NREL)§ Genencor contributed ~$5 million
Goal: Improved Low Cost Cellulase for BiomassConversion to Ethanol§ Original program targeted a 10fold cellulase cost
reduction§ Program achieved a 30fold reduction§ 10 – 20 cents (USD) per gallon on NREL model
substrate
Awards§ R&D Magazine, Top 100 Innovations, 2004
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Cellulase cost is no longer the major bottleneckin cellulosic biomass conversion
The Barrier Has Fallen
Evolution of Enzyme Cost
0
1
2
3
4
5
6
7
2000 2005
Eth
anol
, $/g
al Operating Costs + DeprecEnzymesOther RawsFeedstock
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Technical Strategy
§ Engineer & recruit improved cellulase components§ Protein Engineering: Improved thermostability in CBH1 &
CBH2§ Novel Cellulolytic Activities A. cellulolyticus E1
§ Develop an enhanced T. reesei production organism toproduce all the key activities in one host§ Strain construction§ Fermentation & product performance screening
§ Improve the Manufacturing Process to minimizeproduction cost§ Fermentation & Strain improvement including genomics,
mutagenesis and screening
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0
50
100
150
200
250
300
350
400
450
500
0 10 20 30 40 50 60
Program Months
2.3X
11X20X 30X
Combined Enzyme step cost drop 30X
$/ga
l EtO
H(N
RE
L M
etric
)
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Overall Cellulase Cost Reduction
~30XTotal
~4 X
Improved enzyme performance 41G enzyme mix Recruited cellulase E1 56 oC vs 38 oC conversion
~8X
Improved protein production Whole cell product (i.e., no recovery) Media improvements Carbon source Strain productivity (41G) High cell density fermentation
ImprovementFactorImprovement
Audited by
NREL
Validated by
NREL
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Enzyme cocktail tuned tofeedstock & pretreatment
Biomass Value Chain Integration
FEEDSTOCK
PRETREATMENT
ENZYMEHYDROLYSIS
FERMENTATION
END PRODUCTS
Corn stover,bagasse, pulp, etc.
Mechanical orthermo chemical
Complex sugars tosimpler sugars
Yeast to ethanol (C6) Need a C5 plus C6 bug
Ethanol and other biochemicals
FEEDSTOCK PRETREATMENT FERMENTATION END PRODUCT
CurrentGCOR role
ENZYMEHYDROLYSIS
Process choice needed
No infrastructure for someNo collection implements
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Further Issues… .
Biorefinery Issues Facing Genencor and Others§ Supply Chain
§ What will drive raw material availability?§ What incentives or guarantees will be required?§ What is “value” of each player’s contribution§ Whole broth enzyme formulation
§ IP protection§ Colocation and/or single purpose dedicated facility
§ Demand Chain§ What in addition to ethanol will provide the best
value to investors?§ What will it take for them to be accepted in the
market?§ Investment
§ What is best mechanism to allow regional/localinvestors to participate?
§ What is the role of investment types (angel,traditional, etc.)
§ Derisking funds – federal and state (pioneers face hugerisk)
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crop
GroundCorn/Starch
Saccharification
EtOHFermentation
Water / Heat
Saccharification
EtOHFermentation
Distillation
EtOH
DDG’s
PreTreatment
Saccharification
EtOHFermentation Distillation
Grain
Co
Prod
uct
Unk
now
n Va
lue
Waste
Starch
Oil
Fiber
Protein
The BioRefinery FrontEnd
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Conclusions
§ Technologies are rapidly advancing.
§ Biomass conversion technology continues toprogress. Significant challenges remain.
§ Starch processing technology is rapidlyevolving.
§ Cellulosic & starch technologies & processescould very well merge in synergistic ways.
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Biotechnology offers Sustainable Solutions toGlobal Challenges
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Genencor’s vision
… a leading innovator of products for
the biobased economy.
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Genencor’s vision
Ø We envision a future where biotechnology fulfills manyunmet needs..Ø In development and deployment of industrial enzymesØ In the production of fuels, chemicals & materials
Ø We envision a future where biotechnology helps createsustainable industrial activities
Ø We envision a future where biorefineries take theirplace alongside oil refineries
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