maximising the value from agri-food chain biomass · nrp biorefinery centre institute of food...
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The Waste Biorefinery Platform
Maximising the value from agri-food chain
biomass
Keith Waldron
NRP Biorefinery CentreInstitute of Food Research
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Quantities of waste
• Europe (EU27):• 90 Million tonnes per annum• [European Commission, 2010]
• Globally• Over 1/3rd of food produced for human consumption is wasted
• 1.3 Billion Tonnes
• Per capita = mostly in industrialised nations
• 100 kg/person in EU;
• 6-10 Kg/person in sub Sahara Africa![Gustavsson et al 2011]
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Increased demand for food
• Continued increase in population will result in increased demand for natural resources– Land
– Water
– Energy
– Food
• World Bank predicts– global demand for food will rise by 50% by 2030,
(for meat by 85%) and by 100% by 2050.
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Sustainability and Waste
• Making better use of resources is going to
become more pressing
• There will be increased pressure to avoid a
food-fuel conflict
• There will be increasing pressures and
opportunities to make use of biomass-
waste
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Overview
• Examples of high value components
from agri-food chain wastes
• Exploitation of residues– High quality growing media as a peat replacement
– Conversion of lignocellulose to fuels and
chemicals
• Where Next?
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Waste from the Food Chain
Processing
waste
Field Waste
Product
Transport, Retail
More transport
More storage
Ingested
food
Agronomy
Consumer
Municipal
Waste
Seed
Packaging waste
Out of
spec / date waste
Crop
Storage,
transport
& Processing
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“BIOREFINERY” Concept
Stabilised
Co-product
Organic
Waste
Material
HIGH VALUE
Nutriceuticals
Cosmetics
Food & feed
Additives
Feed Additives
Including fish
Feed
Non-food uses
e.g.
biodegradable
Packaging etc
Composting
% energy use
LOW
VALUE
Ind
us
trial a
nd
co
ns
um
er p
latfo
rms
RE
CO
VE
RY
Breakdown
and
fractionation
HACCP
Feedback processConsumer+retailor acceptance RISK assessment
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polymersO
HOH2 C
o o
O
O
CH2 OH
HOH2 C
o o
A Hierarchy of Structures
plant
tissue
cell
cell wall
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How are cell walls constructed?
cellulose microfibril
© K. W. Waldron, Institute of Food Research
OHOH2C
o o
O
O
CH2OH
HOH2C
o o
O
O
CH2OH
HOH2C
o o
1,4-linked glucose
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cellulose
microfibrils hemicelluloses
proteins
lignin
© K. W. Waldron, Institute of Food Research
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Adding Value to Waste Co-products
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-10
-5
0
5
10
15
20
25
Bifidobacteria Bacteroides Lactobacilli Clostridia Eubacteria
Dif
fere
nces i
n b
acte
rial
po
pu
lati
on
siz
e (
%)
FOS
Bergamot
Adding Value to Waste Co-products
Faulds et al 2010.
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Traditional approach e.g.FAIR CT96-1184
Conversion ofEnvironmentally-unfriendly
Onion wasteinto
Food ingredients
Institute of Food Research (UK)
University Autonoma de Madrid (Spain)
Herbstreith and Fox (Germany)
ATO [Wageningen University] (Netherlands)
TOP (Netherlands)
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Onion waste: The Problem
400,000 tonnes grown in UK (1999)160,000 tonnes peeled57,600 tonnes = waste - disposed of – much by landfill
In UK:600,000 consumption
Allium cepa L.
Vegetable, prized for its flavour, aroma.
Medicinal qualities.Rich in quercetin, an antioxidant
> 500,000 tonnes of onion waste produced annually in Europe
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Industrial peeling of onions
Top n’ tail
Blast with air
Score vertically Outer papery scales (brown)
+ outer fleshy scales (grey)
removed
Inner fleshy scales
Retained for further
processing
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Onion peel Waste
White tissues
Crude Pulp
Instant
thickener
Evaluated Food Additives
TDF/IDF
Flavours
+ FOS
+ sugars
Supplemented Foods
Flavours
Sweet onion
juice
Possible process stream
Brown tissues
Brown IDF
finely ground
Low-
viscosity
SDF White
IDF
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Instant-thickening agent from onion waste
Waldron K, Useful ingredients from onion waste. Food Sci Technol (2001).
