Commodity crops for second generation biofuels

Transcription

1 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 Research Decatur, IL Iowa State Commodity Crops and Second Generation Biofuels May 27-28, 2008 Iowa State University

2

3 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

4 ADM Facts & Figures Financials FY 2007 Revenue: $44 Billion FY 2007 Net Profit: $2.1 Billion ADM Footprint 60 Countries 240 Processing Plants 300 Origination Points 26,000 Employees Food and Feed Ingredients 8% Ag Services 13% Operating Profit Contribution Bioproducts 22% Financial 7% Global Footprint and Logistic Flow Oilseeds Processing 29% Sweeteners and Starches 21% Processing Capability Per Day Oilseeds Corn Wheat 89,000 MT 51,000 MT 27,000 MT Oilseeds Corn Milling Ag Services

5 Soy protein meal Corn gluten meal Lysine Threonine Other feed ingredients Ethanol Biodiesel Feed Fuel Food Vegetable oil Sweeteners Flour Cocoa Soy protein Lecithin Other specialty food ingredients Industrials Linseed oil Soybean oil Lactic acid Starch Biodegradable plastic Polyols Others

6 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.

7 ADM is Uniquely Positioned To Supply Growing Food Demand Growing Demand for Alternative Fuels Food & Fuel

8 New Technology is Needed to Meet Market Demands Food Feed Fuels Industrials

9 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

10 Biofuels Enable New Animal Feeds Develop balanced animal feeds from agricultural and biofuel processing co-products Maximize nutrition and value from 1 st Generation Fuels Develop new uses and product blends for 2 nd Generation co-products 2 nd Generation Biofuels 1 st Generation Biofuels Soybeans Corn Wheat Improve Current Liquid/Dry Coproduct Feeds Improve Current Coproduct Feeds NEW FEED INGREDIENTS Dry Feeds Liquid Feeds NEW FEED INGREDIENTS Fermentation Yeasts Protein/sugar syrups Fiber residues

11 Increased Opportunities in Animal Feed ADM is uniquely positioned to capture synergies in Agricultural Processing and Biofuels platforms to create and deliver new Animal Feed Ingredients and Products Animal Feed Potential USA Feed Production Needed to Support Animal Inventory (1,000 tons) Swine 16,214 Corn Corn Wet Mill Dry Mill Poultry Broilers Poultry Layers/Breeders Turkeys 42,148 16,866 7,858 Oilseeds Process/ Extract Beef/Sheep Dairy Cows 17,634 13,844 Wheat Cocoa Mill Process ADM Feed Ingredients/ Feed Products Other Total 8, ,178 Source: Feedstuffs Feed Marketing Review, September, 2007 Biomass Process/ Hydrolyze

12 ADM s Strategic Areas for Growth CORE BUSINESS MODEL Diversify Feedstocks OILSEEDS CORN COCOA WHEAT Origination Transportation Processing Distribution Expand Geographic Scope of Core Model Sales & Marketing Agricultural Processing Value Chain Grow BioEnergy Business FOOD FEED FUEL INDUSTRIAL Technology and Innovation are Key to Growth

13 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 coproducts 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)

14 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

15 Biorefinery Concept Current 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.

16 Biorefining Depends on Feedstock all biomass feedstocks are local

17 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: million acres - Geographic distribution: primary region is upper Midwest - Potential for further yield and production improvements on current acreage planted

18 Typical Corn Kernel Composition & Current Major Uses Animal Feed Ethanol Other Fermentation Products Food Uses Exports Industrial Uses Biodiesel Ash 1.4% Protein 9.1% Oil 4.4% Lignocellulosics 11.7% Starch 73.4% Corn Uses: Fiber Fuel Feed Food

19 CORN PROCESSING OVERVIEW Corn Germ Washing Drying Dry Germ Steep water Cleaning Steeping Degermination Germ Separation Germ Meal Oil Extraction Crude Oil Corn Fiber Drying Fiber Milling & Washing Separation Deodorization Filtration Gluten Feed Gluten Meal Centrifugation Refined Oil Alcohol Roasting Drying Modification Isomerization Refining Starch Washing Conversion Refining Crystallization Centrifugation Fermentation Xanthan Gum Threonine PHA Lysine Citric/ Lactic Acids Dextrins Fibersol Hi Fiber Dextrose Syrup Hi Fiber Sorbitol Syrup Hi Fiber Fructose Syrup Hi Fiber Maltose Syrup Hi Fiber Maltitol Branched Corn Syrup Hyd. Branched Corn Syrup Starches Industrial -Common Extruded -Industrial (Lysac) -Natural Resistant Fructose Syrups Crystalline Fructose Maltodextrins Corn Syrups Fractionated Corn Syrup 65% Maltose Syrup Dextrose Sorbitol Solution Crystalline Sorbitol Maltitol Solution Crystalline Maltitol Hyd. Starch Hydrolysate Erythritol Mannitol Hydrogenation Polyols

20 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

21 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

22 The Combination of Biotechnology and Breeding Will Increase Corn Supply as a Feedstock Step-Changes in Grain Potential 300 Grain Yield Potential in 2030 Average Corn Yield (in bushels per acre) Sizable Gains Will Be Realized From Marker-Assisted Breeding Average U.S. Corn Yield in 2007 was 153 Bushels Per Acre Historical Yield Projection 30-Year Trend, Based on Historical Yield Projection Molecular Breeding Benefit Biotechnology Yield Benefit Source: Monsanto

