UNESP CAMPUS DE RIO CLARO DEPARTAMENTO DE BIOQUÍMICA E MICROBIOLOGIA

Biorefining

Prof. Dr. Jonas Contiero

Instituto de Biociências de Rio Claro

jconti@rc.unesp.br

A concept designed to utilize the entire biomass feedstock , Renewable Raw Materials-RRM, producing bio-products that displace products originated from petroleum or high cost food feedstocks, extracting value in a series of staged industrial processes to optimize economics of production

Biorefining

Figure 1. Strategic applications of sugarcane plant. The pocessing of sugarcane in fields yield green tops and dried leaves, so-called sugarcane trash (ST). The bagasse is products from the stem after juice extraction. Both have profound importance in biotechnological and non-biotechnological applications.

source : Chandel et al., 2011

Biorefining , Eg. Sugar Cane

The future biorefinery concept of science and industry is defined as a biorefinery that converts a variety of feedstocks, including residues, into a portfolio of products with improved energetic chain efficiency, improved economy and improved environmental effects, compared to standalone processes often producing only one or two products. This concept is also known as the third generation biorefineries.

Biorefining

• A typical example of a first generation biorefinery is a dry milling ethanol plant, which utilizes cereals as feedstock and a fixed production line consisting of ethanol, feed co-products and carbon dioxide • A phase two biorefinery is the wet milling technology which allows the production of various end-products depending on product demand using one feedstock (mainly grain) • To date, the third generation biorefineries have not yet been built, but are in research and development.

Biorefining

Based on Kamm et al., 2006; Kamm & Kamm, 2004b, four concepts of third generation biorefineries are in discussion and under development: 1. Lignocellulosic Feedstock (LCF) biorefinery 2. Whole-crop biorefinery 3. Green biorefinery 4. Two-platform concept

Biorefining

This model requires integration of processes and flows of inputs, optimization of industrial utilities and transportation logistics It also requires high yield conversion and large scale production for the purpose to reduce production costs, promote diversification and enable flexibility of production to respond to market demands, similar to the model used by the petrochemical industry . Biorefineries belong to the category of agribusiness and it should be considered as an extension of agricultural production chain and thus integrated physically in the process of planting, harvesting, processing and transformation of these plantations.

Biorefining

Why Biorefinery?

1. There is an increase in renewable resources (biomass)

2. Renewable resources becoming increasingly cheaper

Biorefining

Source: modified from Wirtschaftliche Vereinigung Zucker e.V. 2009

Figure 2: Sugar production of selected countries for 2008/2009

Sugar Production

Figure 3: Relative cost of producing refined sugar 2003/2004 (source: http://www.illovo.co.za/worldofsugar/internationalSugarStats.htm.

Cost of Production

Figure 4: Technologies for biomass utilization.

Biomass Conversion

Figure 5: Innovative applications of renewable raw materials

Innovation Biomaterials

Biorefinery

In a biorefinery complex, a single raw

material such as e. g. sugar cane is

converted into:

Biorefinery

Biorefinery

Table 1: Industries and material uses of renewable raw materials

Biorefinery

Biorefinery

Biorefinery

Source : Almut Jering and Jens Günther, 2010

Biorefinery

Research of interest that are being developed in the Laboratory of Industrial Microbiology using renewable raw material. •Study of recovery and purification of the lactic acid produced by microorganisms isolated for production of biodegradable plastic. Fapesp:Braskem:Ideom •Metabolic Fluxes Assessment in Complex Network of Rhamnolipids Production by Pseudomonas aeruginosa. Fapesp •Cloning and expression of dha genes from Klebsiella pneumoniae in Escherichia coli strains to 1,3-propanediol production. Fapesp •Dextransucrase from Leuconostoc mesenteroides FT045B: dextran production with controlated molecular weight,production of alfa-ascorbic acid and bromo-dextran. Fapesp

On going Projects

External researchers participating in the projects: Georgina Michelena Alvarez –ICIDCA-CUBA Joachim Venus – Leibniz-Institute for Agricultural Engineering, Potsdam-Bornim, Germany Rudolf Hausmann – KIT- Karlsruhe, Germany Frank Rosenau - Ulm University, Ulm, Germany Cong T. Trinh – University of Tennessee-Knoxville, USA Prof. Dr. Antonio Carlos G. de Almeida-UFSJ

