Fermentation process co-products : Integrated protein, energy and feedstock recovery
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Fermentation process co-products:
Integrated protein, energy and feedstock recovery
Julio Traub23 January 2013ICBD Heriot-Watt University, Edinburgh
18th IBD Video Link Day
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Contents
1. Whisky Process and Industry
2. Whisky co-products: Current and potential markets
3. Experimental Work
4. Conclusions
5. Future Work
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WhiskyA Scottish success story
Source: Diageo
19461949
19521955
19581961
19641967
19701973
19761979
19821985
19881991
19941997
20002003
20062009
- 50,000,000
100,000,000 150,000,000 200,000,000 250,000,000 300,000,000 350,000,000 400,000,000
Scotch Whisky Exports - 1946 to 2011 by volume
Year
Volu
me
(M lp
a)
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Whisky - Waste Fight Club...
The are only 2 Rules...
1. It’s not waste... It’s a co-product!!!
2. Don’t touch the process!
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Whisky Production ProcessMalt Whisky
Extraction
Fermentation
Distillation
Evaporation
Drying
Water
Malted barley
Yeast
Draff
Pot ale
Spirit (Whisky)
Pot ale Syrup
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DraffA good example of the Food vs. Fuel controversy
• Used as animal feed• Cheap, good protein source (21% in DM basis)
• Can be used as a biofuel
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Pot AleTypical Properties
pH 3.5 – 4.1
Solids 3 – 5 % w/v
Yeast count ~ 10 8 cells/mL
Copper Content 2 – 6 mg/ L
BOD 12 – 35 g/ L
COD 38 – 62 g/ L • Water• PROTEINS• Yeast• Yeast Debris• Copper• Carbohydrate
s
Sources: Graham, J., et al. (2012), Russell, I. et al (2003)
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Pot AleCurrent treatment technologies
Fertiliser Consented discharge
Evaporator
Co - product???
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Pot Ale Syrup
• Evaporated Pot Ale (45% Solids)• High capital and running costs• Energy intensive (CO2 emissions)• Limited used (mostly Cattle) –
High copper content = toxic• Current Supply ~ 30 – 50 ktpa
– Protein ~ 5 - 8 ktpa• Commercial products available:
– Spey Syrup (AB Agri), GP feeds
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20012003
20052007
20090
500
1,000
1,500
2,000
2,500
3,000
3,500
Wheat
Barley
Maize gluten feed
Wheat feed
Distillery by-products
Soya cake and meal
k to
nne
UK Animal Feed DemandTotal = 10 m tonne in 2010
8.5%
3.2%
9.2%
28.1%
Source: http://www.defra.gov.uk/statistics
1.2%
11.5%
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UK- BIOETHANOL PRODUCTIONENSUS VIVERGO
Start up May 2009 Teeside
Sep 2012Hull
Investment £300 m £300 mRaw Materials 1 Mt Wheat 1 Mt WheatProduction 400 m L 420 m LAnimal Feeds 350 k tonne 545 k tonneHistory •May 2011 temp closure
•Sep 2012 reopened Dry 390 k tonne
Moist 130 k tonne
Syrup 25 k tonne
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Malt WhiskyVolumes and Co-products
DistilleryCapacity
[M Lpa/ a]
Pot Ale Proteinsa
[Tonne/ a]
DraffProteinsb
[Tonne/ a]
Protein Valuec
[£/ a]
Total 287 32 K 37 K 48 m
Median 2.7 302 347 454 k
Max 10.5 1,176 1,351 1,768 k
Min 0.05 5.6 6.4 8.4 k
a 1 Lpa = 8L Pot Ale 14 g protein = 1L Pot Ale
b 1 Lpa = 2.45 kg draff DM = 25%, CP = 21%
c £700/ ton
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Aquaculture FeedsScottish Salmon – the other Scottish success story
UK Salmon Production 154 k tonne (Atlantic Salmon), 3rd largest producer in the world ~200 k tonne protein , High dependency on FM/ FO
Need for Alternative Feedstuffs Economic and Sustainable Drivers
Ideal Candidate• Price and Logistics: Availability, handling, shipping, storage• Low levels of fibre, High Protein content, Amino Acid Profile,
High Digestibility
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DDGS PAS SBM FMCrude Protein 29 - 35 % 34 -38% 46 - 50% 65 -72%
Lysine 0.55% 2.1% 2.69% 4.72%
Meth + Cyst 0.86% 0.35% 1.18% 3.5%
Threonine 0.81% 1.9% 1.67% 2.5%
Amino Acid Analysiswhat the fish wants...
