7th. Annual Berkeley BioEconomy Conference Berkeley, CA, USA, 26-27 March, 2017 Prof. Dr. Hesham A. El Enshasy Assistant Director for Bioproduct Research & Innovation Institute of Bioproduct Development Universiti Teknologi malaysia
Lecture Outlines Biorefinery (1 st. and 2 nd. Generation of Biorefinery) Cassava: The potential platform for BioEnergy Production Cassava plantation in African and Asian countries. Cassava Biorefinery Conclusions Institute of Bioproduct Development as Bioprocess Industrialization Hub.
Biorefinery concept Molasses (SCM, BM) Starch (MS, CS,PS, TS, SS, etc.) Lignocellulosic (Plant Res.; Baggase, Chemical Treatment Enzymatic Treatment Fermentable Sugar BioFactories (Yeast, Bacterial, Actino., Fungi) BioFuel Org. Acids Amino Acids BioPolymers Antibiotics Spec. Chem.
Industrial Platform (1 st. Generation) Pretreatment/Treatment Phases (washing, crushing, solid/liquid separation, chemical/heat treatment, etc ) Enz. treatment Fermentation + E Downstream Processing + E Product(s) Sugar conv. Enz. Invertase Gluc. Isomer Starch Deg. Enz. -amylase -amylase Glucoamylase
Industrial Platform (2 nd. Generation) Pretreatment/Treatment Phases (washing, crushing, solid/liquid separation, chemical/heat treatment, etc ) Enzymatic treatment Fermentation + E Downstream Processing + E Legnocellulases Cellulases Xylanases Lignin Peroxidases Product(s)
Main Biocatalysis in Biorefinery(2 nd. Generation) Enzyme groups Cellulose Enzymes involved in hydrolysis Endoglucanases, cellobiohydrolase and β-glucosidase β-1, 4endoxylanase, β- xylosidase, α-l- arabinofuranosidase, α-glucuronidase, Hemicellulose Lignin Pectin acetyl xylan esterase Laccase, Manganese, Peroxidase, Lignin peroxidase Pectin methyl esterase, pectate lyase, polygalacturonase, rhamnogalacuronan lyase
Industrial Platform (2 nd. Generation) Challenges for 2 nd. Generation Biorefinery 1. Feedstocks are more complex and need many treatment steps. 2. Synergistic mix of different enzymes are usually required (no single enzyme treatment based on the complexity of the substrate). 3. High quantity of enzyme requirement 4. The produced reduced sugar may include some fermentation inhibitors
Feedstock Preparation Transformation into sugars Fermentation Distillation Sugar case Collection Milling and filtering Fermentation C6 Distillation Cereal case Feedstock cleaning Milling Liquefaction Cooking Saccharification Fermentation C6 Distillation Lignocellulosic Biomass case Conditioning Milling Termochemical Separation L/S hydrolysis Fermentation C5 Distillation 2nd Enzymatic Hydrolysis How much does 1 kg sugar cost? Fermentation C6
The current world map for Starch Feedstocks Sriroth and Piyachomkwan (2013), In Bioprocessing Technologies and Biorefinery for Sustainable production of Fuels, Chemicals, and Polymers. (Ed. S.T. Yang, H.A. El Enshasy, N. Thongvhul), Wiley, USA
World Production and Applications of Sugar and Starch Crops Sriroth and Piyachomkwan (2013), In Bioprocessing Technologies and Biorefinery for Sustainable production of Fuels, Chemicals, and Polymers. (Ed. S.T. Yang, H.A. El Enshasy, N. Thongvhul), Wiley, USA
Chemical Composition of Starch Crops Sriroth and Piyachomkwan (2013), In Bioprocessing Technologies and Biorefinery for Sustainable production of Fuels, Chemicals, and Polymers. (Ed. S.T. Yang, H.A. El Enshasy, N. Thongvhul), Wiley, USA
Why Cassava? An Agroenvironment view 1. Cassava has one of the highest rates of CO 2 fixation and sucrose synthesis for any C3 plant. 2. Transgenic cassava was developed with starch yields up 2.6 times higher than normal plants by increasing the sink strength for carbohydrate in the crop (OSU group). 3. Well known to farmers from developing countries (plantation, harvesting, processing). 4. Grow in different soils, under wide range of cultivation conditions (temperature, humidity), can survive the harsh weather (climate change). 5. Low water and fertilizer requirements. 6. Resistance to plant pathogens / Minimal pest control management.
