Commodity crops for second generation biofuelsCommodity crops for second generation biofuels Plant...

Commodity crops for second generation biofuels

Plant Breeding Lecture Series“ Breeding Lignocellulosic Crops for the Bioeconomy”

Charles A. Abbas, Ph.D.Director Yeast & Renewables Research

Archer Daniels Midland ResearchDecatur, IL

Iowa State Commodity Crops and Second Generation Biofuels

May 27-28, 2008Iowa State University

Changing Face of Agriculture

• Increased complexity of agricultural systems (multiple demands)

• Rapid changes brought about by new genomic approaches to engineering crops

• Changing & challenging global landscape (competing uses)

• Balancing land, water, envt, rural needs and biodiversity

• Reliance on and implementation of holistic approaches to agriculture production practices and emergence of LCA to insure sustainability

• Freedom to farm and other govt/WTO trade issues

ADM Facts & Figures

Financials

FY 2007 Revenue: $44 BillionFY 2007 Net Profit: $2.1 Billion

ADM Footprint

60 Countries240 Processing Plants300 Origination Points26,000 Employees

Processing Capability Per Day

Oilseeds 89,000 MTCorn 51,000 MTWheat 27,000 MT

Financial7%

Oilseeds Processing

29%

Sweeteners and Starches

21%

Bioproducts22%

Ag Services13%

Food and Feed Ingredients

8%

Operating Profit Contribution

Global Footprint and Logistic Flow

Oilseeds

Corn

Milling

Ag Services

•Soy protein meal•Corn gluten meal•Lysine•Threonine•Other feed ingredients

•Vegetable oil•Sweeteners•Flour•Cocoa•Soy protein•Lecithin•Other specialty food ingredients

•Ethanol•Biodiesel

•Linseed oil•Soybean oil •Lactic acid•Starch•Biodegradable plastic•Polyols•Others

Feed

Fuel Industrials

Food

Global Trends in Food and Energy

Global food demand is expected to more than double by 2050 because of population growth and increased per capita consumption.

By 2050, energy from traditional sources will be insufficient to meet projected global demand; and world refining capacity will be insufficient to meet motor fuel demand.

ADM is Uniquely PositionedTo Supply

Growing Demand forAlternative Fuels

Growing Food Demand

Food & Fuel

Food

Feed

Fuels

Industrials

New Technology is Needed to Meet Market Demands

ADM is a Global Leader in Biofuels

• Ethanol capacity of 1.1 billion gal/yr, with additional 0.6 billion under construction

• Biodiesel capacity of over 450 million gallons

• Exploring several other biofuel technologies including:

– alternate feed stocks

– conversion technologies

– alternate products

Develop balanced animal feeds from agricultural and biofuel processing co-products Maximize nutrition and value from 1st

Generation Fuels Develop new uses and product blends for 2nd

Generation co-products

SoybeansCorn

Wheat

1st Generation Biofuels

2nd Generation Biofuels

NEW FEED INGREDIENTS

Fermentation YeastsProtein/sugar syrups

Fiber residues

Improve Current Coproduct Feeds

NEW FEED INGREDIENTS

Dry FeedsLiquid Feeds

Improve Current Liquid/Dry

Coproduct Feeds

Biofuels Enable New Animal Feeds

Increased Opportunities in Animal Feed

Animal Feed PotentialUSA Feed Production Needed to Support

Animal Inventory (1,000 tons)

13,844Dairy Cows

8,639Other

123,178Total

17,634Beef/Sheep7,858Turkeys

16,866Poultry Layers/Breeders

42,148Poultry Broilers16,214Swine

Source: Feedstuffs Feed Marketing Review, September, 2007

ADM is uniquely positioned to capture synergies in Agricultural Processing and Biofuels platforms to create and deliver new Animal Feed Ingredients and Products