DDGS: Wheat Distillers Dried Grain with SolublesPAS: Pot Ale SyrupSBM: Soy bean MealFM: Fish Meal
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The Horizon Protein Project
Identify• Inefficiencies• Proteins• Markets
Optimize
• Process• Product
Scale Up
• Lower Energy Consumption
• Reduce CO2 emissions• Value added By-
products
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Research WorkAnalytical Process
Design &Optimization
EconomicalModelling
•Solid content
•pH
•Yeast count
•Particle size
•Protein content
•Metal Analysis (Cu,
Fe, Zn, Mn)
•Cell disruption
•Protein Purification
and Concentration
•Solid/ liquid
separation
•Cost and Capital
estimation
•Economical
Analysis (NPV, IRR,
etc.)
•Protein Markets
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Process SelectionPotential processes identified:
1. Pot Ale – Barley Protein Fraction
2. Pot Ale – Yeast Protein Fraction
3. Pot Ale – Barley + Yeast Fractions
4. Pot Ale + Draff – Barley Proteins
5. Pot Ale + Draff – Barley + Yeast Fractions
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Process OverviewBarley + Yeast Fractions
PROTEINS
EnzymaticTreatment
High Pressure Homogeniser
Centrifugation
Filtration
Ion Exchange Chromatography
Pot Ale
• Water• PROTEINS• Yeast• Yeast Debris• Copper• Carbohydrates
ExtractionPurification
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Experimental WorkProtein Content and Distribution
Lowland PA (Feb)
Lowland PA (Aug)
Spent Wash (Jun)
Speyside PA (Nov)
02468
10121416
PelletSoluble
Prot
ein
Cont
ent (
g/ L)
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Experimental WorkCopper analysis
Lowland PA (Feb)
Lowland PA (Aug)
Spent Wash (Jun)
Speyside PA (Nov)
0.00
0.50
1.00
1.50
2.00
2.50
3.00
PelletSoluble
Copp
er C
onte
nt (m
g/ L)
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To disrupt or to not disruptThat is the question...
Yes No“Wasted” Protein •~30% of total protein content•Favourable AA profile •Yeast high in Lysine (close to FM)•Better end-product price
Cost + CapitalHomogeniser, enzymes, bioreactor
“Wasted” Minerals Downstream processes•Micronisation, nucleic acids, etc.•Buffers•More cost and capital!
Other value added chemicals•Glucans, chitins, phenols
Toxicity •Copper: ~70% bound to cells
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Experimental Work Protein Purification and Concentration
• Buffers: PBS, lactic acid, citric acid
• Cation and anion exchange
• pH elution: 4-7
• Elution mode: Gradient and Step
• Flowrate: 1 – 5 ml/ min
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Conclusionsso far...
Pot Ale is a co-product Valuable proteins are currently underused at least £20 million pa across Scotland
Current whisky co-product treatment technologies are unsustainable Expensive and energy intensive Increasing supply with static demand New markets: Salmon (?!)
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Conclusions cont’dso far...
More understanding of what is needed for Salmon Feeds AA, minerals, fibres, nutritional properties
Yeast cell fraction has not yet proved to be a viable option High copper, Low protein but it must NOT be “wasted”
Draff proteins may increase feasibility of the project, but with some controversies and problems
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Sustainable protein sources
Carbon Emissions
Energy Efficiencies
Added Value Co-products
Cost Savings
Industrial Symbiosis
Academic Research
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Future work
Proteins• IEC: Columns (media, size), pH, flow rate• Protein Identification (SDS-Page, AA analysis)
Cell disruption • Combined method• Scale up Enzymatic Treatment
Metal Analysis• Protein and metal binding affinity
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AcknowledgmentsThe Horizon Proteins Team
Nik Willoughby Lydia Campbell Paul Hughes Alan Harper Dawn Maskell Jane White Sara Bagés
www.horizonproteins.com
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Acknowledgments
Heriot-Watt University (SLS + EPS) Eileen McEvoy James Bryce Margaret Stobie Sean McMenamy Steve Euston Vicky Goodfellow
Glenkinchie and North British Distilleries
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Industrial Partners, Collaborators and Sponsors
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QUESTIONS?
