Bioconversion of renewable feedstocks and (agri/food) residues into lactic acid

Session 2: Monday, July 20

Panel "Engineering Industrial Biotechnology Projects"

Joachim Venus / PhD

ATB Potsdam, Germany

1927 Experimental farm of the Agricultural UniversityBerlin

1933 Independent research center on agricultural mechanization

1952 Central institute of agricultural engineering of East Germany

1992 Reestablished after the reunification of Germany

Today: Leibniz Institute for Agricultural Engineering Potsdam-Bornim

- member of the Leibniz Association

History

Technology

assessment in

agricultural

systems

Technologies and processes for crop

production and livestock management

Research structure

27.07.2015 4

White Biotechnology - Using renewable resources for industry

Biobased products and processes from renewable resources not only help

preserve the environment and climate,

but also make a significant contribution to the structural change from a

petrochemical to a biobased industry, with related opportunities for growth

and employment. Industrial biotechnology, also known as white

biotechnology, is an important driving force in this transition.

March 2014May 20122010/2011_en

(Different) Composition & Behaviour

of (lignocellulosic) Biomass

27.07.2015 5

M.A. Abdel-Rahman et al.

Journal of Biotechnology 156 (2011) 286– 301

V. Menon, M. Rao

Progress in Energy and Combustion

Science 38 (2012) 522-550

N. Mosier et al. / Bioresource Technology 96 (2005) 673–686

Building blocks that could be produced via fermentation

Numbers next to biochemicals designate the total annual production in thousands of t

SpecialChem - Aug 2014 - http://www.specialchem4bio.com/news/2014/08/20/lactic-acid-market-estimated-to-reach-usd-3577-5-mn-by-2019-

marketsandmarkets

The market for lactic acid is growing as it is largely used in various industrial applications such as in biodegradable polymers,

food & beverages, personal care products, and pharmaceutical industries. The lactic acid market is mainly driven by its end-

use industries.

In 2013, Biodegradable polymers formed the largest application for lactic acid, followed by food and

beverages. The lactic acid market is estimated to grow at a CAGR of 18.8% from 2014 to reach $3,577.5

million by 2019.

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Starchy materials (cereals, industrial grade corn/potatoe starch, tapioca)

Green biomass (alfalfa, grass juice, lupine, sweet sorghum, forage rye, silage, coco juice)

Lignocellulosics (wood/straw hydrolysates, 2ndG sugars, bagasse)

Residues & By-products (oilseed cake/meal, thick juice, molasses, whey, coffee residues, waste bread, waffle

residues, algae biomass, fruit residues, meat & bone meal…)

tapioca

bagasse

waste bread

pine

coco juice

2G sugars 2G sugars

1G/2G sugars

green biomass

several residues…

lupine

cereals,

straw

sorghum

Fermentation feedstocks already tested:

silage

algae

biomass

Coffee residues,

cassava

Turon, X., Venus, J., Arshadi, M., Koutinas, M., Lin, C., Koutinas, A.

(2014) Food Waste and Byproduct Valorization through Bio-processing:

Opportunities and Challenges. BioResources [Online] 9: 4, 5774-5777

27.07.2015 8

Table 1: Overview of chemicals that are currently

produced, or could be produced, from biomass

together with their respective market type, size of

the market, and potential biomass feedstock.

Major players involved are also given.

M.A. Abdel-

Rahman et al.

Journal of

Biotechnology

156 (2011) 286–

301

The conventional processes for producing lactic acid from

(lignocellulosic) biomass include the following 4 main steps:

27.07.2015 9

(1) Pretreatment—breaking down the structure of the (lignocellulosic) matrix

(2) Enzymatic hydrolysis—depolymerizing lignocellulose to fermentative sugars,

such as glucose (C6) and xylose (C5), by means of hydrolytic enzymes

(3) Fermentation—metabolizing the sugars to lactic acid, generally by LAB

(4) Separation and purification of lactic acid—purification of lactic acid to meet

the standards of commercial applications

Pilot plant facility for lactic acid fermentation at Leibniz-Institute for Agricultural Engineering Potsdam-Bornim / ATB

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Biorefinery-concept for (1st, 2nd, 3rd…?) biomass feedstocks

- BIOCONVERSION -

Vodnar, D.C.; Venus, J.; Schneider, R.; Socaciu, C.:

Chem. Eng. & Technol. 33(2010) 468-474

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Pro

cess s

tep

s f

or t

he m

an

ufa

ctu

re o

f la

cti

c a

cid

Raw material storage5 m3 (Trevira®UV–silo, HIMEL

Maschinen GmbH & Co. KG)

Hydrolysis1 m³ stirred vessel; 0.5 m³ storage

tank (Apparate und Behältertechnik

Heldrungen Gmbh)

Pre-, Microfiltration

0.8 mm coarse filter (Sommer &

Strassburger GmbH & Co. KG),

Microfiltration (ZrO2-TiO2

CeRAM®INSIDE, TAMI Industries France)

Sterilization of the

nutrient broth

2 x 400 L, 2 x 250 L stirred vessels

(Apparate und

Behältertechnik Heldrungen Gmbh)

Fermentation with

cell retention

Pilot fermentor Type P, 450 L

(Bioengineering AG)

MOLSEP®Hollow fibre PES membrane

(FS10-FC-FUS50E2, MICRODYN-NADIR

GmbH/Daicen Membrane Systems

Ltd.)

