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Creating a Secure and Sustainable Future

Creating a Secure and Sustainable Future Defining an Achievable Means of Meeting our Food, Fuel and Feed Needs Domestically. Martha Schlicher, Ph.D. National Corn-to-Ethanol Research Center. Definitions. Ethanol A two carbon alcohol produced most easily produced by

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Creating a Secure and Sustainable Future

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  1. Creating a Secure and Sustainable Future Defining an Achievable Means of Meeting our Food, Fuel and Feed Needs Domestically Martha Schlicher, Ph.D. National Corn-to-Ethanol Research Center

  2. Definitions Ethanol A two carbon alcohol produced most easily produced by conventional yeast when they consume single six carbon sugars. Used as spirit or fuel. SucroseTwo six carbon sugars (glucose and fructose) linked together. Table sugar. Found in sugar cane Glucose The sugar in your blood Exists as chains of glucose (e.g. starch or cellulose) or glucose with other sugars Starch Chains of the six carbon sugar glucose present in corn or potatoes that can be easily broken down to free glucose and fermented to ethanol. A carbohydrate. Cellulose Chains of the six carbon sugar glucose present in fiber/biomass. Potential to convert to ethanol. A carbohydrate. Hemicellulose Chains of five and six carbon sugars present in fiber/biomass. Potential to convert to ethanol. A carbohydrate.

  3. Examples Starch Sucrose Cellulose Lignin Robert Shleser , 1994 Lignocellulose

  4. THE POTENTIAL ETHANOL PIPELINE LONG TERM 40% MID TERM 20% GLUCOSE FROM STARCH CORN KERNEL & NEW CELLULOSE BIOMASS PENTOSESFROM NEW BIOMASS HEMICELLULOSE 40 1554 GLUCOSE FROM STARCH CORN KERNEL & AVAILABLE BIOMASS CELLULOSE (wood chips, waste) PENTOSES FROM AVAILABLE BIOMASS HEMICELLULOSE M Barrels of Oil Displaced/Yr B Gallons of Ethanol Produced/Yr NEAR TERM 10% 20 772 GLUCOSE FROM STARCH & CORN KERNEL CELLULOSE SUCROSE FROM SUGARCANE/BEETS 115 4 2005-2015 2016-2030 2031-2040 TIME 21 MBD Oil in 05; Gasoline only; Use held at 05

  5. US Biomass Sources NEAR TERM ECONOMICAL Wheat Barley Corn Starch Sugar Cane Corn Fiber Paper Switch Grass Wood Chips Stover Cottonwoods ABUNDANT & AVAILABLE

  6. NEAR TERM STARCH Important to Remember Secure the Base while Building the Future • 1980's --175 plants (20K to 7M gallons) • 1990's -- 33 plants (1.5M to 30 M gallons) • 2000's -- 91 plants (30M to 110M gallons)

  7. RESOURCING THE ETHANOL PIPELINE LONG TERM 40% MID TERM 20% GLUCOSE FROM STARCH CORN KERNEL & NEW CELLULOSE BIOMASS PENTOSESFROM NEW BIOMASS HEMICELLULOSE 40 1554 GLUCOSE FROM STARCH CORN KERNEL & AVAILABLE BIOMASS CELLULOSE (wood chips, waste) PENTOSES FROM AVAILABLE BIOMASS HEMICELLULOSE Barrels of Oil Displaced NEAR TERM 10% Gallons of Ethanol Produced 20 772 • AGRONOMIC • PRODUCTIVITY • DDGS = CORN • PROCESS • PRODUCTIVITY • ENERGY USE • NEW • COPRODUCTS 115 4 2005-2015 2016-2030 2031-2040 TIME

  8. NEAR TERM STARCH

  9. NEAR TERM STARCH e n S

  10. NEAR TERM STARCH 2004 US Corn Utilization 80.9 Million Acres Harvested - 11.8 Billion Bushels FOOD: 6.7% HFCS: 5.2% FUEL: 11.7% EXPORT: 18.5% FEED: 56.4%

  11. Ethanol Production Locations

  12. Critical Near Term Research Increased Ethanol Yield Per Acre Reduced Energy Use per Gallon Fermentation/Starch to Sugar AgronomicProductivity High Extractable/Fermentable Hybrids Custom Hybrids Process Modifications Cold Cook/Enzyme advancements Degerm/Debran Corn Kernel Fiber to Ethanol Ethanol Isolation Organism Optimization Ethanol Separation Coproduct Optimization and Segregation DDGS Composition, Quality, Transport Wet Distillers/Plant Location Oil Separation for Biodiesel Cogeneration Mining Process Energy and Streams