Why Cassava? Bioprocessing view 1. Biofuel production (ethanol/butanol) using starch as feedstock is well established and economically feasible process. 2. Cassava starch and other starch processing wastes (such as cassava bagasse, waste water from cassava plant) contain high concentration of fermentable sugars. 3. Availability of different genetically modified microbial strains which can use starch directly without any enzymatic treatment for ethanol and butanol production. 4. Availability of new and industrially proven and scalable bioprocess technologies for biofuel production using starch as feedstock such as (Simultaneous Saccharification Fermentation, Mixed Culture System, etc )
Agricultural Practice and Agronomic Traits of Major Starch Crops Sriroth and Piyachomkwan (2013), In Bioprocessing Technologies and Biorefinery for Sustainable production of Fuels, Chemicals, and Polymers. (Ed. S.T. Yang, H.A. El Enshasy, N. Thongvhul), Wiley, USA
Cassava: Crop Story
Top 10 Cassava Producing Countries
Top 10 Cassava Producing Countries Country Root Production (x1000 tonnes) Yield (tonnes/ha) Fresh roots Dry Weight Fresh roots Dry Weight Nigeria 37 500 13 100 12 4.2 Brazil 24 500 8 600 14 4.9 Indonesia 23 900 8 400 20 7.0 Thailand 22 000 7 700 19 6.7 D.R. Congo 15 000 5 300 8 2.8 Angola 13 800 4 800 15 5.3 Ghana 13 500 4 700 13 4.6 Vietnam 8 500 3 000 17 6.0 India 8 000 3 000 34 12.0 Mozambique 5 700 2 000 6 2.1 Source: FAO 2012
Cassava Yield from Different Countries Cassava yield From 22 to 2 ton/ha!! Cassava yield in India reached 34 ton/ha
Source: FAO 2012 Cassava Yield of Top 10 Countries
Potential Cassava Plantation Area: African Scenario Almost half of African Continent is suitable for Cassava Plantation. Keeping in mind the robustness of this crop to climate change and less crop maintenance (fertilization and pest control)
Potential Cassava Plantation Area: African Scenario Country Senegal Burkina Faso Mali Kenya Tanzania Zambia Botswana Total area km² 196 013 272 339 1 252 281 581 871 941 375 751 920 587 337 1 221 361 Arid region km² 14 093 5 117 389 734 230 888 n/a n/a 128 289 378 418 Arid region % 7,1 1,9 31 39,7 n/a n/a 22 31 South Africa km² of arid region available and suitable % of arid region available and suitable 10 200 0 121 397 209 760 n/a n/a 102 193 353 937 72 0 31 91 n/a n/a 80 94 Semi-arid region km² 97 054 144 856 248 226 227 020 316 738 160 281 453 316 522 927 Semi-arid region % 49,5 53,1 19,8 39 33,6 21,3 78 42,8 km² semi-arid region available and suitable % semi-arid region available and suitable 5 583 22 756 71 041 169 938 147 252 67 383 189 667 368 944 6 15 29 75 46 42 42 70 Arid & semi-arid km² 111 147 149 973 637 960 457 908 316 738 160 281 581 605 901 345 Arid & semi-arid region % 56,6 55 50,8 78,7 33,6 21,3 100 73,8 km² arid & semi-arid available & suitable % arid & semi-arid available & suitable 15 783 22 756 192 438 379 698 147 252 67 383 291 860 722 874 14 15 30 82 46 42 51 79 Comparative ranking of available & suitable 8 7 4 2 5 6 3 1 Areas identified as available and suitable for bioenergy crop production in the eight case study countries: Competence Platform on Energy Crop and Agroforestry Systems for Arid and Semi-arid Ecosystems- Africa (COMPETE),
Potential Cassava Plantation Area: Global Scenario
Whole Plant BioRefinery Concept Protein + Carbohydrates Lignocellulosic Material Starch
Cassava Bagasse Composition Component Percentage (%) Carbohydrates 40.5 63.8 Protein 0.3 1.6 Fermentable Sugars Lipids 0.5-1.06 Fibers 14.8 50.5 Ash 0.6 1.5 Humidity 5-11
Domestic and Export portfolio of Cassava in Thailand Export 72% Export
Cassava Export Price (Thailand)
Thailand Export Market
Thailand Policy for Cassava plantation Major Production Policies in Thailand 1. Maintain Planted Area Gr = 11 2. Increase Yield Source: Office of Agricultural Economics
Strategies to Improve Cassava BioEconomy 1. Increase Productivity (Increase yield, GAP, Strengthen farmer union) 2. Increase Product Value (maximal use of all plant parts, zero waste concept, fully integrated process). 3. Development of integrated biorefinery concept to develop product portfolio (Food/Feed/Biofuel/Chemicals) 4. Improving Supply Chain Management 5. More Efforts in Research and Development (for both upstream and downstream)
