Turning Cellulose Into Fuels, Plastics, Chemicals

The bio-gateway to abundant energy and wealth was just opened a crack. Cellulose is one of nature's favourite ways of storing solar energy. But human machines and power systems do not run well on cellulose. Naturally, a conversion from cellulose to high density liquid, solid, and gaseous forms of energy storage is vital. But, how to do it? Using clever and efficient enzymes can be a good way, but single enzymes lack the power and versatility to do everything necessary. Hence, the "gang of 15 enzymes" working together.

Researchers at the California Institute of Technology (Caltech) led by Frances H. Arnold, the Dick and Barbara Dickinson Professor of Chemical Engineering and Biochemistry at Caltech, and gene-synthesis company DNA2.0 have developed a new group of 15 highly stable fungal enzyme catalysts that efficiently break down cellulose into sugars at high temperatures for conversion into a variety of renewable fuels and chemicals.

Previously, fewer than 10 such fungal cellobiohydrolase II (CBH II) enzymes were known. In addition to their remarkable stabilities, Arnold’s enzymes degrade cellulose over a wide range of conditions. A paper on the work was published 23 March in the early edition of the Proceedings of the National Academy of Sciences.

This is a really nice demonstration of the power of synthetic biology. You can rapidly generate novel, interesting biological materials in the laboratory, and you don’t have to rely on what you find in nature. We just emailed DNA2.0 sequences based on what we pulled out of a database and our recombination design, and they synthesized the DNA. We never had to go to any organism to get them. We never touched a fungus.
—Dr. Frances Arnold

...Arnold and Caltech postdoctoral scholar Pete Heinzelman created the 15 new enzymes using a process called structure-guided recombination. Using a computer program to design where the genes recombine, the Caltech researchers mated the sequences of three known fungal cellulases to make more than 6,000 progeny sequences that were different from any of the parents, yet encoded proteins with the same structure and cellulose-degradation ability.

By analyzing the enzymes encoded by a small subset of those sequences, the Caltech and DNA2.0 researchers were able to predict which of the more than 6,000 possible new enzymes would be the most stable, especially under higher temperatures (a characteristic called thermostability). _GCC

Very clever. And this is just the beginning.

We are living in a biological world. When we start working with biology to get more of the things we want, we can begin building a veritable cornucopia of riches.

Cross posted to Al Fin Energy

Peak Oil: Meet Cellulosic Biofuels 2030!

German researchers have published a study revealing that by 2030 cellulosic biofuels using pyrolysis and gasification can provide transportation fuels to meet global needs using land not suitable for growing food.

According to Prof. Jürgen O. Metzger from Carl von Ossietzky Universität Oldenburg, and Prof. Aloys Hüttermann from the Universität Göttingen, a global energy supply based on biomass grown to generate electricity and produce fuel is both a sustainable and economical scenario, contrary to some other current research. Their findings are published online this week in the journal Naturwissenschaften.

The solution, according to Metzger and Hüttermann, is to plant fast-growing trees on degraded areas, and harvest the biomass for energy usage. This afforestation would not compete with the need for arable land for food production. The authors argue that the investment required for afforestation and transformation of the biomass to electrical energy, heat, fuels and chemical feedstock is actually sustainable and not more, probably even less, than what would need to be invested in infrastructure for non-sustainable fossil energy.

For their global overall estimations for transportation fuels, the two used the conversion of the lignocellulosic biomass to biooil (“bioslurry”) via pyrolysis and its subsequent gasification to a syngas followed by Fischer–Tropsch synthesis (biomass-to-liquids, BTL). _GCC

These conclusions suggest that there is no "food vs fuels" issue, and that current technology can solve the global transportation fuels demand in the intermediate future.

Al Fin feels that this study did not go far enough, since huge areas Earth's surface can be used to grow ocean biomass and haplophytic organisms on salty soil. In addition, the potential for growing abundant algae in desert areas using saltwater will multiply potential biofuels much more.