  13. Critical Near Term Research Increased Ethanol Yield Per Acre Reduced Energy Use per Gallon Fermentation/Starch to Sugar AgronomicProductivity High Extractable/Fermentable Hybrids Custom Hybrids Process Modifications Cold Cook/Enzyme advancements Degerm/Debran Corn Kernel Fiber to Ethanol Ethanol Isolation Organism Optimization Ethanol Separation Coproduct Optimization and Segregation DDGS Composition, Quality, Transport Wet Distillers/Plant Location Oil Separation for Biodiesel Cogeneration Mining Process Energy and Streams

  14. NEAR TERM STARCH 2004 US Corn Utilization 80.9 Million Acres Harvested - 11.8 Billion Bushels FOOD: 6.7% HFCS: 5.2% FUEL: 11.7% EXPORT: 18.5% FEED: 56.4%

  15. NEAR TERM STARCH One Bushel (56 lbs) of Corn Entering Dry Grind Ethanol Plant Products from one Bushel of Corn Leaving Dry Grind Ethanol Plant STARCH 0 37.2 lbs ETHANOL 2.75 gallons 0 18.0 lbs CO2 0 DDGS – 16 -18 lbs 5.01 lbs PROTEIN 4.98 lbs 1.74 lbs OIL 2.24 lbs FIBER 4.98 lbs 3.74 lbs Assume corn 15% moisture content Pounds Per Bushel of Corn – Dry Weight

  16. NEAR TERM STARCH 1.38 B Bushels of Corn Entering Ethanol Plants Results in ………… STARCH 0 37.2 lbs ETHANOL 2.75 gallons 0 18.0 lbs CO2 0 Containing 7.04 B lbs PROTEIN 6.88 B lbs Animal Feed

  17. NEAR TERM CORN KERNEL FIBER Amounts of feedstocks to produce 10 ml ethanol ethanol Moisture Content Corn 15% Fiber 46% DDG 64% Stover 5% Corn Fiber DDG Stover 500 ml graduated cylinders used for comparisons

  18. Corn Kernel Cellulosics NEAR TERM Near Term Technology Validation No incremental supply chain Costs Potential 10% Yield increase 4.5 M gal Ethanol per plant Annually Minimal incremental capital DDGS weight reduced 44% No increase in corn acres

  19. Examples Starch Sucrose Cellulose Lignin Robert Shleser , 1994 Lignocellulose

  20. Representative Corn Component Composition Component Stover Cobs Fiber Glucan (%) Xylan (%) Arabinan (%) Lignin (%) Protein (%) Fat (%) 40.9 21.5 1.8 11.0 7.2 1.3 39.4 28.4 3.6 7.0 3.2 0.7 37.2 17.6 11.2 7.8 11.0 2.5 Wyman; Corn Chemistry and Technology, 2nd edtn.

  21. Acid Base Selected Pretreatment Strategies

  22. Sugar and carbohydrates metabolised by Saccharomyces Species Sugar sources Glucose Fructose Mannose Galactose Sucrose Maltose Maltotriose (partially) Raffinose Dextrine (partially) Metabolites Glucose Fructose Mannose Galactose Glucose + Fructose 2 Glucoses 3 Glucoses Raffinose Dextrine (partially) Ethanol Sugar and carbohydrates not metabolysed by saccharomyces species but metabolised by species of other yeast genera Xylose (e.g. Candida shehatae and Pichia stipitis) Cellobiose (e.g. Scwanniomyces castelli and Candida) Lactose ((e.g. Candida curvata and Kluyveromyces fragilis) Starch (e.g. Schwanniomyces castellii and Saccharomyces fibuligera) Inulin (e.g. Kluyveromyces marxianus) Yeast metabolism & nutrition

  23. Recombinant Microorganisms for Fermentation of Mixed Sugars to Ethanol Recombinant organisms are now available Recombinant Escherichia coli  Recombinant Saccharomyces  Recombinant Zymomonas  Recombinant Klebsiella oxytoca  Timid Commercialization prospects BCI with recombinant E. coli Iogen with recombinant Saccharomyces

  24. Utilization of Biomass for Production of Fuel Ethanol Corn Fiber Pretreatment Enzymatic Saccharification Fermentation Ethanol Recovery

  25. Representative Corn Component Composition Component Stover Cobs Fiber Glucan (%) Xylan (%) Arabinan (%) Lignin (%) Protein (%) Fat (%) 40.9 21.5 1.8 11.0 7.2 1.3 39.4 28.4 3.6 7.0 3.2 0.7 37.2 17.6 11.2 7.8 11.0 2.5 Wyman; Corn Chemistry and Technology, 2nd edtn.