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By-product
• Microbiologically compromised
• Difficult mixtures•Contain meat and veg/fruit
• Insufficient economies of scale
• Untraceable
Composting Bio-alcohol
High value, patentedoutputs
residue
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Professional Growers:
•Increasing requirement for horticultural growing media
•EU Wetlands Directive
•Consumer and retailer pressure
•Poor quality / unsuitable peat alternatives
Food processors
•Large quantities of organic, plant-based waste
•Pressure from EU landfill directive / UK landfill tax
The Problem: Sustainability*
Growing-media manufacturers and
composters:
•Paucity of knowledge of functional criteria of peat
•Paucity of understanding of composting process
*Margaret Becket’s speech at opening of
CSD meeting, 28th April, 2003
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Developing a peat replacement
Waste
Stream
HQ
GMCo-productprovision
CompostingAndProcessing
Plant TrialsTailoring ofMedia
Madestein
Ltd
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Required characteristics of a growing
medium
• Water holding and drainage
• Blendable
• Handling quality (e.g. cohesiveness)
• Defined nitrogen and nutrient status
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Why is peat a good growing medium?
Somerset
Sedge H7-8
Ballycommon
H4-5
Latvian
Blonde
H2-3
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Why is peat a good growing medium?
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Why is composted material different
from “peat”?
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Str
uctu
re
0%Time
Controlling the Composting Time Line
100%
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What happens during
peat formation?
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Changes in peat with age
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What happens during composting?
• In Vessel composting: using the bespoke COBRA I and II
• Specific ‘windrow’ trials – generally in the order of 16 tonnes
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ZEE 20160 TSB
COBRA vesselThermal control unit
Filling shute
Electrical control system
Air pump
Electrical control system
Thermal control system showing pumps and valves
Hydraulic pump and
electrical drive
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Sources of plant waste
• Cereal Wastes monocot, cross-linked,
analogous to sedge
• Vegetable and fruit
wastesdicot, closer to parenchyma cells
of mosses
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Waste streams included:
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Changes in composition during composting
0.00
50.00
100.00
150.00
200.00
250.00
300.00
0 20 40 60 80 100 120
Time (days)
Su
ga
rs (
ug
/mg
)
0
5
10
15
20
25
30
35
40
45
50
Lig
nin
(%
w/w
)
Rhamnose
Fucose
Arabinose
Xylose
Mannose
Galactose
Glucose
GalA
lignin
LIGNIN
GLUCOSE
XYLOSEARABINOSE
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Plant selection criteriaSpecies Reason for choosing species
Mossy saxifrage Alpine Subject
Lavender Careful water management essential.
Jasminum officinale Climbing subject
Buddleia alternifolia Hardy deciduous long term crop
Pyracantha Hardy ever green long term crop.
Ceanothus Hardy ever green long term crop. Careful water management essential.
Lobelia Herbaceous Perennial - quick summer crop
Erysimum High feed requirements, perennial medium length crop. Repeat from earlier work
Dianthus Medium term Dianthus crop
Echeveria elegans Needs to be grown very dry
Phlox paniculata Outside over winter Herbaceous Perennial
Veronica Outside over winter Herbaceous Perennial
Euphorbia griffithii Outside over winter Herbaceous Perennial
Argyranthemum Pot plant crop grown on capillary matting.
Cyclamen Pot plant crop grown on capillary matting.
Anemone Problem crop due to potential corm rot - careful water management essential.
Osteospermum Problematic crop, susceptible to water logging.
Dahlia Quick bedding crop grown on capillary matting.
Gypsophila Quick, bedding crop with some watering challenges.