23 Evolution of Corn Ethanol Biorefineries (1 of 6) Food, Feed & Industrial Products Ethanol Corn Wet Mill Dextrose Fermentors Still Simple Wet Mill with Ethanol

24 Evolution of Corn Ethanol Biorefineries (2 of 6) Food, Feed & Industrial Products Ethanol Corn Wet Mill Dextrose Fermentors Still Coal CoGen Heat & Power Provided to Processes Addition of Co-Gen

25 Evolution of Corn Ethanol Biorefineries (3 of 6) Food, Feed & Industrial Products Ethanol Corn Wet Mill Dextrose Fermentors Still Corn Starch Dry Mill Fermentors Still Hydrolysis DDGS Coal Addition of Dry Mill with Ethanol CoGen Heat & Power Provided to Processes

26 Evolution of Corn Ethanol Biorefineries (4 of 6) Food, Feed & Industrial Products Ethanol Corn Wet Mill Dextrose Fermentors Still Corn Starch Dry Mill Fermentors Still Hydrolysis DDGS Corn Stover Coal Co-fired CoGen Heat & Power Provided to Processes Co-firing of Biomass

27 Evolution of Corn Ethanol Biorefineries (5 of 6) Food, Feed & Industrial Products Ethanol Corn Wet Mill Dextrose Fermentors Still Corn Dry Mill Starch Hydrolysis Fermentors Still DDGS Cellulose Hydrolysis Fermentors Still Pre- Treatment Lignin Residue Corn Stover Coal Addition of Cellulosic Ethanol Co-fired CoGen Heat & Power Provided to Processes

28 Evolution of Corn Ethanol Biorefineries (6 of 6) Food, Feed & Industrial Products Ethanol Corn Wet Mill Dextrose Fermentors Still Corn Dry Mill Starch Hydrolysis Fermentors Still DDGS Cellulose Hydrolysis Fermentors Still Pre- Treatment Lignin Residue Corn Stover Other Biomass Decouple from Fossil Energy Bio-CHP Heat & Power Provided to Processes

29 Corn Biorefineries of the Future Starch Hemicellulose Pre-treatment Lignocellulosic Biomass Starch Hydrolysis Cellulose Hydrolysis Handling/Sourcing Fermentation of Sugars Glucose C5/C6 Sugars C5 Sugar(s) Lignin Residue Thermo-chemical Conversion Product Recovery Ethanol Chemicals Materials Liquid Fuels Food & Feed Products Heat & Power Fuels & Chemicals Pyrolysis Oil Syn Gas Source: U.S. DOE (Modified)

30 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

31 Lignocellulosics from Corn Corn Kernel Corn Fiber Hulls Corn Cobs Corn Stover

32 Cellulosics (lignocellulose, biomass) Hydrogen bonding increases crystallinity

33 Crystalline Cellulose Lignin Structure Hemicellulose Structure

34 The Synergistic Action of Fungal Cellulases cellobiose endoglucanase exoglucanase R exoglucanase NR NR cellulose R β-glucosidase glucose Ref: M. Himmel, NREL

35 Enzymes Needed for Hemicellulose Degradation

36 Challenging Processing Attributes of Lignocellulosic Feedstocks Handling characteristics Compositional variation Lignin composition Silica Fiber physical and chemical properties Moisture content Storage and stability

37 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

38 Pretreatment Process Options for Fibers Process Cellulose Hemicellulose Lignin Dilute Acid Some depoly % solub. to monomers Little or no solub. but extensive redist. Steam Expl. at high solids Some depoly % solub. to mon/oligomers. Little or no solub. but extensive redist. Hydrothermal Some depoly % solub. to > 50 % oligomers Partial solub. (20-50 %) Organic Solvents with 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 Sodium Hydroxide Subst. swelling Subst. solub. often > 50% Lime Pretreatment Subst. swelling Sig. solub.( > 30%) under some conditions Some solub. (10-20 %) Subst. solub. often > 50% Partial solub. (40 %)

39 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

40 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)

41 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

42 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).

43 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.

44 Other Feedstocks, Processes and Products Biomass Feedstock Trees Grasses Other Agricultural Crops Residues Animal Wastes Municipal Solid Waste Conversion Processes Fermentation Acid/Base Hydrolysis Gasification Pyrolysis Combustion/Co-firing Trans- esterification Hydrogenation 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

45 Lignocellulosic Processing Portfolio Balancing

46 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

47 LCA: INDUSTRIAL ECOLOGY MODEL (Bruce Dale, MSU)

48 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

49 References 1) Kralova et al. (2006) Plants for the Future. Ecological Chemistry and Engineering 13(11): ) Stricklen,M. (2006) Plant genetic engineering to improve biomass characteristics for biofuels. Current Opinion in Biotechnology 17: ) 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: ) Chang,M (2007) Harnessing energy from plant biomass. Current Opinion in Chemical Biology 11: ) Gressel,J. (2007) Transgenics are imperative for biofuel crops. Plant Science 174: ) Rooney et al. (2007) Designing sorghum as a dedicated bioenergy feedstock. Biofuels,Bioprod.Biorefin.1: ) Ragauskas et al. (2006) The Path Forward for Biofuels and Biomaterials. Science 311; ) Boyer,J.S. (1982) Plant Productivity and Environment. Science 218: ) Himmel et al. (2007) Biomass recalcitrance: Engineering Plants and Enzymes for Biofuels Production. Science 315: ) Chen F. and R.A. Dixon (2007) Lignin modification improves fermentable sugar yields for biofuel production. Nature Biotechnology 25(7):