Microbial Biosurfactants: From lab to market. AOCS meeting, 3 rd of May 2017 Sophie Roelants

Transcription

1 Microbial Biosurfactants: From lab to market AOCS meeting, 3 rd of May 2017 Sophie Roelants

2 Global surfactant market: = 20 Mton/year Bio based surfactants 52 % Biosurfactants 4% Petrochemical surfactants 44% Averagely 40 % biomass derived (5% to 95 %) Chemical processes Example: Sodium dodecyl sulfate (SDS) >95 % biomass derived Chemical and biological processes Example: AGPs and sophorolipids <5 % biomass derived Chemical processes Example: linear alkylbenzene sulfonate (LAS) (C10-C13)

3 3. Biosurfactants >95% Biomass based Chemically produced Biosurfactants Biologically produced

4 3. Biosurfactants >95% Biomass based Chemically produced Biosurfactants Biologically produced

5 3. Biosurfactants >95% BB Chemically produced Biosurfactants Biologically produced

6 3. Biosurfactants >95% BB Plant extraction Biosurfactants Chemically produced Biocatalysis (Enzymatically) Enzymes Biologically produced Fermentation (Microbial)

7 3. Biosurfactants >95% BB Plant extraction Biosurfactants Chemically produced Biocatalysis (Enzymatically) Enzymes Biologically produced Fermentation (Microbial)

8 3. Biosurfactants >95% BB Biologically produced Fermentation (Microbial) Carbon (Sugar, vegetable oil, waste streams, ) Water IN Oxygen, nitrogen, Vitamines and other trace elements OUT Biosurfactant CO 2 Heat By-products

9 Microbial Biosurfactants: Bio-degradable Low eco-toxicity Clean production processes > 95 % based on renewable resources or organic waste streams Lower CMC s compared to chemical surfactants Biological activity High natural productivities Added value Higher price as compared to chemical derived surfactants Structural variety limited Mixtures of molecules are produced + batch to batch variation

10 Fundamental research Research Laboratory scale Market Entry Commercialization Market-ready product

11 Microbial Bio-surfactants: Closing the gap in the innovation chain Market demands: Uniform Characterized Cheap Pure Variation Genetic engineering Products Process development (and sample generation) Necessity for projects tackling both strain- and process development in a combinatorial way in combination with market exploration

12 Microbial Bio-surfactants: Closing the gap in the innovation chain - Biosurfing - IB2M(arket) - Stabosurf (IM) - Carbosurf - Marisurf - Sophorolipids - New to nature glycolipids - Sophorolipids - New to nature glycolipids - Rhamnolipids - Xylolipids - Mannosylerythritol Lipids (MELs) - Mining unknown marine biosurfactants

13 Microbial Bio-surfactants: Closing the gap in the innovation chain Carbosurf project xylolipids

14 Microbial Bio-surfactants: Closing the gap in the innovation chain New to nature sophorolipid like biosurfactants Engineered Starmerella bombicola strains Carbosurf project

15 Starmerella bombicola: is a yeast isolated from honey, capable of producing high amounts of the bio-surfactant sophorolipids Glucose IN IN Oil or fatty acids Starmerella bombicola OUT 16

16 Glucose IN IN Oil or fatty acids Starmerella bombicola OUT IN OUT? 17

17 Sophorolipids: industrially relevant molecules!!! Company Country Productname Allied Carbon Solutions (ACS) Japan ACS-sophor (Choice detergent) Synthezyme LLC + DSM Wheatoleo France Sophoclean Saraya Japan Happy Elephant Ecover Belgium Several products Soliance France Sopholiance Shandong Jinmei Biotechnology US China MG Intobio Co LTD South Sopholin Acne Soap/Sopolin Korea Henkel Europe Sidolin, Instanet, Sonasol, Tenn, and Breff Evonik Global Rewoferm

18 Microbial Biosurfactants: Bio-degradable Low eco-toxicity Clean production processes > 95 % based on renewable resources or organic waste streams Lower CMC s compared to chemical surfactants Biological activity High natural productivities Added value Higher price as compared to chemical derived surfactants Structural variety limited Mixtures of molecules are produced + batch to batch variation

19 Microbial Biosurfactants: Bio-degradable Low eco-toxicity Clean production processes > 95 % based on renewable resources or organic waste streams Lower CMC s compared to chemical surfactants Biological activity High natural productivities Added value Higher price as compared to chemical derived surfactants Structural variety limited Mixtures of molecules are produced + batch to batch variation

20 Strain development with S. bombicola Increasing variety Symmetrical Bolaform SLs Alkyl SLs R HO O HO O CH 3 O OH OH SLs with shorter fatty acid Glucolipids Battery of new S. bombicola strains Lactonic SLs Acidic SLs HO OH O HO R HO HO O R O O O CH 3 OH Cellobioselipids Non- symmetrical Bolaform SLs