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Some (Scottish) thoughts....
“Some hae meat and canna eat,
And some wad eat that want it,
But we hae meat and we can eat,
And sae the Lord be thankit.”
Robert Burns (1759 –1796)
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Experimental WorkCell Disruption
Source: Sara Bagés (2012)
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Malt WhiskyDistillery size distribution
Less
than
500
500
- 100
0
1,00
1 - 2
,500
2,50
1 - 5
000
5,00
1 -7
,500
7,50
1 - 1
0,00
0
Mor
e th
an 1
0,00
0
0
10
20
30
40
0%20%40%60%80%100%
Frequency
% Cumulative Distillery Capacity (k Lpa/ a)
Num
ber o
f Disti
llerie
s
Source: SWA
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Protein MarketsFish Meal and Soybean Meal
Source: http://www.indexmundi.com
Last 12 monthsFM: up 55%SBM: up 48%
Feb-07Dec-07Oct-08Aug-09Jun-10 Apr-11Feb-120
200
400
600
800
1000
1200
1400
Fishmeal PriceSoybean Meal
Poun
d St
erlin
g pe
r M
etric
Ton
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Aug-07
Dec-07
Apr-08
Aug-08
Dec-08
Apr-09
Aug-09
Dec-09
Apr-10
Aug-10
Dec-10
Apr-11
Aug-11
Dec-11
Apr-12
Aug-12
Dec-12
0.0
1.0
2.0
3.0
4.0
5.0
6.0
Poun
d st
erlin
g pe
r Kg
Protein Markets Salmon Price
Last 12 months: up 17%
Down 30% since Apr-11
Source: http://www.indexmundi.com
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Experimental WorkCell Disruption
Particle Diameter (µm.)
Volume (%)
0
10
0
10
20
30
40
50
60
70
80
90
100
0.1 1.0 10.0 100.0 1000.0 10000.0
Particle Diameter (µm.)
Volume (%)
0
10
0
10
20
30
40
50
60
70
80
90
100
0.1 1.0 10.0 100.0 1000.0 10000.0
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Distribution of copper in soluble fraction of pot ale
Supernatant separated into low and high MW fractions using Amicon Ultra-15 Centrifugal filter tubes
Retentate (>3 or 10 KDa)
Filtrate (<3 or 10 KDa)
Pot Ale (Aug) Pot Ale (Feb)
3 K 0.92 1.13 0.95 0.78
10 K 0.92 1.19 0.96 0.90
initialfiltrateV
initialfiltrateV
initialfiltrateCu
initialfiltrateCu
15 ml
Dialysis with 15 ml water
SDS-PAGE analysis
Copper analysis
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SDS-PAGE analysis of proteins
1 2 3 4 5 6 7 8 9 10
38-42 kDa
12-14 kDa
Spent wash and pot ale (Feb) – no pretreatment
175
8058463025
177
5.3 3.5 9.9 6.6 Spent wash
Pot ale
• Gel: 4-20% Bio-Rad Mini-Protean TGX precast gel (Cat No. 456-1094)• Sample buffer: Laemmli 2x sample buffer (Sigma, S3401) • Running buffer: Tris-Glycine• Protein marker: Prestained protein marker, New England Biolabs (P7709V)• Stain: Colloidal Coomassie Brilliant Blue (Kang et al., 2002)
‘Lysed’ Pot ale
‘Lysed’ cells
1 2 3 4 5 6 7 8 9 10
175
8058463025
177
Pot ale (Feb) – Retentate
µg protein: µg protein: 9.9Pot ale
3K Retentate
10K Retentate
Pot ale
9.9131.1 65.6 26.2 66.3132.6 26.5 26.5
72-80 kDa
MWKDa
MWKDa
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Horizon ProteinsPAS Pot Ale Pot Ale + Draff
Barley Yeast MixedBarley +
DraffMixed +
DraffProtein Yield % 71% 29% 100% 87% 100% 100%Protein output ton/ a 216 86 302 563 650 302 Price* £/ ton 545 1,391 787 545 658 545Total Cost £/ ton 364 987 568 314 509 629
Process Selection – Price vs. Cost
*Bulk Protein Price. SBM: £230/ ton, FM : £830/ ton
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Process Selection – Investment + NPV
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Source: FAO
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Source: FAO