Advanced Biofuels (and Bio-products) Process Demonstration …abpdu.lbl.gov/wp-content/uploads/sites/4/2015/07/FATER-ABPDU-Waste... · Todd Pray, Chenlin Li, Ling Liang, Jessica Wong,

Advanced Biofuels (and Bio-products) Process Demonstration Unit

with:

BIO World Congress on Industrial Biotechnology July 22, 2015

Todd Pray, Chenlin Li, Ling Liang, Jessica Wong,

Qian He, Firehiwot Tachea, Ning Sun, Deepti Tanjore

Marcello Somma, Nicola D'Alessio

The FATER – ABPDU partnership

Berkeley Lab’s ABPDU has been developing and validating an integrated waste-to-energy process under a DOE work-for-others (WFO) agreement with FATER, an Italian JV between Procter & Gamble and the Angelini Industrial Group. Key outcomes indicate that post-consumer absorbent hygiene products (AHP) can be readily and economically converted -- without using harsh or expensive pretreatment routes -- to fermentable sugar intermediates as well as biofuel and bio-based chemical products.

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FATER Corporate Summary Founded in 1958 by Angelini Since 1992, a joint-venture of Procter & Gamble and Angelini

• Italian market leader for Hygiene products:

• CEEMEA market key player for hard surface cleaning:

• 1,110 employees • 1,000 related employees • Turnover: € 1,150 million • 4,563,900,882 product units sold per year • 3.5 mil € per year in consumer research • 4 facilities:

• Pescara (Italy) • Campochiaro (Italy) • Porto (Portugal) • Mohammidia (Morocco)

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Key FATER products and EU recycling issues

The 7th Environment Action Programme sets the following priority objectives for waste policy in the EU: • To reduce the amount of waste generated; • To maximize recycling and re-use; • To limit incineration to non-recyclable materials; • To phase out landfilling to non-recyclable and non-

recoverable waste; • To ensure full implementation of the waste policy

targets in all Member States.

“In 2010, total waste production in the EU amounted to 2.5 billion tons. From this total only a limited (albeit increasing) share (36%) was recycled, with the rest was landfilled or burned, of which some 600 million tons could be recycled or reused.”

A significant volume and product development opportunity…

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ABPDU’s Mission

Partner with researchers from

industry, the National Labs, and

academia to optimize and scale

technologies for bio-based chemicals

/ materials / fuels commercialization.

• Established by American Recovery and Reinvestment Act funds in 2009 – roughly $17 million invested in the 15,000 square foot bench-to-pilot demonstration Lab

• Managed by US DOE’s Bioenergy Technologies Office / EERE

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ABPDU technical capabilities

• Process demonstration, integration and techno-economic analysis across varied

bio-process configurations, feedstocks and products

• Can focus on individual unit operations or several processes in succession

Biomass deconstruction /

extraction

Fermentation

Advanced recovery and purification

Chemical catalysis

• Fuels / Chemicals • Proteins • Enzymes • Polymers

• Many feedstocks • Many processes

Simple sugars

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Facility at a glance – from lab-to-pilot scale

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Process development and TEA framework

AHP Collection Sterilization Solids

separation

Enzymatic hydrolysis

Pretreatment

Plastic fraction

Cellulose-rich fraction

Fermentation

SSF & SHF both compatible with upstream processes

Cellulose-rich material readily hydrolyzed w/o pretreatment

Ethanol (or other product stream)

Sugar stream

FATER-developed process

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0

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10% 10% 10% 15% 15% 15% 15% 20% 20% 20%

Sug

ar C

once

ntra

tion

(g/L

)

Solid Loading (w/w)

GlucoseXylose

1x 2x

4x 1x

2x

8x

4x

2x 4x 8x

Lab-scale hydrolysis process optimization

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Bench-scale enzymatic saccharification

Efficient mixing key to reproducible, scalable hydrolysis of mock and actual AHP materials

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0

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10% 10% 15% 15%

Suga

r Cco

ncen

tratio

n (g/L

)

Solid Loading (w/w)

GlucoseXyloseFlask GlucoseFlask Xylose

Optimized hydrolysis performance at bench scale

Solid Loading (w/w)

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Glucose – IKA reactor Xylose – IKA reactor Glucose – shake flask Xylose – shake flask

Sug

ar C

once

ntra

tion

(g/L

)

Bench-scale fermentation validation

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0

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0 10 20 30 40 50 60Co

ncen

trat

ion(

g/L)

Time (hour)

2L Fermentation

Mock GlucoseMock EthanolAcutal GlucoseActual Ethanol

0

10

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0 10 20 30 40 50 60Time (hour)

Shake Flask Fermentation

Mock GlucoseMock EthanolAcutal GlucoseActual Ethanol

Mock & post-consumer AHP material performance

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Shake-flask fermentation Bench-scale bioreactor fermentation

Time Time C

once

ntra

tion

Con

cent

ratio

n

AHP-derived sugars readily fermented with no apparent toxicity in either SHF or SSF production modes.

Glucose – mock Ethanol – mock Glucose – post Ethanol - post

Glucose – mock Ethanol – mock Glucose – post Ethanol - post

Potential commercialization routes

• Pretreated sugar intermediate

o Distributed, relatively small scale production of enzyme-compatible

cellulose-rich material (sugar intermediate) for integration with cellulosic

ethanol or chemical producers

• Sugar product

o Production of sugar monomers and packaging / distribution to users in

traditional first-gen starch- and sugar-based fermentation manufacturers

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Thank You

Contact info

Todd Pray – [email protected] Nicola D'Alessio - [email protected]