On going Projects

Table 2: Main types of biobased plastics

Types of Biobased Plastics

Figure 6: Estimated worldwide production capacity for biobased plastics

Types of Biobased Plastics

Source : K. Jim Jem et al. In:G.-Q. Chen (ed.), Plastics from Bacteria: Natural Functions and Applications, Microbiology Monographs, Vol. 14, 2010

Figure 7 The global commercial market volume of lactic acid and its derivatives, excluding poly(lactic acid) (PLA). Volumes are shown in the equivalent amount of 100% lactic acid

Types of Biobased Plastics

Plants invest in the production of biodegradable plastic PHB Industrial and Usina da Pedra are companies which already producing plastic from sugar cane This industry has grown 20 – 25% annually (is expected to produce 230,000 tones per year over the next decade) 230 million tons of plastics are consumed per year 0.5% of this volume is produced from renewable materials such as biodegradable plastics.

Types of Biobased Plastics

Source : jornal O Estado de São Paulo

Table 3: Basic characteristics of PLA and traditional plastics

Types of Biobased Plastics : PLA

Figure 8:The application of PLA in different markets

K. Jim Jem et al. In: G.-Q. Chen (ed.), Plastics from Bacteria: Natural Functions and Applications, Microbiology Monographs, Vol. 14, 2010

Types of Biobased Plastics : PLA

Food Industry

Chemical Industry

Pharmaceutical Industry

Biopolymers

bags packaging Bags of fertilizer bottles surgical suture implants

Slow-release drugs dialysis tablets

Wetting, Skin Whitening skin rejuvenation, anti-acne anti-tartar

Replacement of antibiotics in animal feeding

Mineral fortifying, acidulant, Preservative, pH adjuster flavoring

Ethyl lactate, acetaldehyde, solvent green

(WEE et al. 2006; DATTA e HENRY, 2006; JOHN et al. 2007, PURAC)

cosmetics

agro farming

Figure 9 Use of lactic acid

Types of Biobased Plastics : PLA

bioresorbable stent

Figure 10 Use of lactic acid

Types of Biobased Plastics : PLA

Figure 14 Japanese electronics products using the bio-based PLA/polycarbonate polymer blending

Types of Biobased Plastics : PLA

Figure 13: Addressable PLA market size by replacing a fraction of the poly(ethylene terephthalate) and polystyrene market. K. Jim Jem et al.

Types of Biobased Plastics : PLA

1. 100% biodegradation within 180 days of composting and landfill, composting plants and agro-industries

2. Safe return to nature with no signs of chemical or toxic waste

3. Incineration: doe not emit dioxin or furan hydrocarbon

4. Recyclability : 40%

5. Biomethanation: biological activity that transforms organic material into methane gas, water and humus, in the absence of oxygen by micro-organisms, with reuse of methane

6. Aerobic biodegradation

Types of Biobased Plastics : PLA

some interesting Information……. - every year 27.712 Million tones of CO2 are emitted - The plastic-consumption utilizes about 6% of oil and 80% of this oil is used for transportation and heating - only 21% ( around 546,000 tons / year) of plastics produced in Brazil are recycled - Brazil produces 230,000 tons / day of solid waste - 22% of waste is plastic

Source : Iraplast, 2010

Sustainability

Energy/Mass (BTU/lb)

Figure 12 comparative data The PLA uses up to eight times less water than ordinary plastics Electric power consumption is reduced by 30% when using the PLA

Sustainability : Tecnical Information

Utilization of non-renewable energy (MJ/Kg)

Sustainability : Tecnical Information

Advantages

Key Sucess Fators

Petroleum vs. Biomass

Biomass , Eg. Industrial Biotechnology

• Current predictions indicate that by 2025, more than 30% of raw materials for the chemical industry will be produced from renewable sources …..

• Are you going to be part of it ?

•.....that will translate into cost savings , improvement of our enviroment and a creation of a new market......

Conclusion

Thanks for your attention

We sure will !!!!!