Post on 15-Mar-2018
transcript
MAXIMISING REVENUES AND MINIMISING WASTE IN FUEL
AND FEED BIOREFINERIES
Processes for Biomaterials and Nutritional Product, Wednesday, July22
Peter Milic
Business Development & IP
MBG background
Founded in 2001 by Dr Philip Bell & Dr Paul Attfield
• Based in Lane Cove Sydney; 16 staff
• Macquarie University spin-out
• Series A, B & C: capital raising secured
Spent over A$10M on 2nd generation biofuels
MBG is a yeast development company
Saccharomyces cerevisiae used for global baking, extracts, brewing, fuel ethanol, distilling, animal feed applications etc. Yeast extracts provide flavor, neutraceuticals (glutathione, glucans, MOS, etc).
Our core technology uses evolution and breeding to produce improved non-GM yeast strains
Our core project is to develop yeast to enable ethanol to be produced from lignocellulosics (2nd Gen biofuels)
MBG
Xylose utilisation is only one of the unique features required to operate under 2nd Gen conditions
XyloseHydrolysate
resistance
Improved ethanol
yield & productivity
Growth at
~ 2-3 hrs/gen
Growth on
non-detoxified
hydrolysate with
>1 % acetic acid
Ethanol titres
of >20% in 48
hours at 30C
Aerobic carbon
scavenger
Efficient
aerobic growth
on a variety of
carbon sources
MBG 2nd Generation Yeast strains
MBG has several active yeast non-GM development programs
Improved yeast for converting waste plant material to feed and fuel (2nd Generation Biofuel)
Improved yeast for the corn ethanol industry(1st Generation Biofuel)
Improved yeast for the bread baking industry
Improved glutathione (antioxidant) levels for pharmaceutical and food applications
Chassis yeast• high level expression and secretion of foreign proteins• Suitable for the production of bio-chemicals
Corn ethanol highlights real world importance of by-productsBiofuels based on new technology and non-food biomass must compete with
biofuels from food (corn)
Margins are high but primarily due to high value by-product sales
• Without a DDGS co-product, corn ethanol facilities make little or no profit
• As industry has matured more high value co-products have been developed such as corn oil
• Emergence of hybrid technologies e.g. ICM “Gen 1.5”
Corn to ethanol experience highlights the benefits of a bio-refinery concept multi, high value products
2nd Gen biorefinery needs to move beyond standard “fuel (and biogas) only” model
• Higher value co-products
• Better utilize low or negative value waste streams
• Increase overall conversion efficiency
• Develop synergistic processes
100
200
300
400
0
Corn Ethanol
Cap
ital
Co
st –
US$
M
100
200
300
400
0
Lignocellulosic Ethanol
Cap
ital
Co
st –
US$
M
100M gallons of Ethanol
40M gallons of Ethanol
Corn ethanol:
• More than double the production of
ethanol
• Less than half the capital cost
4
Capex: Corn to ethanol is capital efficient
7
BiomassConventional
2nd Generation
Fermentation
Fuel EthanolPre-treatment
and hydrolysis
to sugars
Impact on
yield and
costs
Residual
ethanol
Residual
sugars
Organism
growth
By-products (glycerol,
acetate and xylitol)
Incomplete
breakdown
> 30% lossLess than 70% of contained sugars
in biomass converted to
fuel
30%+ of carbon to low value biogas
Lignocellulosic ethanol today…..
