Feedstocks and (Bio)Technologies for Biorefineries

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1 Leibniz-Institute for Agricultural Engineering Potsdam-Bornim Dept. Bioengineering Max-Eyth-Allee 100, D Potsdam Fon: 0331/ , Feedstocks and (Bio)Technologies for Biorefineries Joachim Venus

History 1927 Experimental farm of the Agricultural

agricultural mechanization 1952 Central institute of

after the reunification of Germany Today: Leibniz Institute

2 History 1927 Experimental farm of the Agricultural University Berlin 1933 Independent research center on agricultural mechanization 1952 Central institute of agricultural engineering of East Germany 1992 Reestablished after the reunification of Germany Today: Leibniz Institute for Agricultural Engineering Potsdam-Bornim - member of the Leibniz Association

Industrial biotechnology Better living through chemurgy Jun 26th 2008 NEW YORK From The Economist print edition Illustration by David Simonds Efforts to replace oil-based chemicals with renewable

3 Industrial biotechnology Better living through chemurgy Jun 26th 2008 NEW YORK From The Economist print edition Illustration by David Simonds Efforts to replace oil-based chemicals with renewable alternatives are taking off Chemurgy... This term, coined in the 1930s, refers to a branch of applied chemistry that turns agricultural feedstocks into industrial and consumer products. It had several successes early in the 20th century. Cellulose was used to make everything from paint brushes to the film on which motion pictures were captured. George Washington Carver, an American scientist, developed hundreds of ways to convert peanuts, sweet potatoes and other crops into glue, soaps, paints, dyes and other industrial products. In the 1930s Henry Ford started using parts made from agricultural materials, and even built an allsoy car. But the outbreak of the second world war and the shift to wartime production halted his experiment. After the war, low oil prices and breakthroughs in petrochemical technologies ensured the dominance of petroleum-based plastics and chemicals.

(Lignocellulosic)Biorefineries in the scientific community Biorefineries are classified based on, technological (implementation) status, type of raw materials used or main type of conversion

4 (Lignocellulosic)Biorefineries in the scientific community Biorefineries are classified based on, technological (implementation) status, type of raw materials used or main type of conversion processes applied. A search of the literature revealed a variety of terms describing biorefineries ISI Web of Knowledge SM (Nov) [IEA Bioenergy:T42:2009:01]

5 Definition & Status Biorefineries René van Ree [Biorefineries & Bio-based Products Congress, 15 March 2010, RAI, Amsterdam, the Netherlands]

6 Overview of current platforms, products, feedstocks and conversion processes Biochemical processes

Cultivation area of renewable resources in Germany Development of arable land for cultivation of renewable resources in Germany (source: FNR,BMELV) Approximately 2.

7 Cultivation area of renewable resources in Germany Development of arable land for cultivation of renewable resources in Germany (source: FNR,BMELV) Approximately 2.7 million tonnes are currently used as materials (About % of the biomass used for materials in the non-food sector in Germany are produced by German farmers, remaining is covered by imports!) This portion is equivalent to about 13 % of all resources in chemical industry, whereas the main quantity are fats & oils, starch and cellulose

8 Biomass availability

9 Examples of biomass resources

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

11 NatureWorks LLC (former Cargill Dow) PolyLactidePolymer (PLA) Plant Erwin Vink Reducing the environmental footprint with NatureWorks biopolymer

12 New biorefinery-concept for (starchcontaining) crops and green biomass - BIOCONVERSION - Vodnar, D.C.; Venus, J.; Schneider, R.; Socaciu, C.: Chem. Eng. & Technol. 33(2010)

research-oriented pilot plants to validate the concept of integrated and diversified biorefineries.

13 Demo projects as a tool to shorten time to market Universities, Research Institutes, SMEs Applied & basic research demonstration projects that facilitate the development of flexible, research-oriented pilot plants to validate the concept of integrated and diversified biorefineries. Pilot infrastructures to demonstrate the technologies and to test new feedstocks and pre-treatment processes already exist to some extent but these need to be complemented by larger scale demonstrators to verify scale-up of processes. The initial construction of biorefinery pilot and demonstration plants is not only a costly undertaking but it also involves bringing together market actors along a new and highly complex value chain Brussels, 14 September 2010 Industry Industrial application Large-scale production

Pilot plant facility swift transfer of new biotechnological processes into practice often fails due to the lack of a

consequently fills a gap in the various phases of bioprocess engineering provision of product samples is intended to open

up BIOSTAT Bplus (Sartorius BBI Systems GmbH, Germany) equipped with a digital control unit DCU for the continuous

14 Pilot plant facility swift transfer of new biotechnological processes into practice often fails due to the lack of a reference facility that can be used for multiple applications 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 the 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)

15 Bioconversion of renewables feedstock cereals (e.g. rye), wholemeal lignocellulosics green biomass pretreatment bioconversion biomass hydrolyzates (green) press juice fermentation, down-stream products (raw)lactate, lactic acid, biomass... bioplastics

16 Enzymatic grain/starch hydrolysis Separation of wholemeal particles Membrane filtration Hydrolysis (1 m³) Glucose Storage & Sterilization

17 Mass flow fermentation unit (batch) Dextrose S (24 kg) ph correcting agent Nutrients, salts etc. Inoculum Ultrafiltration Fermentation Y P P / S S 0, Litres Filtrate Lactate P (21,3 kg) 38 Litres Biomass (3,0 kg Lactate)

18 sugar, lactic acid, biomass [g/l] Repeated batch cultivation Lactobacillus paracasei 40,5 C; ph 6,0 Rye hydrolyzate with added nutrients 60 biomass sugar lactic acid time 150 [hours] 200

19 New continuous fermentation process with cell retention Venus, J.: Res. J. Biotech 2009, 4, No. 2, 15-22

Continuous Fermentation in lab scale 100 80 Long-term experience (up to 5 litres) biomass 60

80 1 st run (450 litres) 80 11 th run (450 litres) biomass 60 60 lactate lactate 40 40 20 20

20 Continuous Fermentation in lab scale Long-term experience (up to 5 litres) biomass 60 lactate time [hours] and pilot plant facility st run (450 litres) th run (450 litres) biomass lactate lactate biomass time [hours] time [hours]

21 Downstream processing of raw lactates & lactic acid

ions [mg/l] lactate [g/l] Effect of several down-streaming steps on the purity of lactic acid 5.000 4.500 4.000 3.500 3.000 2.500 2.000 1.500 1.

22 ions [mg/l] lactate [g/l] Effect of several down-streaming steps on the purity of lactic acid Na-Lactate (Fermentation) down-stream processing (Filtration, Softening, Electrodialysis, Ion exchange, Evaporation) Start_Ferm End_Ferm M F So ft EDR EXA 133 EXC08 Evap 0

23 Dependency of the enantiopurity of lactic acid in the course of DSP LA [g/l] L/D 99 [%] 600 L-LA D-LA L/D ratio End_Ferm MF Soft ED IC/K IC/A Evap 95

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

Leibniz-Institute for Agricultural Engineering Potsdam-Bornim e.v. Max-Eyth-Allee 100, D-14469 Potsdam, GERMANY Fon: +49(331)5699-112, email: jvenus@atb-potsdam.de Pilot Plant for the bioconversion of