Lupin Seed raised over winter Herbaceous Perennial
Chaenomeles Slow, long crop, often difficult to reach required size
Hibiscus Woody, long term crop with nutritional challenges
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Lincolnshire Herbs (coriander)
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Stockbridge Violas
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Farplants: Mossy Saxifrage
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Farplants: Erysimum
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Blocking media
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Characterising the Growing Media for
basis of functionality
Industry-standard physical properties
• Moisture retention
• Water potential
• pH
• electrical conductivity
• Bulk density
• dry bulk density
• Air-filled porosity
• Particle size distribution
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B
4 3
232
4
BA
C
6
Air Porosity
Dry Bulk
Density
Moisture
Retention
5
Peat-based
collection
Very immature
Composts
Plant structure
relatively
undegraded
Completely mature
Composts with little or
no structure
1
Arrow represents
direction of loss
of structure
during composting
Fig. 5. Principal components analysis of physical properties of peat and compost-based samples. White circles: general
samples; light grey circles 1-5: compost time course over 4 months; dark grey circles: 75% compost + 25% peat samples;
black circles: peat-based products.
A
C
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C
B
4 3
232
4
BA
C
6
Air Porosity
Dry Bulk
Density
Moisture
Retention
5
Peat-based
collection
1
Fig. 5. Principal components analysis of physical properties of peat and compost-based samples. White circles: general
samples; light grey circles 1-5: compost time course over 4 months; dark grey circles: 75% compost + 25% peat samples;
black circles: peat-based products.
6x Viola 105%
Gypsophila 100%
Lavender 105%
Lobelia 93%
Anemone 130%
Dianthus 109%
Hibiscus 1:1 90%
Jasmin 103%
Cyclamen 81%
Buddleia 96%
Pyracantha 76%
Ceanothus 80%
6x Viola 92%
Gypsophila 75%
Lavender 111%
Anemone 111%
Dianthus 106%
Hibiscus 1:1 90%
Lobelia 103%
Echeveria good, shrnk
Buddleia 60%
Cyclamen 103%
2x Viola 93%
Pyracantha 55%
Ceanothus 73%
Mossy saxifrage 100%
Phlox 100+%
Erysimum 90%
Mossy saxifrage 100%
Phlox 100+%
Erysimum 92%
Mossy saxifrage 100%
Phlox 100+%
Erysimum 86%
Lobelia 94%
Viola 107%
Anemone 85%
Hibiscus 89%
3x viola 82%
A
2x Viola 99%
Gypsophila 67%
Dianthus 106%
Lavender 91%
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C
B
4 3
232
4
BA
C
6
Air Porosity
Dry Bulk
Density
Moisture
Retention
5
Peat-based
collection
1
Fig. 5. Principal components analysis of physical properties of peat and compost-based samples. White circles: general
samples; light grey circles 1-5: compost time course over 4 months; dark grey circles: 75% compost + 25% peat samples;
black circles: peat-based products.
6x Viola 105%
Gypsophila 100%
Lavender 105%
Lobelia 93%
Anemone 130%
Dianthus 109%
Hibiscus 1:1 90%
Jasmin 103%
Cyclamen 81%
Buddleia 96%
Pyracantha 76%
Ceanothus 80%
6x Viola 92%
Gypsophila 75%
Lavender 111%
Anemone 111%
Dianthus 106%
Hibiscus 1:1 90%
Lobelia 103%
Echeveria good, shrnk
Buddleia 60%
Cyclamen 103%
2x Viola 93%
Pyracantha 55%
Ceanothus 73%
Mossy saxifrage 100%
Phlox 100+%
Erysimum 90%
Mossy saxifrage 100%
Phlox 100+%
Erysimum 92%
Mossy saxifrage 100%
Phlox 100+%
Erysimum 86%
Lobelia 94%
Viola 107%
Anemone 85%
Hibiscus 89%
3x viola 82%
A
2x Viola 99%
Gypsophila 67%
Dianthus 106%
Lavender 91%
IMPACT
Output – ability to measure and control (using SI units) the key physical parameters that
determine the quality of growing media from composted food chain co-products.
