Commodity Chemicals from Renewable Sources

Bio-Oxo Technology

Enabling production of commodity chemicals from renewable resources

Aldehydes are important intermedi- ate chemicals used in a wide array of industrial and consumer products, including plasticizers, fine chemicals, and pharmaceuticals. The oxo process, also called hydroformylation, is used to make aldehydes by adding a mixture of carbon monoxide and hydrogen to an olefin. Currently, more than 10 million metric tons of aldehydes are produced by hydroformylation using petroleum- derived propylene and a significant expenditure of energy due to the high temperature and pressure conditions required for production. In addition, these oxo chemical processes all require energy intensive distillation processes to separate the mixture of aldehydes produced.

Researchers propose to develop a more energy efficient bio-oxo process that will Proposed Bio-oxo process will produce isobutyraldehye (aldehyde) using proprietary take advantage of the carbon-carbon bond metabolically engineered microorganisms. Image courtesy of Easel Biotechnologies. formation innate to microorganisms to produce pure isobutyraldehyde, a com- mercially valuable aldehyde used in con- Benefits for Our Industry isobutyraldehyde. It will be the most sumer products such as lube oil additives, and Our Nation straightforward method to convert fossil feedstocks to bio-based feedstocks. surface coatings, plasticizers, fertilizers, The proposed bio-oxo process is much cosmetics, herbicides, flame retardants, The technology platform can easily be more energy efficient than the conven- extended to other bio-based chemicals and adhesives. The bio-oxo process will tional oxo process because it converts use innovative, metabolically-engineered and biofuels, including butyraldehyde renewable resources to isobutyraldehyde and isobutanol. bacteria to convert renewable resources in a low-temperature environment using to isobutyraldehyde via low-temperature, energy efficient separation and purifica- energy-efficient processes. The proposed tion processes. Commodity chemicals Project Description technology takes advantage of the prod- produced from renewable resources will The main goal of this research effort is uct’s low boiling point and vapor pressure have a lower carbon footprint as well. to develop a bio-oxo process that will to use an energy efficient gas-stripping Additional economic benefits will be convert renewable resources, such as process to collect and purify the target realized for feed producers who supply corn stover, to isobutyraldehyde using product. This process also reduces the the renewable feed stock. metabolically engineered bacteria. By exposure of the organisms to the product the end of the project, researchers will while increasing initial yield, making the Applications in Our integrate a pilot scale fermentation unit entire system significantly more sustain- with downstream collection and purifica- able than other biological processes used Nation’s Industry tion units to demonstrate the feasibility to produce chemicals. The availability of bio-isobutyraldehyde of commercial-scale isobutyraldehyde would allow for the direct replace- production. ment of most of the petroleum-derived

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Barriers Commercialization • Production of significant quantities of At every stage of the project, industrial isobutyraldehyde for scale-up using processes are being considered to enable selected enzymatic pathway. commercial scale-up. During the final stage of the project, researchers will de- • Economically favorable integration velop an integrated pilot scale production of the fermentation process with the process, including the fermentation and separation and purification processes. downstream purification units, and will • Confirming bio-oxo isobutyraldehyde conduct approximately 20 fermentation as a drop-in replacement to the oxo- runs. Data from these runs will be used produced isobutyraldehyde. to finalize a techno-economic analysis of the bio-oxo process and will include Pathways production cost estimates, a detailed life Researchers will select and optimize cycle analysis, and potential greenhouse a bacterial production strain that can gas reduction estimates. Researchers use corn stover feedstock to produce are actively seeking a strategic partner, isobutyraldehyde and will then further preferably an aldehyde producer, to form engineer the strain to favor and improve a joint venture to construct a demonstra- isobutyraldehyde production. Separation tion plant once commercial feasibility of and purification methods will be devel- the process is confirmed. oped that are compatible with the fermen- Note that in August,2015, Easel tation process while taking advantage Biotechnologies, LLC was granted a of the low vapor pressure and boiling patent for their “Microbial Synthesis of point of isobutyraldehyde. Operational Aldehydes and Corresponding Alcohols.” conditions will be optimized after the integrated system is constructed. Finally, a fully integrated pilot scale fermentation Project Partners and purification unit will be constructed Easel Biotechnologies, LLC using the final production strain. Los Angeles, CA Principal Investigator: Yixin Huo Milestones Email: [email protected] This three-year project began in December 2014. For additional information, • Develop a fermentation and separa- please contact tion process for the selected strain to Dickson Ozokwelu produce isobutyraldehyde at 0.3 g/L/hr U.S. Department of Energy and titer of 10g/L (Completed). Advanced Manufacturing Office Phone: (202) 586-2561 • Optimize the enzyme strain and path- Email: [email protected] way and develop an integrated process to produce isobutyraldehyde at 0.6g/L/ hr and titer of 30 g/L (2016).

• Demonstrate the integrated production process at pilot scale by producing isobutyraldehyde at 1.0g/L/hr and titer of 50 g/L (2017).

For more information, visit: manufacturing.energy.gov

DOE/EE-1258 • May 2016