Enzymatic Conversion of Biomass to Ethanol

Alfalfa/Corn Rotations for Sustainable Cellulosic Biofuels Production June 29-30, 2010 Pioneer Hi-Bred Carver Center Johnston, IA Genencor, a Danisco Division

1982 Genentech and Corning

Produce over 300 protein products (enzymes)

Markets: Biofuels, Biorefineries, Textiles, Cleaning, Food and Beverage, Biodefense

Research and Development in Palo Alto, CA

Applied Innovation Center in Cedar Rapids, IA

9 Plants worldwide, 2 in US

Apply name/department/presentation title in 'header and footer' 2 Biomass Conversion Processes

Biochemical Uses enzymes and microorganisms to convert biomass to fermentable sugars and then alcohols. (Mascoma, DDCE) Reference: Corn CAPEX= $2.00/gal Yield=100 gal/ton 2010 CAPEX= $6.16/gal Yield= 60 gal/ton 2020 CAPEX= $3.30/gal Yield= 88 gal/ton

Thermochemical Uses gasification to produce syngas that is converted to alcohol by catalysts. (Range Fuels)

2010 CAPEX= $6.00/gal Yield= 75 gal/ton 2020 CAPEX= $4.00/gal Yield= 105 gal/ton

Biothermal Uses gasification to produce syngas that is fermented to alcohols with microorganisms. (Coskata)

2010 CAPEX= $5.00/gal Yield= 90 gal/ton 2020 CAPEX= $3.00/gal Yield= 105 gal/ton

Apply name/department/presentation title in 'header and footer' 3 Biochemical Cellulosic Ethanol

Convert the cellulose (C6) and hemicellulose (C5) to sugars and ferment the sugars to ethanol. Use the lignin for a fuel source.

Production of fermentable sugars is difficult and expensive

Pentose, xylose (C5) sugars are hard to ferment to ethanol

Requires very large volumes of enzymes to produce the sugars

Yields: Corn: 400-450 gal/ac Alfalfa: 350 gal/ac ??? Corn w/ biomass: 600+ gal/ac Switchgrass: 1,000 gal/ac “Sugar corn”: 1,200 gal/ac Miscanthus: 1,500+ gal/ac

Apply name/department/presentation title in 'header and footer' 4 Structure of Biomass

Structure of Biomass

“Recalcitrance of Biomass” Plants were designed by Mother Nature to stand upright and resist harsh environmental conditions

Deconstruction of cell wall is difficult and expensive

Sugar Eat it now for energy

Starch Store it and eat it later

Cellulose Build your house out of it

Apply name/department/presentation title in 'header and footer' 5 Structure of Biomass

Cellulosic biomass is highly recalcitrant. Pretreatment Goal: Make •Cellulose (6-carbon sugars) fibers are highly structured and hard for enzymes to reach cellulose more accessible to •Hemicellulose (mostly 5-carbon sugars) bind enzymatic breakdown in and around the cellulose backbone (hydrolysis) and solubilize •Lignin (complex aromatic polymer) acts as a glue covering and binding everything hemicellulose sugars

Lignin Cellulose

Pretreatment

Hemicellulose Simplified model of plant primary cell wall Figure adapted from Somerville, C. et al. 2004. Science 306(5705), 2206-2211. Figure adapted from N. Mosier et al. 2005. Bioresource Technology 96(6), 673—86. Apply name/department/presentation title in 'header and footer' 6 Cellulosic Enzyme “Coctails”

Cellulase Breaks down cellulose into highly fermentable C6 sugars or glucose. Fermentable by yeasts and other microbial organisms.

Hemi-cellulase Breaks down hemicellulose into hard to ferment C5 sugars called xylose or pentose. Not fermentable by yeast. Subject to substantial amount of ethanologen “bug” research.

Beta Glucanase Breaks down complex oligosaccharides called beta glucans. Conversion to glucose makes them fermentable.

Beta Glucosidase Converts cellobiose, a product of cellulose degradation into glucose.

Accellerase DUET® contains 40+ different enzyme activities

Apply name/department/presentation title in 'header and footer' 7 Dual Cellulosic Ethanol Strategy

Accellerase® family of Products

Result of 25 years of cellulase research and development

Accellerase DUET® launched February, 2010

Accessory or “booster” products: XC, XY, BG

Works with all common feedstocks and pretreatment processes

Apply name/department/presentation title in 'header and footer' 8 Dual Cellulosic Ethanol Strategy

DuPont Danisco Cellulosic Ethanol, DDCE

Joint venture between DuPont and Danisco (Genencor)

Develop and deliver an integrated process technology for cellulosic ethanol production

Demonstration plant in Vonore, TN started up December, 2009

Operated by Genera Energy, LLC (University of Tennessee)

Corn cobs 2010 >>>>> Switchgrass 2011

Apply name/department/presentation title in 'header and footer' 9 Cellulosic Ethanol Process Combinations

FEEDSTOCK PRE-TREATMENT ENZYME FERMENTATION HYDROLYSIS

Alfalfa Dilute Acid The choice of feedstock and Energy Ammonia pretreatment has a big impact Crops Fiber Corn stover Expansion on composition and dose of enzymes required. Corn cobs (AFEX) Wood pulp Steam Explosion Sugarcane bagasse Hot water Municipal Others?? solid waste Recycled Feedstocks will vary by geography paper

Apply name/department/presentation title in 'header and footer' 10 Barriers to Cellulosic Ethanol Production

Technical Pretreatment→Hydrolysis→Fermentation Enzyme production and activity Process efficiency

Economic Capital cost per unit of fuel produced ($/gal) Feedstock costs ($/ton) Delivered enzyme costs (<$0.50/gal)

Policy “Blend Wall” to 15%...... need room to run! Loan guarantees for construction Tax credits and tariffs

Apply name/department/presentation title in 'header and footer' 11 Thank You

Bob Randle Commercial Development, Fuel Ethanol Genencor, a Danisco Division 636-256-3533 office 314-520-5530 cell [email protected] www.genencor.com

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