ADM Feed Ingredients/

Feed Products

Dry Mill

Wet Mill

Process/Extract

Corn

Oilseeds

Process/Hydrolyze

Biomass

Wheat Mill

ProcessCocoa

Corn

Expand GeographicScope of Core Model

Grow BioEnergy Business

Diversify Feedstocks

FOOD

FEED

FUEL

INDUSTRIAL

OILSEEDS

CORN

COCOA

WHEAT

CORE BUSINESS MODEL

Orig

inat

ion

Tran

spor

tatio

n

Proc

essi

ng

Dis

trib

utio

n

Sale

s &

Mar

ketin

g

Agricultural Processing Value Chain

Technology and Innovation are “Key to Growth”

ADM’s Strategic Areas for Growth

Definition of Commodity Crops• A crop grown by a farmer primarily for sale to others

rather than for his or her own use• Ideal commodity crop is one that can be used for food,

feed, industrial, and/or fuel purposes and therefore addresses several market needs

• ADM will process energy dedicated crops and/or other commodity crops that can be used for energy provided a feedstock supply chain is established and that co-products have markets to insure profitability

• Definition of a commodity crop needs to encompass any crop whether a dedicated food, feed, fiber and/or energy crop that can be used also to address environmental, wild life maintenance, or biodiversity land use issues

• “Lignocellulosic feedstock prices will trade in the market in a similar fashion to the existing commodity crops.”(C. Abbas, 1996 talk 18th Symposium on Biotechnology for Fuels and Chemicals)

Processors needs and drivers• Abundant and increased feedstock supply that utilizes

existing infrastructure and cropping systems • A dedicated feedstock supply system for identity

preserved commodity crop varieties to insure or retain premium pricing for certain end products (non-GMO, nutraceutical, pharmaceutical)

• A diverse feedstock base that expands production to marginal and dry areas with minimal farming inputs

• Consistency in feedstock composition that enables processing with minimum adjustments to yield a variety of products

• Increased or higher value addition and consumer acceptance

• Ability to expand end product portfolio beyond current markets and the development of new markets

Biorefinery ConceptCurrent Definition:Processing of renewable agricultural feedstocks to higher value added products for use as food, feed, fuel, or fiber.

Advanced Definition* :Processing of renewable agricultural crops, their fiber residues, high yielding energy crops, other plant fiber streams from municipal wastes and paper mills to higher value added biodegradable products such as polymers, industrial solvents, agrichemicals, fertilizers, dyes, adhesives, detergents, lubricants, inks, fuels, food, feed, power and other products.

* See also: M J Realff and C A Abbas “Industrial Symbiosis: Refining the Biorefinery “ Journal of Industrial Ecology (7)3-4:5-9,2004.

Biorefining Depends on Feedstock“all biomass feedstocks are local”

Corn - A Versatile Biorefinery Commodity Feedstock

- Largest grain commodity crop grown in US.- USDA 2007 estimates 13.1 Billion Bushels.- One bushel is appr. 54 lbs or 23 kg on as is basis. - Over 4 Billion Bushels processed annually- Land areas planted: 78-93 million acres- Geographic distribution: primary region isupper Midwest- Potential for further yield and production improvements on current acreage planted

Typical Corn Kernel Composition& Current Major Uses

• Animal Feed• Ethanol• Other Fermentation

Products• Food Uses• Exports• Industrial Uses• Biodiesel

Starch 73.4%

Lignocellulosics 11.7%

Ash 1.4%

Protein 9.1%

Oil 4.4%

Corn Uses:Fiber Fuel Feed Food

Steepwater

GlutenFeed

GermCORN PROCESSING

OVERVIEWOil

Extraction

WashingDrying

DryGerm

GermMeal

RefinedOil

CrudeOil

SeparationDeodorization

Filtration

GlutenMeal

Corn

Fiber Milling & Washing

CleaningSteeping

Drying

DegerminationGerm Separation

Centrifugation

Dextrins Starches

StarchWashing

Modification Fermentation

Polyols

Hydrogenation

IsomerizationRefining

ConversionRefining

CrystallizationCentrifugation

Alcohol

Threonine

XanthanGum

PHA

LysineCitric/LacticAcids

FructoseSyrups

CornSyrups Dextrose

CrystallineFructose

Malto-dextrins

65%MaltoseSyrup

FractionatedCorn Syrup

FibersolHi Fiber Dextrose SyrupHi Fiber Sorbitol SyrupHi Fiber Fructose SyrupHi Fiber Maltose SyrupHi Fiber MaltitolBranched Corn SyrupHyd. Branched Corn Syrup

