Pilot Plant for the bioconversion of renewable feedstocks and (agro/food )residues Joachim Venus

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1 Leibniz-Institute for Agricultural Engineering Potsdam-Bornim e.v. Max-Eyth-Allee 100, D Potsdam, GERMANY Fon: +49(331) , Pilot Plant for the bioconversion of renewable feedstocks and (agro/food )residues Joachim Venus

2 White Biotechnology - Using renewable resources for industry Biobased products and processes from renewable resources not only help preserve the environment and climate, but also make a significant contribution to the structural change from a petrochemical to a biobased industry, with related opportunities for growth and employment. Industrial biotechnology, also known as white biotechnology, is an important driving force in this transition

3 Biorefinery-concept for (1 st, 2 nd, 3 rd?) biomass feedstocks - BIOCONVERSION - - FERMENTATION - Vodnar, D.C.; Venus, J.; Schneider, R.; Socaciu, C.: Chem. Eng. & Technol. 33(2010)

4 Top Value Added Chemicals from Biomass Volume I Results of Screening for Potential Candidates from Sugars and Synthesis Gas (August 2004)

5 Scale-up of bioprocesses

6 (Pilot)Biorefineries in the scientific community 650 Biorefineries are 600 classified based on, 550 technological 500 (implementation) status, 450 type of raw materials 400 used or main type of 350 conversion processes 300 applied. A search of the 250 literature revealed a 200 variety of terms 150 describing Biorefineries Oct '13 [IEA Bioenergy:T42:2009:01]

7 The Copenhagen Declaration for a Bioeconomy in Action Universities, Research Institutes, SMEs Applied & basic research 9. The conference also underlined the need for new pilot and demonstration plants and scaling up facilities, in particularly biorefineries. It was stressed, that the development of these facilities requires smart integration of various funding sources, including the Common Agricultural Policy, the Common Fisheries Policy, the Cohesion Policy, the Renewable Energy Policy, Horizon 2020, and private investments. Valley of death Copenhagen conference Bioeconomy in Action on 26 March - 28 March 2012 Industry Industrial application Large-scale production Carus/Carrez/Kaeb/Ravenstijn/Venus: Level Playing Field for Bio-based Chemistry and Materials. bioplastics MAGAZINE [03/11] Vol. 6,

8 Pilot plant facility pilot facility for production of lactic acid at the ATB consequently fills a gap in the various phases of bioprocess engineering provision of product samples is intended to open up the possibility of interesting partners in industry with specific product requirements in various applications scale up BIOSTAT Bplus (Sartorius BBI Systems GmbH, Germany) equipped with a digital control unit DCU for the continuous fermentation with cell recycling Venus, J.; Richter, K.: Eng. Life Sci. 2007, 7, No. 4, Pilot fermentor Type P, 450 L (Bioengineering AG)

9 Characteristic parameters of the used fermentation units Lab / BIOSTAT Bplus Bench / Biostat UD Pilot / Bioengineering Typ P V L 1 10 Litres Litres Litres d 1 0,13 0,19 m 0,315 m 0,6 m d 2 0,053 0,070 m 0,125 m 0,25 m d 2 /d 1 0,40 0,40 0,42 z 1 3 (rushton) 2 (rushton) 1 (propeller)

10 Continuous fermentation process with cell retention Unbelievably, a cheap product such as lactic acid has until recent-ly been manufactured by batch processes, although continuous production is the only economically viable way of producing it biomass 60 lactate time [hours] Venus, J.: Res. J. Biotech 2009, 4, No. 2,

11 Downstream processing of raw lactates & lactic acid Fermentation with cell retention Pilot fermentor Type P, 450 L (Bioengineering AG) MOLSEP Hollow fibre PES membrane (FS10-FC-FUS50E2, MICRODYN-NADIR GmbH/Daicen Membrane Systems Ltd.) Softening 2 x 135 L PUROLITE, 1,5 m³/h (UIT GmbH Dresden) Monopolar/Bipolar Electrodialysis FT EDR/ ED4 15; 7,68 m 2 monopolar/3,2 m 2 bipolar (FuMA-Tech GmbH Vaihingen) Ion exchange Cationic resin, 50 L; Anionic resin, 2 x 90 L (UIT GmbH Dresden) Decolorization Activated carbon, several specific resins Evaporation «chemreactor» CR15 (Büchi AG Uster/Switzerland); Rotary Evaporator LABOROTA 20 S (Heidolph Instruments) 11