  26. 1993 Corn Kernel Fiber Solved

  27. Strategy 1 Design a method to CONVERT ALL possible sugars in kernel, maximum increase In ethanol would be 0.328 gallons/bushel. Weight, lbs/bushel*Ethanol, gal/bushel* Starch 33.93 2.93 Hemicellulose 2.59 0.228 Cellulose 1.16 0.100 *From Gulati, et al., 1996 Bioresource Technology Math for 50 mgy plant: 0.328 gal/2.7 gal is 12% increase 0.10 gal/2.7 gal is 3.7% increase

  28. US Biomass Sources ECONOMICAL Wheat Barley Corn Starch Sugar Cane Corn Fiber MID TERM Paper Switch Grass Wood Chips Stover Cottonwoods ABUNDANT & AVAILABLE

  29. RESOURCING THE ETHANOL PIPELINE LONG TERM 40% GLUCOSE FROM STARCH CORN KERNEL & NEW CELLULOSE BIOMASS PENTOSESFROM NEW BIOMASS HEMICELLULOSE MID TERM 20% 40 1554 • AVAILABLE BIOMASS • SEPARATION AND • PRETREATMENT • OPTIMIZED • FIVE CARBON SUGAR • CONVERSION • OPTIMIZED • MIXED SUGAR • OPTIMIZED • REGULATORY • FRAMEWORK • ESTABLISHED • PROCESS EFFICIENCY • OPTIMIZED Barrels of Oil Displaced NEAR TERM 10% Gallons of Ethanol Produced 20 772 • AGRONOMIC • PRODUCTIVITY • DDGS = CORN • PROCESS • PRODUCTIVITY • ENERGY USE • NEW • COPRODUCTS 115 4 2005-2015 2016-2030 2031-2040 TIME

  30. Representative Corn Component Composition Component Stover Cobs Fiber Glucan (%) Xylan (%) Arabinan (%) Lignin (%) Protein (%) Fat (%) 40.9 21.5 1.8 11.0 7.2 1.3 39.4 28.4 3.6 7.0 3.2 0.7 37.2 17.6 11.2 7.8 11.0 2.5 Wyman; Corn Chemistry and Technology, 2nd edtn.

  31. Ethanol Fermentation Of Corn Fiber Hydrolysate by E. coli FBR5

  32. Future Strains: Critical Traits • Pentose utilization • High ethanol yield and productivity • Genetic and phenotypic stability • Hardiness (tolerance to ethanol and inhibitors) • Efficient use of multiple sugars • Growth at low pH/high temperature • Ease of use with current production technology

  33. US Biomass Sources ECONOMICAL Wheat Barley Corn Starch Sugar Cane Corn Fiber LONG TERM Paper Switch Grass Wood Chips Stover Cottonwoods ABUNDANT & AVAILABLE

  34. RESOURCING THE ETHANOL PIPELINE LONG TERM 40% MID TERM 20% IDEAL BIOMASS BY GEOGRAPHY PRODUCTION, HARVEST, And TRANSPORT BIOMASS SEPARATION PRETREATMENTCONVERSION ORGANISM OPTIMIZATION COPRODUCTS 40 1554 • AVAILABLE BIOMASS • SEPARATION AND • PRETREATMENT • OPTIMIZED • FIVE CARBON SUGAR • CONVERSION • OPTIMIZED • MIXED SUGAR • OPTIMIZED • REGULATORY • FRAMEWORK • ESTABLISHED • PROCESS EFFICIENCY • OPTIMIZED NEAR TERM 10% Barrels of Oil Displaced Gallons of Ethanol Produced 20 772 • AGRONOMIC • PRODUCTIVITY • DDGS = CORN • PROCESS • PRODUCTIVITY • ENERGY USE • NEW • COPRODUCTS 115 4 2005-2015 2016-2030 2031-2040 TIME

  35. Cost Comparison for Corn & Stover Hope for future 1Corn at $2.25/bu & stover at $40/ dry ton USDA, ERRC, March 2005

  36. Micro-Biorefineries Unique Resources vary by Local Geography • OUTPUTS • Process Streams • Feed and Fuel • Food • INPUTS • Feedstock Sources • Agricultural Production • Agricultural Waste • Biomass • Industrial Waste • COMPONENTS • Process Fuel • Labor • Transportation

  37. Key Areas of Focus Across a Portfolio of Time Secure the Base Supply Demand • Feedstock Optimization • Process Optimization • Animal Feed Optimization • FFV Availability • E85 Availability • Consumer Knowledge and Demand • Workforce Grow the Future • Get the sugars out without destroying them or • Creating a hostile environment • Convert all sugars – effectively and efficiently • Address regulated organisms • Address inefficiencies of low concentration of alcohol in beer for • isolation

  38. Key Areas of Focus Across a Portfolio of Time • Ensure there is research funding • – nationally as well as locally • Ensure it is spent well • Balance near, mid and long term research needs • Identify local resources and ensure funds are aligned • to solve the technical problems you need addressed • Require measurable commercial outcomes • Don’t create champions • Don’t starve the troops • Be realistic • Don’t be redundant • Do reward results

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