Further development of plant genetics, chemical catalysts, other synthetic and separation technologies, etc. will be helpful--but not necessary for biofuels to play a huge role in the future energy menu.

Previously published at Al Fin Energy

Synthetic Biology and BioSynthetic Fuels

The best time to work on alternatives to fossil fuels is while fuel prices are temporarily low. Better prepare now, because when those prices start rising again it may be too late to block another energy-recession.

Synthetic biology is in its early bloom. Soon, it will begin offering a greater abundance of products such as fuels, plastics, chemicals, pharmaceuticals, and other things unimaginable now. Unless the ever-lurking Luddites burn the bridges before they are built. That is a danger under the current political current. But the need for alternative fuels is so apparent, that it is possible the Luddites in political control will overlook this one shining promise.

Synthetic biology refers to both the design and fabrication of biological components and systems that do not already exist in the natural world, and the redesign and fabrication of existing biological systems. As tools are developed to hone and refine this technology, researchers across multiple disciplines are finding novel applications for it.

...One company that provides the raw material for the creation of biofuels is Agrivida, an agricultural biotech firm that creates renewable, biomass-based alternative fuels and raw materials. “We are working upstream, making plants that are more easily degradable, primarily switchgrass, sugar cane, and corn,” states R. Michael Raab, founder and president. “We are focused on nonfood crops and crop residues that are degradable into fuel.”

...Gevo develops advanced biofuels technology based on butanol and its derivatives. “The magic isn’t in the biology alone,” according to Pat Gruber, Ph.D., CEO. “It’s in the chemistry, fermentation, processing, and genetic engineering all together; knowing what tools you need, and having the tools to make it happen.”

Dr. Gruber points out that three critical pieces of technology have helped Gevo produce these on a commercial scale. “We have a group that’s been working on this for 20 years or longer. Metabolic engineering of suitable host organisms make it possible to use carbon and energy efficiently for fuel production. Process engineering makes it possible to lower product separation costs and chemistry to produce valuable hydrocarbons.”

...Two other companies working in the metabolic engineering space are Mascoma and LS9. Mascoma recently received $26 million in DOE funding, which will be applied toward the development of a cellulosic fuel production facility that uses nonfood biomass to convert woodchips into fuel. Mascoma’s production facility is expected to produce 40 million gallons of ethanol and other valuable fuel products per year.

LS9 developed new metabolic pathways that efficiently convert fatty acids to a broad portfolio of petroleum replacements. It also discovered and engineered a new class of enzymes and their associated genes that catalyze the efficient conversion of fatty acids to hydrocarbons. They recombinantly produce hydrocarbons (oxygen-deficient biocrudes), fatty acid alkyl esters (biodiesel), and a variety of industrial chemicals from sugars via fatty acid biosynthesis.

...Codexis’ technology enables solutions for cost-effective, efficient, and environmentally sound production of pharmaceuticals, transportation fuels, and industrial chemicals, reports David Anton, Ph.D., vp, bioindustrials R&D. The company focuses on biocatalysts—enzymes or microbes that initiate or accelerate chemical reactions. At Codexis, biocatalysis is used to design faster, less costly, and greener chemistry-based manufacturing processes in the life science and energy industries.

According to Dr. Anton, Codexis’ technology makes it possible to customize enzymes capable of selectively and efficiently performing a desired chemical process that doesn’t exist in nature.

...SunEthanol was recently awarded a $750,000 Phase II Small Business Technology Transfer Program contract. This award, made as a follow-up for successfully completing a year-long Phase I grant, will allow SunEthanol to continue pioneering a process that converts plant waste into clean ethanol fuel in one simple step, saving time and money over the traditional two-step cellulosic conversion process, the company claims.

