Creating a Secure and Sustainable Future
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Transcript of Creating a Secure and Sustainable Future
Creating a Secure and Sustainable Future
Defining an Achievable Means of Meeting our Food, Fuel and Feed Needs Domestically
Martha Schlicher, Ph.D.
National Corn-to-Ethanol Research Center
DefinitionsEthanol A two carbon alcohol produced most easily produced by
conventional yeast when they consume single six carbon sugars. Used as spirit or fuel.
Sucrose Two six carbon sugars (glucose and fructose) linked together. Table sugar. Found in sugar cane
Glucose The sugar in your blood Exists as chains of glucose (e.g. starch or cellulose) or glucose with other sugars
Starch Chains of the six carbon sugar glucose present in corn or potatoes that can be easily broken down to free glucose and fermented to ethanol. A carbohydrate.
Cellulose Chains of the six carbon sugar glucose present in fiber/biomass. Potential to convert to ethanol. A carbohydrate.
Hemicellulose Chains of five and six carbon sugars present infiber/biomass. Potential to convert to ethanol.A carbohydrate.
Robert Shleser , 1994
Starch
Cellulose
Lignocellulose
Sucrose
Lignin
Examples
TIME
M B
arr
els
of
Oil
Dis
pla
ced
/Yr
THE POTENTIAL ETHANOL PIPELINE
NEAR TERM 10%
MID TERM20%
LONG TERM40%
B G
allo
ns o
f Eth
an
ol
Pro
du
ced
/Yr
GLUCOSE FROM STARCH
& CORN KERNEL CELLULOSE
SUCROSE FROMSUGARCANE/BEETS
GLUCOSE FROM
STARCH CORN KERNEL &
AVAILABLE BIOMASS
CELLULOSE(wood chips,
waste)
PENTOSES FROM
AVAILABLE BIOMASS
HEMICELLULOSE
GLUCOSE FROM
STARCHCORN KERNEL
& NEWCELLULOSEBIOMASS
PENTOSESFROM
NEW BIOMASS HEMICELLULOSE
2005-2015 2016-2030 2031-20404115
21 MBD Oil in 05; Gasoline only; Use held at 05
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ABUNDANT & AVAILABLE
ECONOMICAL
Corn Starch
Switch Grass
US Biomass Sources
Paper
Sugar Cane
Cottonwoods
Stover
Wood Chips
Corn
Fiber
NEAR TERM
Wheat Barley
NEAR TERM STARCH
•1980's --175 plants (20K to 7M gallons)
•1990's -- 33 plants (1.5M to 30 M gallons)
•2000's -- 91 plants (30M to 110M gallons)
Important to Remember Secure the Base while Building the Future
TIME
Barr
els
of
Oil D
isp
laced
RESOURCING THE ETHANOL PIPELINE
NEAR TERM10%
MID TERM20%
LONG TERM40%
Gallo
ns o
f Eth
an
ol
Pro
du
ced
•AGRONOMIC PRODUCTIVITY•DDGS = CORN•PROCESS PRODUCTIVITY•ENERGY USE•NEW COPRODUCTS
GLUCOSE FROM
STARCH CORN KERNEL &
AVAILABLE BIOMASS
CELLULOSE(wood chips,
waste)
PENTOSES FROM
AVAILABLE BIOMASS
HEMICELLULOSE
GLUCOSE FROM
STARCHCORN KERNEL
& NEWCELLULOSEBIOMASS
PENTOSESFROM
NEW BIOMASS HEMICELLULOSE
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20
40
NEAR TERM STARCH
e
S
n
NEAR TERM STARCH
2004 US Corn Utilization
FEED: 56.4%EXPORT: 18.5%
FUEL: 11.7%
FOOD: 6.7%HFCS: 5.2%
80.9 Million Acres Harvested - 11.8 Billion Bushels
NEAR TERM STARCH
Ethanol Production Locations
Critical Near Term ResearchIncreased Ethanol
Yield Per AcreReduced EnergyUse per Gallon
Agronomic Productivity
High Extractable/Fermentable HybridsCustom Hybrids
Process ModificationsCold Cook/Enzyme advancementsDegerm/DebranCorn Kernel Fiber to Ethanol
Coproduct Optimization and Segregation
DDGS Composition, Quality, TransportWet Distillers/Plant LocationOil Separation for Biodiesel
Fermentation/Starch to Sugar
Ethanol IsolationOrganism OptimizationEthanol Separation
Cogeneration Mining Process Energy and Streams
Critical Near Term ResearchIncreased Ethanol
Yield Per AcreReduced EnergyUse per Gallon
Agronomic Productivity
High Extractable/Fermentable HybridsCustom Hybrids