Cassava Products Portfolio
Current Utilization of Cassava Cassava Stem Pellet (LC M) (Pro 18-22% Leaf ) (St 44%) Root Chip (Pro 2%, St 50-60%) Flour&Starch Modified Starch ANIMAL FEED Poultry Pigs Cows FERMENTATION Et/But/Prop Organic acids Amino Acids Bioplastics Biobased-Chem FOOD Non-FOOD
Conclusions Cassava is potential feedstock for integrated biorefinery concept in tropical and subtropical region. The price of cassava is stable for many years and its expected to be reduced in the near future based on the future growth of cassava plantation and the increase of the current production yield. Cassava shows high potential as source of food/feed/biofuel/chemical with minimal or zero waste processing Cassava has high resistance for climate change and low water consumption. Thus, it is recommended to use it in certain percentage to overcome the possible crop loss based on climate change. The yield of cassava is highly fluctuated from one region to others. Thus, International cooperation is required to transfer the knowledge of cassava GAP to increase the plant production yield.
Advantage of Location - Johor state have the largest oil palm and cassava plantation in Malaysia - BioEconomy Malaysia (BiotechCorp Investment Policy), Jbiotech. - Located in Iskandar investment Zone, BioXcell, next door to Singapore - Connected with TH, ID, KH, VN with the largest port in South East Asia (Tanjung Pelepas)
Techno-Industrial Platform Design Traditional Universities Knowledge for Knowledge Sake - Teaching - Research - Service - Development Technology Development Institute - Industrial Research - Commercialization of applied Research Biotech-Industry Management of Knowledge for Profit - Profit Oriented Organization - R&D based Industry Academic freedom: Open discourse Research Platform Techno-industrial Platform Confidentiality: Limited public disclosure Industrial Platform
From Research to Industry Developing the concept Testing the concept Industrializing the Concept R&D Pilot Plant Large Scale Production Discovery Scalability/profitability Money Making Scientific value Industrial value +ve Cash flow -ve Cash flow
1- Technology transfer hub for biotechnology companies: 1.1. Phase I: - Cell banking - Technology Evaluation - Process re-adaptation - Dissolve of non-process related issues - Process scaling up and industrialization - Contract Manufacturing for short time market penetration 1.2. Phase II: - Consultation during the design and building new facility (Basic Engineering, Project and process validation) - Human resource development and training of new staff 1.3. Phase III: - Master cell bank of the original strain - RTD centre for continuous process optimization
Microbial Processing Pilot Plant at IBD
IBD and EDUCATION Work as important component of the university education system through teaching and practicing the platform models and the art of technology integration Education tool for hand-on operation with industrial case study rather than teaching different subjects in segregated modes Students (starting from undergraduate level) work in industrial climate structure. This will improve their practical skills and they will easily integrated in the industrial society without lag time
IBD and BUSINESS Minimizing the risk of failure during technology transfer process RTD is the main assets of the BioTech based companies. This system supports the innovation based industry with minimal direct investment. Provide the high skilled human resource required for Biotech Industries as students from undergrad. level work in industrial projects and hired by the companies doing running of the project This type of platforms act as RTD hub and toll manufacturing facility for SME (full acting incubator) to help companies for market penetration before large investment in their own facility.
Released: July, 2013