2 patents granted: GB2445560 and US 8,361,171B2
One (refereed) publicationWaldron, K.W., Moates, G.K., Merali, S.R.A., Collins, D.R., Wilson, T.F., Brocklehurst, T.F., Bragg, N.C., and
Carter, S. (2013). Retaining cell wall structure in producing quality composts to replace peat as growing media.
Acta Hort. 1013: 181-188.
Most promising Innovator of 2011
New DEFRA project started 1st January 2015
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Transition to responsibly sourced
growing media use within UK horticulture
www.adas.uk
Dr Barry Mulholland (ADAS), Prof. Keith Waldron (IFR), Dr
Henri Tapp (IFR), Graham Moates (IFR), Chloe Whiteside
(ADAS) and Ryan Hickinbotham (ADAS)
Dove Associates
PAUL WALLER
CONSULTING
Susie Holmes
Consulting Ltd
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Biorefining on the Norwich Research Park
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biomass
distillation
bioalcohol
Simplified scheme for ethanol production from biomass
PretreatmentAvailable cellulose
hydrolysis sugars
fermentation alcohol
•Steam explosion
•Extrusion
•Acid/alkali
•Temperature
•Milling
•Hot solvent
•etc
•Hot acid
•Enzymatic
•Thermophilic?
•Multi enzyme
•Combination?
•Glucose
•Xylose
•Arabinose
•Uronic acid
•etc.
Problem of inhibitors
•Lignin
•Enzyme inhibitors
•Product and
metabolite inhibition
Range of fermenting
micro-organisms
•Yeasts
•Bacteria
Distillation or membrane technologies
10 x 5 x 2 x 2 x 3 x 2 = 1200 permutations (non-optimised)
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Academic partners(Environment for invention)
LIGNO-
CELLULOSEBIO-
ALCOHOL
Selection and
categorisation
Digestion and
Release of sugars
And oligosaccharides
Fermentation &
separation
Research programme: Environment for invention and innovation
FEEDBACK
CHAIN INTEGRATION
Task 3: Further
saccharification and
Fermentation
MEEP
Industrial
Bio-alcohol
Task 1: Supply and
characterise
Lignocellulosic co-
products
Provision of industrial
wastesoptimising
combustion
Task 4:
Evaluation of
Combustion
Industrial partners(environment for exploitation)
Task 2: Cell wall
disassembly
depolymerisation and
saccharification
Industrial
enzymes
Pre
treatment
HOOCH
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Straw: 500g
10% Ethanol
750-800ml
Ethanol 75-80ml
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High torque
bioreactor
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Elliston A., Faulds C. B., Roberts I. N., Waldron K. W. (2014)
Biorefining of waste paper biomass: Increasing the concentration of glucose by optimising
enzymatic hydrolysis at high substrate loads
Applied Biochemistry and Biotechnology 172 3621-3634
Elliston A., Collins S. R. A., Wilson D. R., Roberts I. N., Waldron K. W. (2013)
High concentrations of cellulosic ethanol achieved by fed batch semi simultaneous saccharification
and fermentation of waste-paper.
Bioresource Technology 134 117-126
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Impact of steam explosion on methane
production from OSR straw
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Steam explosion and biogas production at 36 hours
Vivekanand et al (2012) Bioresource Technology 123, 608-615
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Adding value to lignocellulosic
residues
• What about products other than
ethanol?
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Sugar
Source
distillation
bioalcohol
Pretreatment
hydrolysis sugars
fermentation alcohol
Conversion of Lignocellulose to ???
Different fermenter
=
Different product
co-products
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1. Four Carbon 1,4-Diacids
(Succinic, Fumaric, and Malic)
2. 2,5-Furan dicarboxylic acid (FDCA)
3. 3-Hydroxypropionic acid (3-HPA)
4. Aspartic acid
5. Glucaric acid
6. Glutamic acid
7. Itaconic acid
8. Levulinic acid
9. 3-Hydroxybutyrolactone
10. Glycerol
11. Sorbitol
12. Xylitol / Arabinitol
(Bozell and Petersen 2010)
Top 12 chemical opportunities
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High-throughput screening of
yeast biodiversityfor the production of
high value bio-based chemicals
from agri-food waste
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100 litre pilot
WHERE NEXT: chemicals from yeasts
• UK's premier collection of yeast cultures
• over 4000 strains collected over 50 years
• large collections of brewing yeast, genetically-defined
yeast (used in many applications including cancer
research), yeast associated with food spoilage and yeast
of medical and industrial importance.