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Fuel Ethanol
High value feed
Pre-treatment
and
hydrolysis to
sugarsBiomass “Fuel and
Food” Process
MBG
“Fuel and Feed”
bio-refinery
fermentation
High value
co-productLow value
biogas
Residual C6+C5 sugarsGlycerolAcetate
Organic acidsXylitol
Fermentation yeast
MBG biorefinery maximizes value and efficiency – multi use yeast
> 15% loss
e.g. Aquaculture feed
MBG Fuel & Feed Biorefinery
pretreatment
& hydrolysis
wastewater Process Water
Pitch yeast
ETOH
fermentationdistillation
Lower COD
YEAST
propagation
Lignin
residueEthanol
Yeast BiomassAnimal Feed
Human Food
biogas
C5 sugars
C6
sugars
80%
20%
stillage
(‘waste’)
sugar
syrups
Collaboration with NREL demonstrates economics
The “fuel and feed” bio-refinery project has been in development for over 10 years
Completed a 2 year pilot program with the US DOE where:
• MBG demonstrated process and generated detailed data inputs for engineering model
• DOE developed detailed engineering models based on inputs
• All calculations based on “real world” demonstrated productivity, yields and efficiency
Feedstock Preparation Corn Stover & Sugarcane Bagasse were pretreated by NREL in Aug-Oct 2011 and shipped to Microbiogen P/L, Sydney, Australia
400 kg of wet bagasse being dried out prior to pretreatment at NREL’s pilot plant in
Golden, Colorado
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Pretreated corn stover upon arrival in Sydney pH 1-2 and 28-31%TS
MBG
Solid/Liquid separation
% w/v Pressate
Glucose 3%
Xylose 9%
Acetate 2%
HMF 0.4%
Furfural 0.2%
% w/w dry Solids
Cellulose 60%
Xylan 5%
Lignin 25%
Ash 4%
Pretreated
Corn Stover
30%TS
Pressed
Solids
50%TS
Filter Press
to 3 ton
Pressate
C5 liquor
Cellulosic fibre
Fermentation of the cellulosic syrup
0
30
60
90
120
150
0 4 8 12 16 20
Co
nce
ntr
atio
ns
(g/L
)
Fermentation Time (hr)
Glu g/L Gly g/L Acet g/L EtOH g/L MBG3248 inoculated at 10 g/L and 34oC
%w/v 0 h 19 h
Glucose 14.47% 0
Xylose 3.9% 3.4%
Glycerol 0.01% 1.1%
Acetate 0.4% 0.5%
Ethanol 0 6.01% wt./vol
Ethanol Titre 7.62% vol/vol
Ethanol Yield 0.42 gEtOH/gGlu
Productivity 3.16 g/L/h
Two stream process
% w/v Pressate
Glucose 3%
Xylose 9%
Acetate 2%
HMF 0.4%
Furfural 0.2%
% w/v Stillage
Glucose 0%
Xylose 6%
Glycerol 1%
Acetate 0.7%
Ethanol 0.4%
Pretreated
Corn Stover
30%TS
Separate Hydrolysis &
Fermentation of C6s Distillation
Ethanol
Stillage
Pressed
Solids
50%TS
Filter Press to
3 ton
Lignin Rich
Residue
“Green Coal”
Pressate
Propagation on stillage & pressate blend
o Aerobic & stirred vessel at 32oC
MAP/Urea Added
o 80% of available carbon was consumed
o 0.42 grams yeast biomass made per gram carbon used
o 55% COD Reduction
0
10
20
30
40
50
60
0 2 4 6 8 10 12 14 16 18 20 22 24
Co
nce
ntr
atio
ns
(g/L
)
Propagation Time (hrs)
Glu g/L Gly g/L Acet g/L EtOH g/L Xyl g/L Yeast g/L Arab g/L
Fed-batch Batch (5-24hrs)
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Key assumptions:
- Life of facility = 30 years.