21 Integrated process design for biosurfactant production Example of IPD: bolaform SLs New S. bombicola strain producing bolaform SLs Bolaform SLs

22 New S. bombicola strain producing bolaform SLs Overall productivity lower as the wild type Bolaform SLs

23 New S. bombicola strain producing bolaform SLs Overall productivity lower as the wild type - Strain improvement: ongoing Bolaform SLs

24 Integrated process design for biosurfactant production Strain engineering Fermentation Purification (DSP)

25 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development:

26 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development: - Fermentation

27 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development: - Fermentation: => strain productivity (0.28 g/l.h) - Medium optimization (0.42 g/l.h) - Substrate optimization (0.72 g/l.h) - Fermentation optim. (1.5 g/l.h)

28 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development: - Fermentation: => strain productivity (0.28 g/l.h) - Medium optimization (0.42 g/l.h) - Substrate optimization (0.72 g/l.h) - Fermentation optim. (1.5 g/l.h)

29 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development: - Fermentation - DSP

30 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development: - Fermentation - DSP: - 85 to 95 % purity - 70 to 98 % recovery

31 Integrated process design for biosurfactant production Strain engineering Fermentation Purification (DSP)

32 Integrated process design for biosurfactant production Strain engineering Fermentation Purification (DSP) Scale up

33 Integrated process design for biosurfactant production Strain engineering Fermentation Purification (DSP) Scale up = sample generation

34 Inegrated process design for biosurfactant production: Application research : Paints, dyes,.. Pharma/medicine Nanotechnology Cosmetics Material synthesis Agro Detergent Chemo- (enzymatic) modifications Food (contact)

35 Inegrated process design for biosurfactant production: Application research : Paints, dyes,.. Pharma/medicine Nanotechnology Cosmetics Material synthesis Agro Detergent Chemo- (enzymatic) modifications Food (contact)

36 Integrated process design for biosurfactant production Strain engineering Fermentation Application partner 6 Scale up = sample generation Purification (DSP) Application partner 3 Application partner 5 Application partner 1 Application partner 2

37 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity)

38 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity) - Emulsification - Wetting ability - Film formation/contact angle - Anti scaling properties - Foaming - CMC - Stability

39 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity) - Emulsification - Wetting ability - Film formation/contact angle - Anti scaling properties - Foaming - CMC: 200 mg/l ~ SLES - Stability

40 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity) - Emulsification - Wetting ability - Film formation/contact angle - Anti scaling properties - Foaming - Stability

41 Integrated process design for biosurfactant production Strain engineering Fermentation Application partner 6 Scale up = sample generation Purification (DSP) Application partner 3 Application partner 5 Application partner 1 Application partner 2

42 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity) Stability issues

43 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity) Stability issues: - New strain development

44 Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity) Stability issues: - New strain development Bolaform SLs (non-symmetrical) Bolaform SLs (symmetrical)

45 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity) Stability issues: - New strain development - Turning this disadvantage into an advantage

46 Bolaform SLs Overall productivity lower then the wild type - Strain improvement - Process development (fermentation + DSP) Application testing (batch to batch and purity) Stability issues: - New strain development - Turning this disadvantage into an advantage: production of 100 % nonacetylated acidic SLs and sophorose from one fermentation product

47 cells Supernatant Purify or Selective hydrolysis of the ester bond Sophorose (kg scale) Bola SLs (kg scale) Acidic SLs non-acetylated (kg scale)

48 Integrated process design for biosurfactant production Strain engineering Fermentation Purification (DSP) Scale up

49 Integrated process design for biosurfactant production Strain engineering Fermentation Purification (DSP) Scale up Techno economic analysis LCA analysis Sensitivity analysis and hot spot definition

50 Inegrated process design for biosurfactant production: Application research : Paints, dyes,.. Pharma/medicine Nanotechnology Cosmetics Material synthesis Agro Detergent Chemo- (enzymatic) modifications Food (contact)

51 Integrated process design for biosurfactant production Scale up: - LCA analysis Sophorolipids

52 Integrated process design for biosurfactant production Scale up: - LCA analysis Sophorolipids Use of second generation streams Effect on price Lots of engineering work to be done

53 Integrated process design for biosurfactant production Strain engineering Fermentation Application partner 6 Scale up = sample generation Purification (DSP) Application partner 3 Application partner 5 Application partner 1 Application partner 7 Application partner 2

54 Integrated process design for biosurfactant production Strain engineering Fermentation Application partner 6 Scale up = sample generation Purification (DSP) Application partner 3 Application partner 5 Application partner 1 Application partner 7 Application partner 2

55 Fundamental research Research Laboratory scale Market Entry Commercialization Market-ready product

56 Fundamental research Research Laboratory scale Strain Engineering Integrated Proces Design Market Entry Commercialization Market-ready product

57 InBio.be (University of Ghent) Bio Base Europe Pilot Plant

58 InBio.be (University of Ghent) Bio Base Europe Pilot Plant