... _GenEngNews

Several more companies are mentioned and linked in the above Genengnews article. It is impossible to keep track of all the research efforts in synthetic biology that will influence biosynthetic fuels development. Every university biology or agriculture department with a significant research program will be working on this problem, in all likelihood. Whether or not the world economy improves, fuel prices will rise. If the Luddites in control suppress energy technologies, energy prices will rise out of scarcity. If the Luddites are given a well-deserved boot in the arse, energy prices will rise as economies improve. Those who are prepared will prosper. Those who are not prepared, will dieoff.org. It is the harsh way of the universe.

Biomass Is a Versatile Energy Suite

Biomass can be turned into gasoline, into a renewable natural gas, into bio-coal, into ethanol, or directly into electricity. Combined cycle biomass to electricity plants can be 45% efficient generating electricity. Even more efficiency can be achieved by using the waste heat productively.

What is biomass? It is waste wood from forestry, waste stover/straw/bagasse etc. from crops, waste cardboard and paper products, byproducts of paper manufacture etc. Or biomass can be grown specifically for energy production--miscanthus, switchgrass, fast-growing poplar, bamboo, etc. are all being tested for the ability to create a prolific bio-feedstock for conversion to energy.

Biomass energy makes far more sense currently than wind energy schemes. It is suitable as a local or regional enterprise--which means that thousands of small biorefineries and biomass processors and pre-processors will be set up across North America. Biomass is far less dense than most other forms of energy, and must be converted to other forms (pellets, cubes, bales, torrefied, gasified, liquified, etc) for transport or use.

As economies of scale are achieved by the most efficient producers, a significant shakeout of less efficient biorefineries and cellulosic electricity producers will occur over time.

The replacing of fossil fuels by bioenergy will be a gradual process that takes decades, at least. You do not replace a multi-trillion dollar infrastructure overnight. Over the next 40 years, current energy infrastructure will be largely replaced by bioenergy, by new generation nuclear energy, by solar and geothermal heat-to-power, by photovoltaics, possibly by orbiting solar power sats, and not so much by wind.

Al Fin Energy has many other articles and links on this topic and other energy topics.

Skipping Ethanol: Going Directly to Gasoline

Ethanol as fuel for automobiles seems to work alright for Brazil. But modern infrastructure is built for gasoline, and most North American automobiles were built to run on gasoline. What if biofuels producers could go directly from cellulose biomass to gasoline, without producing alcohols? With the right sequence of processes and the proper catalysts, it could be done. The problem is doing it efficiently, with high yields.

By speeding up the formation of certain products and slowing down the formation of others, catalysts effectively steer a reaction to a subset of possible products. In the refinement of biomass-to-fuel, catalysts can steer reactions to the most valuable biofuels and bioproducts thereby minimizing costs associated with product separation and feedstock recycling. “This is the real magic and promise of catalysis,” Auerbach says.

...Christopher Jones, a chemical engineer at Georgia Institute of Technology, works from a number of different angles when it comes to biofuels research. The common thread to his team’s projects, however, is that they all focus on lignocellulosic feedstocks, mainly pine and switchgrass, as opposed to edible starches. One of their ongoing projects is gathering data on the behavior of mineral acids such as sulfuric acid in the pretreatment of biomass. “It’s not a particularly interesting or sexy catalytic process,” Jones says. “Mineral acids have been used for a number of years to break down biomass but there are only small, isolated studies in the literature.” Jones’ team is taking a single biomass and systematically studying the effect of certain types of acids and reaction temperatures to gain a greater understanding of how these catalysts act.

...Brent Shanks, a chemical engineer at Iowa State University, first gains an understanding of the characteristics of a reaction and then designs catalysts around that. He calls this “rational design.” His approach is one of bio-inspiration in that it aims to take certain characteristics of enzymes and build them into chemical catalysts. “Enyzmes are beautiful catalysts but they have some issues such as sometimes they’re too specific, too selective, and also you can’t go to high temperatures with them,” he explains. “With chemical catalysts you can go to higher temperatures but they’re not nearly as specific as enzymes.”

