Replacing Petroleum with Renewable Fuels and Chemicals Buckeye Technologies & Florida Crystals
We have created an environmental problem. While US pundits turn climate change into a joke, China turns this opportunity into jobs. (T. Friedman, 2010) You re going to ruin everything! Burning fossil biomass fuels releases fossil CO 2.
We have created a strategic vulnerability. US Source and Use of Petroleum 65% CO 2 Solvents Plastics 5 bil barrels/year Fuels 35% Fossil Biomass CO 2
Replace Fossil Biomass with Modern Biomass Nature s solar energy! Renewable fuels and chemicals (~ 100 bil gal fuel per year) To replace 1 lb petroleum: 2 lb Carbs 1 lb ethanol + 1b CO 2 1 lb Carbs 1 lb organic (plastics) acid polymer***
What role can Florida play? 1. Florida has the market, >9 bil gal/yr fuel. 2. Florida has farmers and families that need jobs. 3. Florida has natural resources to grow biomass. 4. Florida needs to invest in energy research for biomass production (plant breeding & best practices). 5. Florida needs to invest in research to develop new bioproducts -- new biocatalysts & novel processes. 5. Florida will need to provide competitive incentives for new industries to locate here. 6. States that are winning are states that are Making Big Investments!
Modern Biomass All parts: stems, leaves, roots, etc. CO 2 Can this be done at $ 50 / dry ton? N,P,K,Mg,Fe Water & Nutrients Ammonia Phosphorus Potassium Magnesium Sulfate Iron and trace metals IFAS Crop Production Short rotation trees New plants, new diseases, new practices Energy crops must use water and nutrients efficiently!
Biomass Biorefinery -- Renewable Cycle CO 2 Biomass No Net Greenhouse Gas Emissions Liquid Fuels C x H y + (X + CO 2 + ( y 4 )O 2 y 2 )H 2O Bio-Refinery Plastic & Solvents Cars, Trucks, and Planes Lignin, composites, biomaterials, fertilizer, biogas, and other products DOE
Replace a Petroleum Refinery with a Bio-Refinery Feedstocks Energy Crops and Trees Agricultural Residues: Forrest Residues, trees Municipal Green Waste: Technologies Bio-Chemical Saccharification Fermentation Biocatalysts Thermochemical Pyrolysis Gassification Chemical catalysis Markets Intermediary Products Biosynthesis gas Organic Acids Hydrogen Methanol Ethanol Final Products Electricity Heat/Steam Fuels/Ethanol Plastic Solvents s Fertilizer (Modified from DOE, 2002)
Woody Biomass ~60-70% Carbohydrate Corn ~70% starch Black thermoplastic that can be burned to provide energy for ethanol production. Lignin Nature s plastic glue (thermoplastic) Cellulose Hemicellulose Primarily pentoses, 5-carbon sugars also 6-C sugars Homopolymer of glucose, hexose, a 6-carbon sugar. Composition of Lignocellulosic Biomass
Acid or Base pretreatment is essential for deconstruction of lignocellose. Glucose Cellulase Xylose, arabinose, gal, man, rham 1. Dilute acid pretreatment syrup of hemicellulose sugars 2. Enzymes to convert cellulose glucose syrup
Examples of pathway construction to make biocatalysts Succinate X frd Fumarate Ethanol FAD FADH 2 Malate NAD + NAD + mdh NADH NADH Zymomonas pdc-adhab OAA NAD - NADH ATP ADP ppc ADP ATP Pyruvate aceef lpd Acetyl-CoA 2NADH 2NAD + Gly3P PEP X pflb X adhe NAD + NADH Xylose or Glucose NADH NAD + Formate gloc ADP ATP DHAP Acetyl-P acka mgsa Methylglyoxal gloa X glob D-lactate pta methylglyoxal reductase aldb alda L-Lactate E. coli ldha/ Pediococcus ldhl Bacillus coagulans, others X Ethanol Acetate
Engineering Strategy Select Platform Organism Pathway construction for single product Metabolic evolution for strain performance Introduce beneficial mutations Metabolic evolution to maximize rate, titer, & yield)
