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Industrial Biotechnology-Sustainable Biorefineries - Richard LaDuca - Genencor - April 2010


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Presented at Nordic Green II conference, April 2010

Published in: Business, Technology

Industrial Biotechnology-Sustainable Biorefineries - Richard LaDuca - Genencor - April 2010

  1. 1. Industrial Biotechnology: on the Road to Sustainable Biorefineries for Biochemical and Biofuels Production Richard J. LaDuca April 28, 2010 Nordic Green II Conference Palo Alto, CA
  2. 2. Genencor at a Glance…. We put Biotechnology to work… developing & Industrial producing enzymes for industrial applications. Enzymes Animal Feed Enzymes Cellulosic Enzymes History traced to 1982 Food Enzymes Fabric & Household May 2005: Division of Danisco Care Grain Processing Industrial Biotechnology Focus Textiles Enzymes Over 250 commercial products Biochemicals Proven innovator: ~3,500+ Lysine owned & licensed patents and Threonine Tryptophan patent applications 1,3 Propanediol Indigo H Biotin > $800 MM USD annual turnover C C CH3 Ascorbic Acid 1,3 Propanediol ~ 1,500 employees worldwide H2C CH2 BioIsoprene™ BioIsoprene™ 2
  3. 3. Genencor® business timeline A Leader in Industrial Biotechnology Danisco acquires GCOR, 100% Eastman Chemical 1993, Danisco 50% 1999, 50% Dual Kodak-Cultor ownership that forms: Genencor International, Inc. GCOR buys Gist- Brocades Enzymes (Brugge, New Wuxi China plant and BE) application laboratories Genentech & Corning GCOR buys Solvay Enzyme (USA, Argentina, Germany) Shanghai Research Center form Genencor, Inc. GCOR buys Wuxi Enzymes (China) Cedar Rapids GCOR buys Enzyme Bio-Systems, (USA) expansion and establishment of GCOR buys Rhodia Enzymes (UK) Grain CoE 1982 1990 1995 1996 1999 2002 2003 2005 2007 2008 2009 An early pioneer in modern industrial biotechnology 3
  4. 4. Genencor Biotechnology Our Core Competency: We design and operate Cell Factories – We rapidly create engineered proteins that accomplish the previously impossible and deliver significant value to our most important customers. – We engineer the metabolic pathways of micro-organisms to produce enzymes, proteins, and other bio-molecules at industrial scale and economics. 4
  5. 5. Industry Trends: Fuels / Chemicals Petroleum-based Processes Biobased Processes Existing, mature refining infrastructure; Building off of early successes using starch-based feedstocks high efficiencies, low cost Enables a $5-10 billion dollar industry Enables a $2+ trillion dollar chemical Driven by a renewable raw material industry worldwide base Volatility in oil price leads to volatility in Innovation and advances in enzyme chemical / fuel prices processing efficiencies and costs Feedstock source is non-renewable Trend towards: less GHG emissions; less non-renewable energy usage; and Innovation potential around existing reduced environmental impact chemical processes has been played Move to waste biomass as a feed out source GHG / CO2 abatement concerns Technology innovation and systems integration drive move to BIOREFINERIES 5
  6. 6. Biorefinery: “A biorefinery is a facility that converts waste biomass into fuels, power, and chemicals. The biorefinery concept is analogous to today's petroleum refineries, which produce multiple fuels and products from petroleum.” - DOE 2008, Biomass Program 66
  7. 7. Industrial Biotechnology: delivering technology enabling Biorefineries Non-Renewable Renewable Renewable Feedstocks Feedstocks Feedstocks Crude Agricultural Biomass Oil Products Wastes Petro-Refining / Bio Bio Cracking Refining Biorefineries Refining using E E renewable raw Fractionation Starch Processing Fractionation materials as Cellulose Processing Fractionation Enzymes feedstocks are TODAY Enzymes Chem Building Starch C5/C6 Blocks delivering products C5/C6 Sugars, Sugars Lignin that compete with Chem Syn. & Bio Bio Conversion E Conversion petroleum refining E Conversion Metabolic Metabolic Pathway Pathway Petro-based Engineering Biobased Biobased Engineering Products Products Products Chemicals Fuels Biochemicals Biofuels Biochemicals Biofuels Not Sustainable Sustainable Sustainable Proven Method Proven Method In Development Price Volatility Food Based Ag Wastes Existing Infrastructure Existing Infrastructure No Existing Infrastructure 7
  8. 8. Genencor’s Road to Sustainable BIOREFINERIES Enzymes for starch processing 1st Generation Biochemicals & Bioethanol 2nd Generation Bioethanol Renewable Biochemicals and Biofuels 98
  9. 9. Conventional 1st generation ethanol production process Thermo-stable E Alcohol alpha amylase Glucoamylase Yeast recovery Milo Liquefaction Saccharification Distillation & Fermentation Corn dehydration Wheat Water Rye JET COOKER * Barley >100° C Tapioca 5–8 MIN STORAGE TANK 60° C 8–10 HRS (optional) GRINDING SLURRY TANK SECONDARY LIQUEFACTION 95° C * ~90 MIN DDGS pH adjustment steps are not shown 9
  10. 10. No-cook ethanol production process Alcohol recovery Milo Corn Wheat Saccharification & Distillation & Rye fermentation dehydration Water Barley Tapioca STORAGE TANK SLURRY GRINDING TANK * STARGEN™ & Yeast DDGS E pH adjustment steps are not shown 10