Process ModificationsCold Cook/Enzyme advancementsDegerm/DebranCorn Kernel Fiber to Ethanol
Coproduct Optimization and Segregation
DDGS Composition, Quality, TransportWet Distillers/Plant LocationOil Separation for Biodiesel
Fermentation/Starch to Sugar
Ethanol IsolationOrganism OptimizationEthanol Separation
Cogeneration Mining Process Energy and Streams
2004 US Corn Utilization
FEED: 56.4%EXPORT: 18.5%
FUEL: 11.7%
FOOD: 6.7%HFCS: 5.2%
80.9 Million Acres Harvested - 11.8 Billion Bushels
NEAR TERM STARCH
One Bushel (56 lbs) of Corn Entering
Dry Grind Ethanol Plant
STARCH
PROTEIN
OIL
FIBER
Pounds Per Bushel of Corn – Dry Weight
Assume corn 15% moisture content
37.2 lbs
4.98 lbs
2.24 lbs
4.98 lbs
0
5.01 lbs
1.74 lbs
ETHANOL
CO2
DDGS – 16 -18 lbs
Products from one Bushel ofCorn Leaving
Dry Grind Ethanol Plant
0
0
2.75 gallons
18.0 lbs
3.74 lbs
NEAR TERM STARCH
1.38 B Bushels of Corn Entering Ethanol Plants
STARCH
PROTEIN
37.2 lbs
6.88 B lbs
0
7.04 B lbs
ETHANOL
CO2
Results in …………
0
0
2.75 gallons
18.0 lbs
Containing
Animal Feed
NEAR TERM STARCH
Amounts of feedstocks to produce 10 ml
ethanol
500 ml graduated cylinders used for comparisons
Corn Fiber DDG Stover
ethanolMoisture Content
Corn 15%
Fiber 46%
DDG 64%
Stover 5%
NEAR TERM CORN KERNEL FIBER
Corn Kernel CellulosicsNear Term Technology Validation
No incremental supply chainCosts
Potential 10% Yield increase
4.5 M gal Ethanol per plantAnnually
Minimal incremental capital
DDGS weight reduced 44%
No increase in corn acres
NEAR TERM
Robert Shleser , 1994
Starch
Cellulose
Lignocellulose
Sucrose
Lignin
Examples
Representative Corn Component Composition
Component Stover Cobs Fiber
Glucan (%)
Xylan (%)
Arabinan (%)
Lignin (%)
Protein (%)
Fat (%)
40.9
21.5
1.8
11.0
7.2
1.3
39.4
28.4
3.6
7.0
3.2
0.7
37.2
17.6
11.2
7.8
11.0
2.5
Wyman; Corn Chemistry and Technology, 2nd edtn.
Selected Pretreatment Strategies
Acid
Base
Pretreatment Pentoses Inhibitors
Strong Acid + ++
Dilute Acid + ++
Hot Water - +
AFEX - -
Alkaline Peroxide - -
Yeast metabolism & nutrition
Sugar and carbohydrates metabolised by Saccharomyces Species
Sugar sources
GlucoseFructose MannoseGalactoseSucroseMaltoseMaltotriose (partially)RaffinoseDextrine (partially)
Sugar and carbohydrates not metabolysed by saccharomyces species but metabolised by species of other yeast genera
Xylose (e.g. Candida shehatae and Pichia stipitis)
Cellobiose (e.g. Scwanniomyces castelli and Candida)
Lactose ((e.g. Candida curvata and Kluyveromyces fragilis)
Starch (e.g. Schwanniomyces castellii and Saccharomyces fibuligera)
Inulin (e.g. Kluyveromyces marxianus)
Metabolites
GlucoseFructose MannoseGalactoseGlucose + Fructose2 Glucoses3 GlucosesRaffinoseDextrine (partially)Ethanol
Recombinant Microorganisms for Fermentation of Mixed Sugars to Ethanol
Recombinant organisms are now available
Recombinant Escherichia coli Recombinant Saccharomyces Recombinant Zymomonas Recombinant Klebsiella oxytoca
Timid Commercialization prospects BCI with recombinant E. coli Iogen with recombinant Saccharomyces
Utilization of Biomass forProduction of Fuel Ethanol
Corn Fiber
Ethanol Recovery
Pretreatment
Enzymatic Saccharification
Fermentation
Representative Corn Component Composition
Component Stover Cobs Fiber
Glucan (%)
Xylan (%)
Arabinan (%)
Lignin (%)
Protein (%)
Fat (%)
40.9
21.5
1.8
11.0
7.2
1.3
39.4
28.4
3.6
7.0
3.2
0.7
37.2
17.6
11.2
7.8
11.0
2.5
Wyman; Corn Chemistry and Technology, 2nd edtn.
1993
Corn Kernel Fiber Solved
Strategy 1
Design a method to CONVERT ALL possible sugars in kernel, maximum increase In ethanol would be 0.328 gallons/bushel.