Renewable Fuel and Chemicals Pentose Sugars Uronic Acids Succinate Malate Acetate D & L- lactate Hexose Sugars Pyruvate Biodiesel Butanediol Alkanes Butanol Propanol Plastics L-Alanine Ethanol Fuels
Cellulosic Sugars Commercial D-lactic acid BioEnergy International, LLC Now Myriant Technologies Sublicensed to Purac PLA + PDLA Blends PLA PLA+5% PDLA
Polylactic Acid PLA
Glucose Glucose glk G6P galp (30 mil lb/yr) Plant under construction in Louisiana 2 ADP + 2 NAD + 2 ATP + 2 NADH PtsI Pyruvate 2 PEP ppc CO 2 Pi Oxaloacetate NADH NAD + H 2 O NADH NAD + 2 G3P mdh Malate pck* fumab C Fumarate frdabcd Succinate (1.4) ADPCO 2 ATP Acetate (0.6)
Succinate a key building block with billon ton/year potential DOE Top 10 Building blocks
UF Biofuels Pilot Plant (unit ops) BOG Center of Excellence (Frazier-RogersHall)
Conversion of Biomass to Fuel Ethanol & Chemicals A. Sulfuric Lignocellulose Process Washing Cellulose +Lignin Lignocellulose Dilute Acid Hydrolysis (Zirconium Hydrolyzer) Liquid/solid Separation Hemicellulose Syrup Fermentation Cellulose+ Cellulase Hemicellulose Cleanup Hemicellulose Fermentation Purification B. Phosphoric Lignocellulose Process Lignocellulose Dilute Acid Hydrolysis Liquifaction (+cellulase) Fermentation cellulase & hemicellulase Purification (Stainless Steel Hydrolyzer) C. Mature Corn to Ethanol Industry Corn Steam Cooker (Stainless Steel Cooker) Liquifaction (+ amylase & glucoamylase Fermentation + amylase & glucoamylase Purification
Process Development Biofuels Pilot Plant Process for Cellulosic Ethanol Steam Pretreatment + Phosphoric Acid (presteamer, hydrolyzer and blow tank) Similar to Liquifaction (enzymes, ph) Borrowing water and nutrients Corn Dry Milling N, P, K, Mg S, Fe, Ca Sized Bagasse Or Wood Single Vessel Fermentation Distillation Ethanol Heat - kill Cleanup Stillage Centrifugation Waste treatment (energy crops) Ca-Phos Coproduct Boiler & Coproducts Lignin enriched fiber
Stan Mayfield Biorefinery Pilot Plant with Buckeye Technologies, Perry FL Woody Residues Woody Crops and Trees BKI materials Size: 3 tons of cellulosic biomass/day for Bagasse; ~ 5 tons/day wood Sorghum syrup Partial Saccharification CO 2 Fuel Ethanol Lignin Fertilizer Co-products Hemi streams Sweet Sorghum and Related sugar crops Organic acids, Plastics Maximum Capacity per Day (lignocellulose) 400 gal ethanol/day or 5,000 lb of organic acids Process borrows water and nutrients that are used to grow new energy crops.
Buckeye Technologies, Inc., Perry Florida Future Stan Mayfield Biorefinery Pilot Plant This Application contains proprietary information that University of Florida requests not be released to persons outside the Government, except for purposes of review and evaluation.
Stan Mayfield Biorefinery Pilot Plant 8,500 sq. ft. process 6,000 sq. ft. client space 3,500 sq. ft. service labs biomass 18,000 sq. ft. Looking Northwest
Stan Mayfield Biorefinery Pilot Plant 8,500 sq. ft. process 3,500 sq. ft. service labs 6,000 sq. ft. client space chiller 18,000 sq. ft. Distillation
Good things are already happening in Florida (Replacing Petroleum with Renewable Fuels and Chemicals) BP/Verenium/Lykes -- biofuel Myriant Technologies (Purac)-- bioplastics Licensees of UF technology for fuels and chemicals Biodiesel: LS9 bacterial oils from sugar Seed oils Jatropha Petroalgae, oil from duckweed US Envirofuel Ethanol from the juice of sweet sorghum Buckeye Technologies & Florida Crystals (power from woody residues; exploring fuels and chemicals) Universities - Biofuels Pilot Plant (unit ops) Stan Mayfield Biorefinery Pilot Plant/Buckeye Florida Crystals/FIU Pilot Plant Florida Center for Renewable Chemicals and Fuels (FCRC)
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