Industrial-CommonExtruded-Industrial (Lysac)-Natural Resistant

Sorbitol SolutionCrystalline SorbitolMaltitol SolutionCrystalline MaltitolHyd. Starch HydrolysateErythritolMannitol

DryingRoasting

Corn Fiber

Desirable plant traits/ideotypes“corn”

• Higher or modified starch, oil and/or protein• Higher value oils:

– higher phytosterols, higher omega oils, higher Vit A (carotenes), higher α-tocopherols/other tocols, lower saturates or higher poly unsaturates, higher xanthophylls

• Higher bushel yield produced per acre with reduced nitrogen input, enhanced drought & pest resistance

• Reduced lignin/phenolics in stalks/stover/cobs to lower processing cost and improve feed/co-product value

• Better feed value varieties – reduced phytate; varieties selected for protein amino acid content:

lysine, tryptophan, threonine; high oil• Engineered plants with plant compartment targeted in situ

enzymes to reduce cost and improve ease of processing• New varieties selected for higher cellulose or higher

biomass (i.e. ton per acre) • Kernel integrity and other physical attributes

Genomic Tools and Plant Engineering of Corn: Approaches and Limitations

• Conventional breeding• Mutagenesis and selection• Molecular marker assisted breeding• Genetic engineering and transgenics• Limited genotypes to select from; need to

expand genetic pool to insure greater ability to introduce multiple traits and to improve transgene expression for the desired agronomic traits

• Cytological maps, sequence databases and cell lines available

Step-Changes in Grain Potential

The Combination of Biotechnology and Breeding Will Increase Corn Supply as a Feedstock

Molecular Breeding Benefit

Biotechnology Yield Benefit

Grain Yield Potential in 2030

Historical Yield Projection

30-Year Trend, Based on Historical Yield Projection

Sizable Gains Will Be Realized From Marker-Assisted Breeding

0

50

1970

Aver

age

Corn

Yie

ld

(in

bush

els

per

acre

)

100

150

200

250

300

1990 2010 2030

Average U.S. Corn Yield in 2007 was 153 Bushels Per Acre

Source: Monsanto

Evolution of Corn Ethanol Biorefineries (1 of 6)

Wet Mill FermentorsStill

EthanolFood, Feed & Industrial Products

Corn Dextrose

Simple Wet Mill with Ethanol


CoGenCoal

Heat & PowerProvided toProcesses

Addition of Co-Gen



Corn Dextrose


Starch HydrolysisDry Mill Fermentors Still

DDGS

CoGenCoal


Corn

Addition of Dry Mill with Ethanol



Corn Dextrose


Starch HydrolysisDry Mill Fermentors Still

Corn Stover

DDGS

Co-firedCoGenCoal


Corn

Co-firing of Biomass



Corn Dextrose


Starch HydrolysisDry Mill Fermentors

CelluloseHydrolysis

Still

Still

Corn Stover

DDGS

Co-firedCoGenCoal


Corn

Pre-Treatment

Fermentors

Lignin Residue

Addition of Cellulosic Ethanol



Corn Dextrose


Starch HydrolysisDry Mill Fermentors

CelluloseHydrolysis

Still

Still

Corn Stover

DDGS

Bio-CHPOther Biomass


Corn

Pre-Treatment

Fermentors

Lignin Residue

Decouple from Fossil Energy



Corn Dextrose

StarchHydrolysis

Thermo-chemicalConversionLignocellulosic

Biomass

LigninResidue

Fermentation of Sugars

Glucose

C5 Sugar(s)

C5/C6 Sugars

Pre-treatment

CelluloseHydrolysis

ProductRecovery

Starch

Hemicellulose

• Ethanol• Chemicals • Materials• Liquid Fuels• Food & Feed Products

• Heat & Power• Fuels & Chemicals• Pyrolysis Oil• Syn Gas

Corn Biorefineries of the Future

Source: U.S. DOE (Modified) Handling/Sourcing

Goal set for 85% of the Energy in Our Corn Mills and Ethanol Plants From CoGen by 2009

