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EMERGING TRENDS in BIOPROCESSING: FOOD, FUELS, and the ENVIRONMENT | [email protected]

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EMERGING TRENDS in BIOPROCESSING: FOOD, FUELS, and the ENVIRONMENT | Hello@Merrick.Com EMERGING TRENDS IN BIOPROCESSING: FOOD, FUELS, AND THE ENVIRONMENT www.merrick.com | [email protected] By Crystal Bleecher and Michael Washer Merrick has been engineering bioprocessing projects for over 25 years. We’ve seen the range of products broaden from biofuels to include sustainable proteins, food ingredients, biochemicals, and cosmetic products. Ten years ago, most of our projects involved either thermo-chemical or biological conversion of cellulosic feedstocks to fuels. Now, fermentation and purification processes are being used to generate a multitude of sustainable products. The ever-growing industrial bioprocessing market has continued to evolve throughout the years, and these are the emerging trends we see today. PROTEIN PRODUCTION VIA FERMENTATION New technologies are emerging to sustainably meet the rapidly increasing global demand for protein. Growing crops to feed animals to produce meat can be an inefficient process, requiring large amounts of resources and generating waste. The UN estimates that the world population will increase to 9.7 billion humans by 2050. Thus, new companies are entering the market with alternative processes to produce proteins using less water, less land, and creating less waste. At the center of many of these technologies is protein production via fermentation. In the near future, fermentation may play a role in everything from the meat you find in the grocery store to the shoes you purchase at the mall. How does this work? A host organism is modified to include the desired protein gene. The organism then rapidly multiplies through fermentation, producing large quantities of the desired protein. The protein can then be separated from the remaining cell mass and processed into the final product. One company in this market, Impossible Foods, uses this process to produce a key ingredient, heme, which is an iron-containing molecule that is naturally occurring in animal tissue. It gives meat it’s smell and flavor [1]. Through fermentation, heme can be efficiently produced in large quantities and added to a plant-based burger, giving it the taste and look of the real, meaty version. Similarly, another company, Perfect Day, is using fermentation to produce the exact proteins found in milk (whey and casein). Modern Meadow and Bolt Threads are two companies using fermentation to produce proteins for the fashion industry. Modern Meadow produces collagen which is processed into a bioleather called ZoaTM. Bolt Threads produces proteins inspired by natural silks which are then spun into fibers that can be weaved into fabrics and garments. Additionally, Geltor is creating collagen proteins for the cosmetics industry. The ability to engineer cells to produce a desired protein, allows for naturally occurring proteins to be generated more efficiently and more sustainably through fermentation. With so much versatility, we expect to see more and more fermentation based sustainable products enter the bioprocessing market. 1 CARBON INTENSITY REDUCTION California’s Low Carbon Fuel Standard (LCFS) has been in effect for almost a decade and continues to have far reaching impacts across multiple industries. The aim of the LCFS is to reduce the carbon intensity (CI) of transportation fuels by 20% over the period from 2010 to 2030. This is achieved by blending low-CI liquid fuels, such as ethanol and biodiesel, with gasoline and diesel and/or buying LCFS credits generated from other alternative fuels, including renewable natural gas and electricity for electric vehicles. Low-CI fuels that would otherwise be consumed where they are produced are now being shipped to California in order to capitalize on the price premiums created by the LCFS program. Currently ethanol is the low-CI fuel produced in the largest quantity. To maximize the benefits of the LCFS incentives, ethanol producers are considering investing in capital projects to further reduce the carbon intensity of their fuel. The highest profile technologies target the conversion of corn fiber to ethanol. These are collectively termed 1.5 Gen technologies and they are installed at existing corn ethanol facilities. Such technologies not only increase the per bushel ethanol yields, but also increase the value of the distiller’s dried grains with solubles (DDGS) due to the higher protein content achieved. 1.5 Gen ethanol qualifies for D3 RINs and LCFS premiums. Several technologies have been developed with different benefits. Edeniq’s Intellulose pathway uses enzymes to maximize the conversion of corn fiber to ethanol using the host plant’s existing hydrolysis, fermentation and distillation systems. Whereas, other technology packages, such as that offered by D3Max and Syngenta, consist of dedicated process trains that convert the corn fiber from the whole stillage. This approach avoids bottlenecking issues in the host plant. Additionally, energy integration and onsite power technologies can also significantly reduce carbon intensity. These types of projects include mechanical vapor recompression in distillation, addition of let-down steam turbines, combined heat and power technologies, addition of solar or wind energy generation, and using biogas for power generation. The California LCFS program is leading the way and other states may soon follow. Oregon has already implemented a Clean Fuels Program and Washington and New York are considering adopting LCFS-like programs. If the incentives under the LCFS remain high, we expect more and more biofuel producers to invest in these technologies to capitalize on the attractive premiums. 