Weight, lbs/bushel* Ethanol, gal/bushel*
Starch 33.93 2.93
Hemicellulose 2.59 0.228
Cellulose 1.16 0.100
*From Gulati, et al., 1996 Bioresource Technology
Math for 50 mgy plant: 0.328 gal/2.7 gal is 12% increase
0.10 gal/2.7 gal is 3.7% increase
ABUNDANT & AVAILABLE
ECONOMICAL
Corn Starch
Switch Grass
US Biomass Sources
Paper
Sugar Cane
Cottonwoods
Stover
Wood Chips
Corn
Fiber MID TERM
Wheat Barley
TIME
Barr
els
of
Oil D
isp
laced
RESOURCING THE ETHANOL PIPELINE
NEAR TERM10%
MID TERM20%
LONG TERM40% G
allo
ns o
f Eth
an
ol
Pro
du
ced
•AGRONOMIC PRODUCTIVITY•DDGS = CORN•PROCESS PRODUCTIVITY•ENERGY USE•NEW COPRODUCTS
GLUCOSE FROM
STARCHCORN KERNEL
& NEWCELLULOSEBIOMASS
PENTOSESFROM
NEW BIOMASS HEMICELLULOSE
2005-2015 2016-2030 2031-2040
•AVAILABLE BIOMASS SEPARATION AND PRETREATMENT OPTIMIZED•FIVE CARBON SUGAR CONVERSION OPTIMIZED•MIXED SUGAR OPTIMIZED•REGULATORY FRAMEWORK ESTABLISHED•PROCESS EFFICIENCY OPTIMIZED
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Representative Corn Component Composition
Component Stover Cobs Fiber
Glucan (%)
Xylan (%)
Arabinan (%)
Lignin (%)
Protein (%)
Fat (%)
40.9
21.5
1.8
11.0
7.2
1.3
39.4
28.4
3.6
7.0
3.2
0.7
37.2
17.6
11.2
7.8
11.0
2.5
Wyman; Corn Chemistry and Technology, 2nd edtn.
Ethanol Fermentation Of Corn Fiber Hydrolysate by E. coli
FBR5
Time (h)
0 20 40 60 80 100
Con
cent
ratio
ns (
% w
/v)
0
1
2
3
4
ArabinoseGlucoseXyloseEthanol
Future Strains: Critical Traits
• Pentose utilization
• High ethanol yield and productivity
• Genetic and phenotypic stability
• Hardiness (tolerance to ethanol and inhibitors)
• Efficient use of multiple sugars
• Growth at low pH/high temperature
• Ease of use with current production technology
ABUNDANT & AVAILABLE
ECONOMICAL
Corn Starch
Switch Grass
US Biomass Sources
Paper
Sugar Cane
Cottonwoods
Stover
Wood Chips
Corn
Fiber
LONG TERM
WheatBarley
TIME
Barr
els
of
Oil D
isp
laced
RESOURCING THE ETHANOL PIPELINE
NEAR TERM10%
MID TERM20%
LONG TERM40%
Gallo
ns o
f Eth
an
ol
Pro
du
ced
•AGRONOMIC PRODUCTIVITY•DDGS = CORN•PROCESS PRODUCTIVITY•ENERGY USE•NEW COPRODUCTS
IDEAL BIOMASS BY GEOGRAPHY
PRODUCTION, HARVEST,And TRANSPORT
BIOMASSSEPARATION
PRETREATMENTCONVERSION
ORGANISM OPTIMIZATION
COPRODUCTS
2005-2015 2016-2030 2031-2040
•AVAILABLE BIOMASS SEPARATION AND PRETREATMENT OPTIMIZED•FIVE CARBON SUGAR CONVERSION OPTIMIZED•MIXED SUGAR OPTIMIZED•REGULATORY FRAMEWORK ESTABLISHED•PROCESS EFFICIENCY OPTIMIZED
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Cost Comparison for Corn & Stover
Corn Starch
Corn Stover
Annual Ethanol (MMGal) 50 50
Ethanol Prod. Cost ($/gal) 0.96 1.45
Total Prod. Costs (MM$/yr) 47.8 72.0
Co-product Credit ($/gal) 0.26 0.13
Feedstock costs1 ($/gal) 0.793 0.51
Capital Invest. (MM$) 48.0 193.7
USDA, ERRC, March 2005
Hope for
future
1Corn at $2.25/bu & stover at $40/ dry ton
INPUTS Feedstock Sources
• Agricultural Production• Agricultural Waste• Biomass• Industrial Waste
Micro-BiorefineriesUnique Resources vary by Local Geography
OUTPUTS • Process Streams• Feed and Fuel• Food
COMPONENTS • Process Fuel• Labor• Transportation
Key Areas of FocusAcross a Portfolio of
TimeSecure the Base
Grow the Future
•Feedstock Optimization •Process Optimization•Animal Feed Optimization
Supply Demand•FFV Availability•E85 Availability•Consumer Knowledge and Demand•Workforce
•Get the sugars out without destroying them or•Creating a hostile environment•Convert all sugars – effectively and efficiently•Address regulated organisms•Address inefficiencies of low concentration of alcohol in beer for isolation
Key Areas of FocusAcross a Portfolio of
Time
•Ensure there is research funding – nationally as well as locally
•Ensure it is spent well•Balance near, mid and long term research needs•Identify local resources and ensure funds are aligned to solve the technical problems you need addressed•Require measurable commercial outcomes•Don’t create champions•Don’t starve the troops•Be realistic•Don’t be redundant•Do reward results