• Efficient and cost effective supply of heat and power

• Uses abundant U.S. coal today – reduces demands on oil and gas

• Positioned to use biomass co-firing when policies and/or economics warrant

Corn Cobs Corn Stover

Corn Fiber Hulls

Corn Kernel

Lignocellulosics from Corn

Cellulosics(lignocellulose, biomass)

Hydrogen bonding increases crystallinity

Crystalline Cellulose

Hemicellulose Structure

Lignin Structure

celluloseRNR

exoglucanaseRexoglucanaseNR

endoglucanase

β-glucosidase

cellobiose

glucose

The Synergistic Action of Fungal Cellulases

Ref: M. Himmel, NREL

Enzymes Needed for Hemicellulose Degradation

Challenging Processing Attributes of Lignocellulosic Feedstocks

• Handling characteristics• Compositional variation• Lignin composition• Silica• Fiber physical and chemical properties• Moisture content • Storage and stability

Cellulosic Ethanol Challenges• Logistics

– Contract farming, harvest, collection, densification, infrastructure and transportation systems

– Centralization or Mobile Processing• Water Usage for Processing• Pretreatment

– Chemical, mechanical & physical – Fermentation Inhibitor Production

• Enzymatic Hydrolysis– Enzymes and Enzyme cocktail– Cellulases, hemicellulases, ligninases, esterases

• Concentration of Hydrolysate for Fermentation• Fermentation

– Overcoming Fermentation Inhibitors– Organism Selection

• Adaptation for Inhibitor and Ethanol Tolerance• Conventional & non-conventional yeast, aerobic & anaerobic bacteria

• Alternative Ethanol Recovery & Fermentation Processes• Removal of Agricultural Residues from Fields

– Soil Tilth• Economic Modeling & Life Cycle Analysis

Pretreatment Process Options for FibersProcess Cellulose Hemicellulose Lignin

Dilute Acid Some depoly. 80-100 % solub. to monomers

Little or no solub. but extensive redist.

Steam Expl. at high solids

Some depoly. 80-100 % solub. to mon/oligomers.

Little or no solub. but extensive redist.

Hydrothermal Some depoly. 80-100 % solub. to > 50 % oligomers

Partial solub. (20-50 %)

Organic Solventswith water

Some depoly. Subst. solub. to near completion

Subst. solub. to near completion

AFEX* Some decryst. Solub. from 0-60 % depending on moisture with > 90 % oligomers

Some solub. (10-20 %)

Sodium Hydroxide Subst. swelling Subst. solub. often > 50%

Subst. solub. often > 50%

Lime Pretreatment Subst. swelling Sig. solub.( > 30%) under some conditions

Partial solub. (40 %)

Pretreatment

• Fermentation Inhibitor Production– Heat and acidic conditions degrade sugars to

form inhibitors • HMF, furfural, formic acid, levulinic acid

– Lignin depolymerization forms phenolic compound degradation products that can act as inhibitors

• Ferulic acid, coumaric acid– Hemicellulose contains acetate,

depolymerization forms acetic acid– Many other reactions possible

Enzymatic Hydrolysis• Pretreatment step begins solubilization,

depolymerization, decrystallization• Further processing can be accomplished

enzymatically• As shown before, many enzymes are necessary

for lignocellulosic degradation (i.e. cellulases, hemicellulases, ligninases, esterases)

• Current enzymes are not effective at lignocellulosic hydrolysis and have feedback inhibition (glucose)

Fermentation

• Organism Selection- Genetic Engineering for Sugar Utilization to Ethanol- Pentoses and Hexoses: glucose, xylose, arabinose, mannose, galactose

• Overcoming Fermentation Inhibitors– Adaptation for Inhibitor and Ethanol Tolerance– Start with a robust microorganism

• Industrial ethanol yeast already is highly tolerant• Batch vs. Fed Batch vs. Continuous• SSF vs. separate enzyme hydrolysis

– Solids mixing– Feedback inhibition – Concentration of hydrolysates

Pragmatic vs. Bold Vision for Cellulosics “An evolutionary process”

• Evolution and implementation of new cropping system, harvest and collection will take over a decade for dedicated energy crops.