- 2,000 dry tonnes/day of bagasse
- Dilute sulphuric acid continuous process (NREL process)
- Purchased enzymes
- Natural gas for heating
- Ethanol yield at 0.44g/gram of sugar
- Yeast yield of 0.35g/gram of carbon
- Production of 131M liters of fuel ethanol per year
- 117,000 tonnes of dried yeast per year
Key inputs for the NREL model
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In the MBG Feed and Fuel process selling high-value co-products such as yeast can negate the impact of dropping fuel price
MBG
Impact of Yeast price on MESP (@10%IRR)
Ethanol only 2nd Gen
Bio-refinery“Fuel and Feed”
Bio-refinery
1 tonne of sugar cane
including trash and
tops (dry basis)
1 tonne of sugar cane
including trash and
tops (dry basis)100
200
300
400
0
Ethanol
BioGas
Kg
of
pro
du
ct p
er t
on
ne
of
dry
mat
ter
100
200
300
400
0
Ethanol
Yeast
Kg
of
pro
du
ct p
er t
on
ne
of
dry
mat
ter
5% more product
13% less fuel
Conventional
2nd Gen
“Fuel and
Feed”
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MBG biorefinery maximises product available for sale
Ethanol only 2nd Gen
Bio-refinery“Fuel and Feed”
Bio-refinery
1 tonne of sugar cane
including trash and
tops (dry basis)
1 tonne of sugar cane
including trash and
tops (dry basis)$100
$200
$300
$400
$0
Ethanol
BioGas
US$
val
ue
gen
erat
ed p
er t
on
ne
of
dry
mat
ter
Ethanol
Yeast
15% higher unit revenues
US$
val
ue
gen
erat
ed p
er t
on
ne
of
dry
mat
ter
$400
$300
$200
$100
$0
13% less fuel
Key assumptions:Ethanol Price: US$0.60/literYeast: US$1.00/kgBiogas: US$4.50/MMBtu
Conventional
2nd Gen
“Fuel and
Feed”
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MBG biorefinery maximizes revenue
High quality, nutritional product - value >US$1/kg?
Yeast already proven as a feed supplementAlready widely sold as a feed additive Currently feed yeast costs between US$2.5 & $5/kg
High levels of crude proteinHigh levels of bio-available phosphorousRange of other key amino acidsDoes not contain anti-nutritionals
MBG3248 Soymeal *
Moisture (%) 5.3 5.4
Ash (%) 7.9 5.2
Crude Protein
(%)
58.0 43.6
Energy
(MJ/kg)
10.47 9.37
Phosphorous
(g/kg)
30.0 6.6
Amino Acids (mg/100mg)
Methionine 0.91 0.65
Isoleucine 2.66 2.39
Histidine 1.58 1.10
Lysine 3.45 2.93
Tryptophan 0.71 0.67
Arginine 2.90 3.28
(*) http://www.fao.org/ag/aga/agap/frg/feedback/war/v0600b/v0600b0s.htm0
500
1000
1500
2000
2500
Fishmeal Monthly Prices - US$/metric tonne
Yeast price?
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Cost to Produce Ethanol - US$/liter
0.50 0.55 0.600.35 0.65 0.70 0.75 0.800.40 0.45
Co
st t
o p
rod
uce
ye
ast –
US$
/kg
(dry
)
Base Fishmeal Price
Cost to Produce Yeast versus Price of Fishmeal – Fuel Bio-Refinery
Marginal price benefit over fishmeal
0.30
1.20
0.90
0.60
1.80
1.50
0.00
Note: Operating costs are estimated after crediting green coal at US$90/t
Break even curveMBG Biorefinery = low production cost
yeast=$0.47/kg & ethanol=$0.50/l
MBG bio refinery is viable today (without credits)
Feed yeast price
Implications are clear –High value Bio-refineries are the future
Relying on ethanol as the only product is a challenge
• Need to make better use of waste streams
• Need to add higher value by-products
Utilizing NREL engineering models and assumptions plus:
• An ethanol sale price of US$0.53/liter
• A yeast sale price of US$1.00/kg
Then an MBG based bio-refinery can:
• Generate bio-refinery cash margins of 39%
• Produce 131M liters of fuel ethanol/yr
• Produce 117,000 tonnes of high grade yeast/yr
• Generate a high volume feed source that ranks between soy meal and fish meal
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Questions…
Peter Milic
Microbiogen Pty Ltd
peter.milic@microbiogen.com
Ph: +61 2 9418 3182