  11. 11. Genencor & DuPont: 1st Generation Biochemicals from Renewable Raw Materials E 11
  12. 12. 1st Generation Biochemicals Genencor’s enzyme technology is at the heart of the integrated bioprocess to produce 1,3 propanediol 12
  13. 13. Enzyme Activities Important in Biomass Hydrolysis Accellerase® DUET achieves 3- Many customers and pilot fold dose reduction on multiple facilities are trialing Accellerase® substrates Genencor® is actively working Accellerase® DUET enabling on future generations of commercialization with $0.50 Accellerase® products. enzyme cost / Gal EtOH E 13
  14. 14. Total Sugar Conversion: Pretreated Hardwood Pulp, 3 day Saccharification E 0.17 mL Accellerase® DUET vs. 1.0 mL Accellerase® 1500 (5.9X) 14
  15. 15. 2nd Generation Advanced Biofuels 50/50 Joint Venture between Danisco and DuPont Commercializing integrated technology to produce cellulosic ethanol Over $140mm investment over 3 years Biomass feedstock-flexible (utilizing cob and switchgrass in Eastern Tennessee) pilot plant 2010 Commercial plant in 2012 E 15
  16. 16. Isoprene Production: PETROLEUM CHEMICAL BIOBASED TREES CRACKING SYNTHESIS PROCESS • Slow • Extractive • High cost • Renewable distillation from feedstocks • Not Ethylene & • Petroleum commercially Propylene feedstocks • Biochemical relevant production AND Biofuel • Mfg. Products • Price linked to infrastructure in oil prices Russia & Japan • Moving to “light” streams 16
  17. 17. The Vision: Isoprene from Biomass Biomass Sugars OH Isoprene O HO HO Corn Switchgrass OH OH D-Glucose 2-Methyl-1,3-butadiene + other C5 and C6 sugars Sugar cane Woody Molasses biomass We aim to develop an efficient and sustainable fermentation route to isoprene from carbohydrate feedstocks 17
  18. 18. Genencor and Goodyear leveraging each others’ expertise … H CH3 E E C C H2C CH2 BioIsoprene™ Polymer-Grade Renewable Microbial Strain Large Scale recovery & BioIsoprene™ Feedstock(s) Development Fermentation purification Product knowhow Integrated biobased process for production of BioIsoprene™ 18
  19. 19. C5 Platform Progress – Stage I Biochemicals BioIsoprene™ Technology Conceptual View of Cell Factory Glucose C6 ►3C DXP Pathway Sucrose / (C5) Biomass Isoprene Isoprene 3C ►2C Cells Synthase Recovery Glycerol 16C ►2C MVA Pathway E Plant Oils Multiple feedstocks possible Two feeder pathways to isoprene precursor Isoprene synthase Gas Phase recovery 19
  20. 20. BioIsoprene™ BioRefinery: Market Applications Polymer Grade Cis 1,4 Tires / BioIsoprene™ Polyisoprene Elastomers Product Synthetic Rubber Replace Natural Rubber Renewable Gas-phase Feedstocks BioIsoprene™ Synthetics in tires product recovered & purified to liquid- phase rDNA Host Non-tire synthetics BioIsoprene™ produced in Systems: gas-phase E.coli; Yeast; Fungi; Adhesive E • in-situ others Applications purification • relieves end product inhibition/toxicity Other styrene adhesives • faster, better, cheaper 20
  21. 21. BioIsoprene™ Molecule: Genencor’s Unique C5 Platform Tires Biochemicals Purification Adhesives High Purity BioIsoprene™ monomer Specialty Polymers H CH3 C C H2C CH2 Isoprene Monomer Gasoline Renewable Microbial Strain Large Scale Gas Phase C10 Isomers Feedstocks Development Fermentation Recovery C15 Isomers + + Other Fuels & Blends Diesel Biofuels BioIsoFuel™ Examples Jet Fuel Chemical Catalysis 21
  22. 22. C5 Platform Progress – Stage I Biochemicals Tires BioIsoprene™ Project Purification Adhesives High Purity BioIsoprene™ monomer Specialty Polymers H CH3 C C H2C CH2 Isoprene Monomer Microbial Strain Large Scale Gas Phase Sugar Development Fermentation Recovery In Stage I development we have started from sugar 22
  23. 23. C5 Platform Progress – Stage II Biofuels BioIsoFuel™ Products Concerted effort converting biomass to sugar • Leverage long history / IP with biomass enzymes Continued optimization Hybrid biological + chemical process H CH3 C C H2C CH2 Isoprene Monomer Gasoline Renewable Microbial Strain Large Scale Gas Phase C10 Isomers Feedstocks Development Fermentation Recovery C15 Isomers + + Other Fuels & Blends Diesel BioIsoFuel™ Exaamples Jet Fuel Chemical Partner Catalysis 23
  24. 24. Genencor®: on the Road to Sustainable Biorefineries The biobased economy is here and its growing • ~5-10% of chemicals will be bio-based by 2012 (McKinsey 2006) High oil prices and environmental concerns are key factors fueling the biobased economy Innovations in enzyme processing are enabling the development of sustainable integrated systems for biomass processing to fermentable sugars New business models / Strategic relationships and Technology Integrators will speed Biorefinery development Biobased processes will continue to deliver Strategic alternatives to petrochemicals 24
  25. 25. Our Vision of the Biobased Economy We envision a future where biotechnology fulfills many unmet needs…  In development and deployment of industrial enzymes  In the production of fuels, chemicals and materials We envision a future where biotechnology helps create sustainable industrial activities We envision a future where biorefineries take their place alongside oil refineries We aspire to be recognized as a leader in world-changing technology solutions. 25
  26. 26. Questions: 26