2 BIOGAS TO RNG Biogas is naturally produced from the decomposition of organic waste and is primarily comprised of methane and carbon dioxide. The largest sources are landfills, followed by wastewater treatment plants and then animal manure. Even small quantities of biowaste, such as grass clippings and spoiled food can be collected in cities and converted to useful biogas at a central processing site. Traditionally, captured biogas has been used for process heating and/or power generation via reciprocating engines. However, biogas usage is beginning to shift away from power and towards fuels due to the increased market value. In 2014 Renewable Natural Gas (RNG) gained pathway approval from the EPA for D3 RINs. Each 77,000 BTU of RNG qualifies for a D3 RIN. Thus, the value of RNG can rise as high as $45/MMBTU, due to D3 RINs and LCFS credits [2]. In addition, RNG can leverage the extensive and mature existing natural gas pipeline infrastructure. Prior to being injected into the pipeline, raw biogas must be processed to remove contaminants, such as CO2, N2, moisture, and H2S. In addition, pipeline utilities also require their own conditioning and metering system prior to injection to ensure pipeline standards are being met. This includes a gas chromatograph, odorizer, regulator, flowmeter, remote terminal unit (RTU), and emergency shut-off valve. These unit costs and pipeline extensions can be considerable, which can significantly impact the economics of small-scale projects. Despite the potential hurdles, as long as the transportation fuel market incentives remain strong, expect the interest in biogas production and gas clean-up to continue to increase. HYDROTHERMAL LIQUEFACTION OF ORGANIC WASTE While Hydrothermal Liquefaction (HTL) was first discovered in the 1920’s, there has been an explosion of interest in the recent years due to its ability to process wet waste materials to produce renewable fuels. Unlike many pyrolysis and gasification processes, HTL does not require that the feed be dried. The feedstock slurry is processed at high temperatures and pressures in the liquid phase, eliminating efficiency losses associated with phase changes. The process produces biocrude, methane gas, and inorganic salts. The most promising commercial opportunity for HTL is the treatment of wastewater primary sludge and biosolids. This is a large and growing problem for many water utilities and HTL may hold the answer. Nearly 15 million dry tons of wastewater biosolids are generated in the US per year with a liquid fuel equivalent of 2 billion gallons [3]. A consortium headed by WRF (Water Research Foundation) and consisting of private companies, utilities, non-profit foundations, and the DOE have invested in a project to accelerate the scale-up of HTL technology. The HYPOWERS Project (Hydrothermal Processing of Wastewater Solids) will process 15 wet tons per day of biosolids supplied from the Central Contra Costa Sanitary District in Martinez, CA. This is an order of magnitude scale-up from the 3 HPPS (Hydrothermal Processing Pilot System) project that earned Genifuel and Merrick a national ACEC Award. Several other companies are also developing pilot and demonstration scale projects. Steeper Energy is partnering with Silva Green Fuel to construct an industrial scale demonstration plant at a former pulp mill located in Tofte, Norway. In Australia, Licella offers a catalytic hydrothermal reactor, known as Cat-HTR, that has been operational in a pilot plant located on the NSW Central Coast. Other players include Tyton Biosciences, Synpet Technologies, and Manta Biofuel, as well as research projects at universities. Hydrothermal Liquefaction shows a lot of promise for converting wet wastes and other organics to liquid fuels and there are several companies working hard to realize commercialization. CONCLUSION Technologies and products in the industrial bioprocessing market are broadening and evolving, but all companies in this space share a common goal. They are committed to sustainability and have the potential to have a lasting impact on the environment. As the innovation in this industry continues to grow, new and exciting projects will be ready for scaleup and commercial deployment, creating Bio Solutions to Better Our World. References: 1. Impossible Foods Website – Heme. https://impossiblefoods.com/heme/ January 14, 2020. 2. Renewable Natural Gas Project Economics. Renewable Natural Gas Issue Brief, Part IV of IV, July 2019. 3. Biofuels and Bioproducts from Wet and Gaseous Waste Streams: Challenges and Opportunities- U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Bioenergy Technologies Office, January 2017. 4.
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