Venus, J.: Res. J. Biotech 2009, 4, No. 2, 15-22

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70time [hours]

conce

ntr

ati

on [

g/L]

27.07.2015 12

Example wheat straw: Sugar uptake &

product formation

Lactate [g·L-1

]

Sugars [g·L-1

]

Fermentation ended after 50-60 hours with a yield

of nearly 100% and 64 g/L (top left)

(Total) Sugars (firstly Glucose followed by

Arabinose/Xylose with residues of Disaccharides)

have been used completely in the same time

(bottom left)

(Max) Lactate productivity (>5 gL-1h-1) is much

higher than comparable published results

[Li/Cui: Microbial Lactic Acid Production from Renewable

Resources, pp. 211-228. In O.V. Singh and S.P. Harvey

(Eds.), Sustainable Biotechnology - Sources of Renewable

Energy. Springer, 2010]

WO 2013164423 A1; WO 2013164425 A1

Pleissner, D.; Venus, J.: Agricultural residues as feedstocks for lactic acid fermentation. - ACS

Books "Green Technologies for the Environment" (2014) in press

0

5

10

15

20

25

30

35

0 10 20 30 40 50 60 70time [hours]

Dis

acc

h,

Ara

, Xyl

[g/L]

0

10

20

30

40

50

60

70

Glu

, T

ota

l su

gars

[g/L]

DisacchAra

XylGluTotal

Example green biomass:

Grass processing with a

screw press into juice

and pellet

27.07.2015 13

Papendiek, F.; Venus, J.: Cultivation and

fractionation of leguminous biomass for lactic

acid production. Chem. Biochem. Eng. Q., 28

(3) 375–382 (2014)

Example sugar beets:

e.g. molasses, thick juice

Koch, T.J.; Venus, J.; Bruhns, M.: Sugar beet syrups in lactic acid

fermentation – Part I. Sugar Industry 139(2014) No. 8, 495–502

Koch, T.J.; Venus, J.: Sugar beet syrups in lactic acid fermentation

– Part II - Saving nutrients by lactic acid fermentation with sugar

beet thick juice and raw juice. Sugar Industry 139(2014) No. 11,

683–690

Exp. No SF1167 SF1166 SF1168

Substrate Code SB-006 SB-002 SB-005

Total turnover 93% 91% 86%

Yield 77% 74% 74%

Max. Productivity

[g L-1 h-1]

4.90 5.50 4.93

Results of repeating fermentation experiments with

different thick juice sample0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50

Lacta

te [

g/L]

time [hours]

SF 1167SF 1166SF 1168

Example food waste: Bakery industry

González, R.; Venus, J.: BREA4PLA Project (tandem lecture). V Intern. Seminar “Biopolymers &

Sustainable Composites”, AIMPLAS (6&7 March, 2014 in Valencia)

Venus, J.: Utilization of Waste Bread for Lactic Acid Fermentation. ASABE and CSBE | SCGAB

Annual International Meeting, July 13-16, 2014 – Montréal, Volume 1, 2014, Pages 557-562

& Partner

27.07.2015 16

The Copenhagen Declaration

for a Bioeconomy in Action

…

9. The conference also underlined the

need for new pilot and demonstration

plants and scaling up facilities, in

particularly biorefineries. It was stressed,

that the development of these facilities requires

smart integration of various funding sources,

including the Common Agricultural Policy, the

Common Fisheries Policy, the Cohesion Policy,

the Renewable Energy Policy, Horizon 2020, and

private investments.

…

Copenhagen conference “Bioeconomy in Action”on 26 March - 28 March 2012

Universities, Research Institutes, SMEs

Applied &basic research

IndustryIndustrial application

Large-scale production

„Valle

y o

f death

“

Carus/Carrez/Kaeb/Ravenstijn/Venus: Level Playing Field for Bio-based Chemistry

and Materials. – bioplastics MAGAZINE [03/11] Vol. 6, 52-55

27.07.2015 17

Pilot plant facility• pilot facility for production of lactic acid at the ATB consequently fills a gap in the

various phases of bioprocess engineering

• provision of product samples is intended to open up

the possibility of interesting partners in industry with

specific product requirements in various applications

BIOSTAT® Bplus (Sartorius BBI Systems GmbH, Germany)

equipped with a digital control unit DCU for the

continuous fermentation with cell recycling

scale up

Pilot fermentor Type P, 450 L (Bioengineering AG)

Venus, J.; Richter, K.: Eng. Life Sci. 2007, 7, No. 4, 395-402

Venus, J.: Feedstocks and (Bio)Technologies for Biorefineries. – In: G.E. Zaikov, F. Pudel, G. Spychalski (Eds.), Renewable

Resources and Biotechnology for Material Applications (pp. 299-309), Nova Science Publishers, 2011 (ISBN: 978-1-61209-521-9)

27.07.2015 18

Pilot plant for „Fermentation Process Improvement“

Opportunities & Challenges …

starchy materials,

lignocellulosics, residues & by-

products, green biomass

feedstock

sugars, hydrolyzates

press juice…

fermentation, down-stream

pretreatment bioconversion

(raw)lactate, lactic

acid, biomass...

…bioplastics

products

Venus, J.: Biotechnol. J. 1(2006) No. 12, 1428–1432

Thank you very much for your attention!

With the support of:

Leibniz-Institute for Agricultural Engineering Potsdam-Bornim e.V.

Max-Eyth-Allee 100, D-14469 Potsdam, GERMANY

Fon: +49(331)5699-112

email: jvenus@atb-potsdam.de

http://de.linkedin.com/pub/joachim-venus/15/276/3b2/