...In a different approach, the team at PNNL, which Holladay is a part of, uses high-throughput screening to test multiple catalysts at a time and to increase the number of experiments they can do over a given period of time. This method for identifying new catalysts is carried out at PNNL’s Combinatorial Catalysis Lab. Initially, robotic equipment is used to form each catalyst to be tested. Solids handling robots weigh and add an appropriate amount of solid support to a small well on a microtiter plate. Each plate holds 96 wells, so up to 96 catalysts can be developed and tested together. Liquids handling robots then add a salt solution of metals, which fill the pore spaces of the support. The liquid is evaporated leaving the metals embedded in the support. Once the catalyst is treated to set the metals in the active state, the plate is moved to a reactor system where the biomass to be tested is applied to each well. The reaction is carried out in a second reactor and then another set of robotic systems draws samples from each well for analysis, Holladay explains. _EthanolProducer

Different approaches are being taken by different research groups, because it is still very early in the game of thermochemical conversion of cellulose to hydrocarbon fuels. Ethanol producers will have at least a decade to prove what they can do--in terms of efficiencies and yields, not to mention making a profit.

In today's uncertain (and rather deranged) political environment, where entire blocs of nations chase after the "climate change" delusion, one can never predict what will be encouraged and what will be prohibited, politically. We live in an age of "political peak oil", which distorts energy costs significantly, and makes it much harder for entrepreneurs and venture capitalists to plan new ventures and startups.

As usual, our friends at Oynklent Green [OTC:OYNK] are following the situation closely, putting themselves into a better position to react as situations warrant.

Cellulosic Electricity: The Most Efficient Biomass

One of the easiest ways to utilise biomass to produce energy, is to partially substitute biomass for coal in a traditionally coal-fired power plant. Yorkshire based Drax power plant intends to do exactly that, making Drax the largest biomass producer of electricity in the UK.

Executives from Yorkshire-based Drax signed a deal with Alstom to build a processing plant that could prepare 1.5m tonnes per year of biomass for use in the power station. Under the plans, biomass would be ground into a fine powder and injected directly into the power station's coal-fired furnaces. Building work for the processing plant will start later in 2008 and the first part of the facility is expected to be completed by the end of 2009.

...Neil Crumpton, energy campaigner at Friends of the Earth, said that using biomass in power stations or combined heat and power schemes is a better use of the resource than, for example, turning it into liquid biofuels for use by diesel-engine vehicles. "Co-firing with biomass is a reasonable way forward - it's a logical extension of what Drax is already doing and I've got no qualms with it on that score. If it helps build the sustainable biomass market in the UK, then all well and good."

...To test whether co-firing would work, Drax has used a 2-3% mix of biomass in some of its coal-fired furnaces for several months already. In their current experiments, the biomass fuel is mixed directly into the coal as it burns but this technique would not work for larger quantities of biomass.

"When you burn just a few per cent of biomass, you can afford to use exactly the same lines as coal," said Patrick Fragman, managing director of Alstom, the company that will build the biomass processing plant at Drax. But, for a higher percentage, he said, dedicated infrastructure is needed.

Peter Emery, production director at Drax, said that the new processing plant was a crucial part of the power station's attempt to scale up their biomass usage. He also added that it would be able to handle a wide variety of biomass fuels.

Different biomass materials burn in different ways, so the processing plant needs to be able to handle the materials accordingly. The resulting fuels then need to be inserted into the coal-fired boilers at different positions to ensure they burn properly. Engineers at Drax estimate that it will take 1.5m tonnes of biomass to replace the energy that comes from 1m tonnes of coal. __Guardian

Biomass CHP or cellulosic electricity, is clearly the most efficient way of producing energy from cellulosic biomass. The only reason for taking the less efficient route of producing liquid fuels (BTL) from biomass is that most of the transportation infrastructure cannot run without liquid fuels, at this time. It will likely require 20 years or more to achieve significant conversion of transportation from liquid fuels to electric drives running on stored electricity. Even fuel cells will probably need to run largely on liquid fuels such as methanol, for the next 10 to 20 years minimum.

Previously published at Al Fin Energy