Michael Ladisch+

Laboratory of Renewable Resources EngineeringAgricultural and Biological Engineering

Weldon School of Biomedical EngineeringPurdue University

West Lafayette, IN 47907-2022

Corn UtilizationNew Technology for New Uses

+ Chief Technology Officer, Mascoma Corporation

Acknowledgements

Indiana Corn Marketing Council Ryan West

National Corn Growers Association Gary Niemeyer

Mascoma Corporation Frank Agbogbo, Kevin Wenger

Purdue University Youngmi Kim, Eduardo Ximenes, Nathan Mosier

US Agricultural Productivity

OutputInputTotal Factor Productivity

1948 1978 2008

3.0

2.0

1.0

0.0

Source: USDA ERS

Indices 1948 = 1

1.65 Bn Bu

NCGA, 2012 World of Corn Report

US Corn Usage by Segment, 2011 Crop value of $ 76.6 Billion

How do we add more value? Examples (from CUTC 2012)

BiotechnologyEnzyme technologyBioprocessingMimetics

Chemical Building Blocks

better corn, better uses & biorefineries

Hydrolysis

Starch GlucoseEnzymes

Sugars are starting feedstock for biochemical and chemical conversion

6

INTRODUCTION TO MGT YEAST

Yeast

Wet cake

Syrup

Evaporator

Dryer

CentrifugeDistillation

Jet cookerLiquefactionSlurry

Fermentation

Backset

Ground corn

CO2

Fuel Ethanol

Distillers dried grains (DDGS)

Thin stillage

Whole stillage

Alpha-amylase

Gluco-amylase (GA)MGT

X

Preview from CUTC presentation of Frank Agbogbo, Mascoma

7

INTRODUCTION TO MGT YEAST

Polymeric Sugars Mascoma CBP

Soluble Sugars

Yeast

Yeast-Secreted Enzymes

Added Enzyme

Ethanol

Chemicals

Fuels

• Yeast makes its own glucoamylase (GA) as it grows• This leads to less sugar stress on the yeast during fermentation

Preview from CUTC presentation of Frank Agbogbo, Mascoma

Glucose Converted to Levulinic Acid (Precursor for Polymers) via chemical catalysis

Bozell and Petersen, 2010

Glucose

Levulinic

Precursors, chemical building blocks

Platform Chemicals from Sugars

Bozell and Petersen, 2010

Sugar derived platform chemicals include

Hydroxymethylfurfural(HMF) Furfural Levulinic acid γ-valerolactone

Catalytic conversion to alkanes, and to precursor molecules for use in production of polymers, lubricants, and herbicides.

Catalytic conversion uses high concentrations of glucose

Chemical building blocksHydrocarbon fuels

Achieving high glucose concentrations

Pre-process corn kernels into solid fractions

Starch

Germ (oil)

Pericarp (fiber)

Separate by gravity to concentrate feedstocks

Then hydrolyze and process into value added components

Use enzyme science and engineering derived from biomass conversion research.

Untreated Corn Kernels

Preview from CUTC poster of Youngmi Kim, Purdue University

Enzyme Treated Corn Kernels

Preview from CUTC poster of Youngmi Kim, Purdue University

Germs and Starch in Slurry

Germ floating on top Starch precipitated at bottom

Work is just beginning

Preview from CUTC poster of Youngmi Kim, Purdue University

Concept of a Biomimetic Catalyst for Chemical Catalysis

downsizing

MW 55kD

active site

Cellulolytic Enzyme

downsizing

Thousands Daltons

active site

Cellulolytic Enzyme Biomimetic Catalyst

Active site only; residue carboxylate pair retained

Hundred Daltons

Superior Catalysis with minimal sugar degradation

Preview from CUTC presentation of Nate Mosier, Purdue University

Partnerships

Chemical enterprise (exports of $ 86.9 billion, 2011). Possible partnerships based on

1. discovery of new processes based on sugars 2. research on utilization of renewable resources 3. business models based on products from

agricultural (particularly cellulosic) commodities

US Agriculture (net balance of trade of $43 billion, 2011; projected $24 billion in 2012) 1. design / grow crops for value-add chemicals

2. continue improvements in productivity 3. business models for year round supply

4. Industrial fermentation capacities

CCR, 2012

New technology enhances marginsFrom 1 bushel of corn (15% MC, 75% starch)

Assumptions: Glucose yield: 100% from starch; Enzyme: 0.2% w/w of inlet solid;Enzyme cost: $15/lb; Water: $0.07/gal; Corn: $6.9/bushel; Ethanol: $2.5/gal; DDGS: $180/ton;Levulinic acid: $5/lb; Levulinic acid yield from hexose sugar: 50%

Corn to ethanol

Corn to levulinic

acid

4

83.

Economic Synergies

Agriculture is market for: Seeds Fertilizers

Pesticides / herbicides

Agriculture provides hedge for some feedstocks needed by chemical enterprise

Oil Carbohydrates, chemical feedstocks Cellulosics

Fermentation substrates

Translation of science from discovery to commercial scale is critical: requires sustained research and development

CCR, 2012

ConclusionsNew technology for value-added products from corn opens a new

frontier.

Utilize biotechnology, chemical catalysis and the chemical enterprise. New tools make the difference.

Resources are available to produce both food and chemicals through corn:

1. Land 2. Seeds. 3. Productivity

Combined impact could be to reduce feedstock risk for chemical industry, produce biofuels, and reduce petroleum imports.