• Addressing gaps in infrastructure and logistics with the need for greater investments in rural community development (education, utilities, roads, rail etc.).

• Time and investment needed to educate scientists and engineers and supporting workforce.

• Current capital requirements are prohibitive for stand alone facilities so current economic models favor integration into existing corn biorefineries.

• Need to form the right partnerships to leverage resources (technology, know-how, market access, ability to make investments).

Path to Commercialization of Cellulosics Ethanol

“Staging is essential”• Technology validation and staging require emphasis on

practical feasible approaches to validate bioethanol production technologies from cellulosics at a commercial scale.

• Short term: use of captive fibers from grain processing such as corn fiber/soybean hulls, waste streams from paper and pulp industry, sugarcane bagasse and sugar beet pulp.

• Midterm opportunities: agriculture residues and tree wastes such as straws, stover, stalks, cobs, hardwood and possibly softwood residues.

• Longer term: energy crops such as switch grass/miscanthus and short rotation fast growing trees such as poplar.

Bio-Products• Fuels

– Ethanol– Renewable diesel

• Power– Electricity– Heat

• Chemicals– Plastics– Solvents– Chemical Intermediates– Adhesives– Organic Acids– Carbon Black– Paints– Dyes, Pigments, and Ink– Detergents

• Food and Feed

• Fermentation• Acid/Base Hydrolysis• Gasification• Pyrolysis• Combustion/Co-firing• Trans- esterification• Hydrogenation

Conversion Processes

Other Feedstocks, Processes and Products

• Trees• Grasses• Other Agricultural

Crops• Residues• Animal Wastes• Municipal Solid Waste

Biomass Feedstock

Lignocellulosic Processing“Portfolio Balancing”

What Are Life Cycle (LCA) Models?• Full system studies of material/energy inputs & outputs of both

products & processes

• Inventory environmental impacts of products & processes (many possible impacts, select “key” ones)

• Methods for doing LCA studies are not universally agreed upon—allocation issues in particular are both important and somewhat controversial

• Objectives:

– Benchmark, evaluate & improve environmental footprint. Compare with competition

– Comply with regulations or consumer expectations?– In short: assist corporate & government decisions &

identify tradeoffs

LCA: INDUSTRIAL ECOLOGY MODEL (Bruce Dale, MSU)

Concluding Remarks• Increased reliance on domestic sources for the

production of biofuels and alternative fuels from lignocellulosic feedstocks and a move to dedicated energy crops

• A continued and expanding partnership role for land grant universities in research

• Witnessing a second green revolution or blue revolution that goes beyond current commodity crops to new dedicated energy crops

References• 1) Kralova et al. (2006) Plants for the Future. Ecological Chemistry and Engineering

13(11):1179-1207.• 2) Stricklen,M. (2006) Plant genetic engineering to improve biomass characteristics for

biofuels. Current Opinion in Biotechnology 17:315-319.• 3) Ortiz,R. (1998) Critical role of plant biotechnology for the genetic improvement of

food crops: perspectives for the next millennium Electronic Journal of Biotechnology 1(3):1-8.

• 4) Torney et al. (2007) Genetic engineering approaches to improve bioethanol production from maize. Current Opinion in Biotechnology 18:193-199.

• 5) Chang,M (2007) Harnessing energy from plant biomass. Current Opinion in Chemical Biology 11:677-684.

• 6) Gressel,J. (2007) Transgenics are imperative for biofuel crops. Plant Science 174:246-263.

• 7) Rooney et al. (2007) Designing sorghum as a dedicated bioenergy feedstock. Biofuels,Bioprod.Biorefin.1:147157.

• 8) Ragauskas et al. (2006) The Path Forward for Biofuels and Biomaterials. Science 311;484-489.

• 9) Boyer,J.S. (1982) Plant Productivity and Environment. Science 218:443-448.• 10) Himmel et al. (2007) Biomass recalcitrance: Engineering Plants and Enzymes for

Biofuels Production. Science 315:804-807.• 11) Chen F. and R.A. Dixon (2007) Lignin modification improves fermentable sugar

yields for biofuel production. Nature Biotechnology 25(7): 759-761.

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