• Robotic screening
systems
• Small, medium, large
scale digestion and
fermentation facilities
(Biorefinery)
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Where do yeasts in the NCYC collection originate from?
NCYC 2254: Sugar factory
NCYC 2895: Hibiscus flower
NCYC 582: Strawberry juice
NCYC 2493: Nematode worm
NCYC 2610: Fish paste
NCYC 3788: Guava plant
NCYC 3064: Apple skin
NCYC 2869: Insect frass
NCYC 3729: Banana
NCYC 3264: Lici fruit
NCYC 3391: Seawater
NCYC 546: Fruit fly
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Antarctic Yeast
• Yeast isolates sent to NCYC for
identification
• Growth temperature testing at
25°C and 1°C
• Cultures are pink and mucoid
• Synthesises carotenoid pigment
• Potential industrial applications
e.g. low temperature
biochemistry and/or source of UV
protectant molecules
Scanning electron micrograph (SEM) of a
yeast recovered from a glacier ice sample
Rhodotorula isolates grown at 1°C for 3 weeks on YM agar
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Hydrolysis
Biomass
Pretreatment
Fermentation
Purification
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Hydrolysis
Biomass (4)
Pretreatment
Fermentation
Purification
4
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Hydrolysis
Biomass (4)
Pretreatment (4)
Fermentation
Purification
16
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Hydrolysis (4)
Biomass (4)
Pretreatment (4)
Fermentation
Purification
64
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Hydrolysis (4)
Biomass (4)
Pretreatment (4)
Fermentation
(4k)
Purification
256,000
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Hydrolysis (4)
Biomass (4)
Pretreatment (4)
Fermentation
(4k)
Purification (4)
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High through-put screening
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Effect of volumeElliston et al (2015) Biotechnology for Biofuels
OK – but what about lignocellulose?
– it is solid!!!!
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Repeatable aliquoting of finely milled biomass
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19
8
11
17
16
10
13
9
18
3
1 7
valine
15
1412
4
ethanol
6
5
2
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0
1E+10
2E+10
3E+10
4E+10
5E+10
6E+10
7E+10
8E+10
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76 79 82 85 88 91 94 97
NM
R in
ten
sity
Low producers
Ethanol
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0
1E+09
2E+09
3E+09
4E+09
5E+09
6E+09
7E+09
8E+09
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76 79 82 85 88 91 94 97
NM
R in
ten
sity
Low producer
High producer
Succinic acid
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co-products
Sugar
Source
distillation
bioalcohol
Pretreatment
hydrolysis sugars
fermentation alcohol
RESIDUE???
co-products
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dry bulk
density
air-filled
porosity
moisture
retention
Little structure Over-structured
190oC
195oC
200oC
180oC
210oC
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Horticultural Trials
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Bioethanol production from duckweed
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A high productivity
BACKGROUND
• Dry mass of 20 t ha-1 y-1 in 25 m2 lagoon Culley et al. 1981. J World Mariculture Soc. 12,27-
49.
• 105 t ha-1 y-1 was harvested in waste
water system.Xu et al. 2012. Biofuels. 3,589-601.
• Other potential energy crops:
willow 10 t ha-1 y-1,
poplar 9 t ha-1 y-1,
switchgrass 12 t ha-1 y-1
World Watch Institute. London: Earthscan; 2007.
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Acknowledgements• Ian Wood
• Sam Collins
• David Wilson
• Graham Moates
• Adam Elliston
• Peter Ryden
• Henri Tapp
• Klaus Wellner
• Zara Merali
• Xin Zhao
• Ian Roberts
• Jo Dicks
• Ian Bancroft
• Andrea Harper
• David Boxer
• David Richardson
• BBSRC
• Defra
• Innovate UK
• EEDA
• EU