12 Pilot plant for Fermentation Process Improvement Opportunities & Challenges feedstock starchy materials, lignocellulosics, residues & byproducts, green biomass pretreatment bioconversion sugars, hydrolyzates press juice fermentation, down-stream products (raw)lactate, lactic acid, biomass... bioplastics Venus, J.: Biotechnol. J. 1(2006) No. 12,

13 Fermentation feedstocks already tested: 1G/2G sugars green biomass several residues lupine 2G sugars cereals, straw 2G sugars silage coco juice waste bread sorghum tapioca algae biomass Coffee residues bagasse pine Starchy materials (cereals, industrial grade corn/potatoe starch, tapioca) Green biomass (alfalfa, grass juice, lupine, sweet sorghum, forage rye, silage, coco juice) Lignocellulosics (wood/straw hydrolysates, 2 nd G sugars) Residues & By-products (bagasse, oilseed cake/meal, thick juice, molasses, whey, coffee residues, waste bread, waffle residues, algae biomass, fruit residues, meat & bone meal )

14 Projects & Partners: FNR joint project SynRg (FKZ ) AiF ZIM/KF (FKZ ST0 & FKZ SB1) International cooperation in education & research with Brazil (DLR BRA 08/A02 & FKZ 01DN12053) International cooperation in education & research with Russia (DLR RUS 10/128) COST-Aktion TD1203 "Food waste valorisation for sustainable chemicals, materials & fuels (EUBis, MC Member EU-Project BREAD4PLA, LIFE10 ENV/ES/479 ( EU-Project CELLULAC, CIP-EIP-Eco-Innovation-2011 (GA304523) Contract research / bilateral assignments (among others Uhde Inventa-Fischer Berlin; UIT GmbH Dresden; Pfeifer & Langen KG Elsdorf; Uhde BT Leuna; Endress+Hauser Conducta Gerlingen; NordBioChem Tallinn; Sustainable BioPoloymers Ltd.& NUI Galway; HF Biotec Berlin GmbH; American Science and Technology Chicago; Fresh Factory GmbH & Co. KG Hamburg; Stenger Waffelfabrik GmbH; Cenicafe-FNC Colombia; DIREVO Industrial Biotechnology GmbH; Hermetia Baruth GmbH)

15 Example agro-residues: Rapeseed cake/meal A cluster of 17 partners will explore the recycling of vegetable raw materials along the complete value chain Start of project: July 1 st, nd phase: July 1 st, WP2: Technologies and Processes for the harvest, pre-treatment, and purification, in particular: utilization of (oilseed/rapeseed) residues Eruca- und HO, polyphenolarm (Süd Chemie)

16 Substrate [g/l] Lactate [g/l] Example fruit residues: e.g. mixed residues, apple, orange, pineapple Mischobst Ananas Orange Apfelkern time 150 [hours] Mischobst Ananas Orange Apfelkern time 150 [hours] 200 I. Körner, C. Ezebuiro, R. Janzon, A. Ballon, J. Venus: Verwertung von Reststoffen der Lebensmittelindustrie Biogas und Milchsäure aus Fruchtabfällen (Tandemvortrag) Mai 2013 Bad Wildungen

17 Lactate formation [g/l] Example coffee residues: coffee ground from the coffee percolator Fermentationen of pre-treated coffee ground in several concentrations SF g/l coffee grounds SF g/l coffee grounds SF g/l coffee grounds time 25 [hours] 30

18 Thank you very much for your attention! Leibniz-Institute for Agricultural Engineering Potsdam-Bornim e.v. Max-Eyth-Allee 100, D Potsdam, GERMANY Fon: +49(331) With the support of: