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DOE OSTI2023

Biochemical Process Modeling and Simulation (BPMS)

The Biochemical Process Modeling and Simulation project aims to reduce the cost and time of research by applying theory, modeling, and simulation to the most relevant bottlenecks in the biochemical process. We use molecular modeling, quantum mechanics, metabolic modeling, fluid dynamics, and reaction-diffusion methods in close collaboration with pretreatment, hydrolysis, upgrading, and TEA. The project's outcomes are increased yields and efficiency of the biochemical process, added value to products, and reduced price of fuels by specifically targeting catalytic efficiency, reactor design, enzyme efficiency, and microbial design. We work closely with experimental projects to identify problems and iterate with experiments to find and refine solutions. By working with experimentalists, we decide on problems that can be solved with simulation that could otherwise not be solved or would take too long with experiment alone to reach BETO's targets. Over the years, we have produced solutions that have resulted in determining the most likely fatty-acid derivative for passive transport out of bacteria that upgrade biomass, and we have also designed enzyme mutations for enhanced lignin upgrading. Metabolic models have been developed to tune the activity of 2,3 butanediol production for the 2030 target. A computational method to deliver understanding of how complex omics data can be interpreted in the metabolic pathways of organisms used in the Agile Biofoundry. We have found methods to overcome specific barriers and continue to develop those methods. Our reactor studies have guided the design of both the microbes and reactors for aerobic and micro-aerobic production at all scales and have been instrumental in improving the accuracy of techno-economic analysis models. This project is essential in the process of selecting the final processes for 2030 SAF production targets. More specifically, recently, we have: 1) Predicted the strength of the basic structural interactions in commodity plastics to provide guidance for plastics upcycling strategies. 2) Developed computational tool to improve the characterization of lignin-derived compounds 3) Developed new methodologies to enable Machine Learning-based Directed Evolution for protein engineering. 4) Developed Machine Learning methods to predict protein promiscuity and mutations to further improve microbial and enzymatic driven processes and demonstrated the utility of ML approaches to engineering proteins from sparse experimental datasets. 5) Developed new methods to enable high-fidelity simulation of aerobic fermentation at industrial scale and resolving mismatch of time scales through subcycling/operator splitting 7) Identified the difficulty in preventing local high-oxygen conditions in industrial bubble columns, which leads to less-desirable acetoin production, suggesting future research directions in alternative reactor configurations (e.g loop reactors, shallow-channel reactors).

BIOMASS FUELS↗

DOE OSTI2017

Current Problems and Solutions for the Long-term Storage of LLW in Germany - 17512

The primary aim of the Lower Saxony regulating authority is that all radioactive waste in long-term interim storage is made safe and their contents precisely documented. The requirements for regulating authority include: documentation, recovery, inspection, reconditioning, longer-term interim storage with full accessibility for inspection and transfer to the national disposal facility. The waste acceptance requirements of the disposal site Konrad as well as requirements for the interim storage facilities have to be met for all stored waste packages. Beside this, some challenges came up in the last few years, e.g. waste products with restrictions concerning the stability because of corrosion, fouling or fermentation processes. Some of these examples are shown. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Analysis of countercurrent membrane vapor extraction of a dilute aqueous biosolute

Removal of dilute bioproducts from fermenter broths is a major challenge both to avoid microbe inhibition and to recover solutes economically without water loss. We analyze a proposed new process, membrane vapor extraction (MVE), where semi-volatile dilute aqueous solutes vaporize at the upstream side of an omniphobic, microporous membrane and dissolve into a nonpolar solvent highly favorable to the solutes but not to water. A new membrane-process analysis is outlined and applied to the countercurrent recovery of 2 wt % aqueous butanol by a prototype solvent (dodecane) at 40°C. Thermodynamic phase equilibria, pioneered by the Prausnitz school, are crucial to MVE process design. Over 90% of the feed butanol is recovered with essentially no water loss giving a separation factor of over 1000. Energy requirements in MVE are low. In this study, our design calculations demonstrate that MVE is a viable separation process to remove and recover dilute aqueous biosolutes.

mass-transfer resistance↗

DOE OSTI2020

An Arduino based automatic pressure evaluation system to quantify growth of non‐model anaerobes in culture

Abstract Measuring the growth rate of non‐model anaerobic microbes typically requires the use of time‐consuming and often destructive manual measurements. Here, an Arduino based automatic pressure evaluation system (A‐APES) was developed to automatically measure the rate of fermentation gas production as a proxy for microbial growth in anaerobic systems. The A‐APES system measures accumulated gas pressure in sealed cultures accurately at high‐resolution, while venting the system at programmed intervals to prevent over pressurization. The utility of A‐APES is demonstrated in this study by quantifying the growth rate and phases of a biomass‐degrading anaerobic gut fungus, which cannot be otherwise measured via conventional techniques due to its association with particulate substrates. Given the utility of the A‐APES approach, we provide a complete construction guide to fabricate the device, which is three times less expensive compared to existing commercial alternatives.

Wilken, St. Elmo↗

DOE OSTI2023

Investigation of the effects of ternary deep eutectic solvent composition on pretreatment of sorghum stover

Biomass‐derived deep eutectic solvents (DESs) have been introduced as promising pretreatment and fractionation solvents because of their mild processing conditions, easy synthesis, and green solvent components from biomass. In recent DES studies, solvent‐based third constituents like water, ethanol, and others improve the processibility of typical binary DESs. However, the impacts of these components are not well understood. Here, two solvent‐based constituents, including water and ethylene glycol, were applied to 3,4‐dihydroxybenzoic acid (DHBA)‐based DES system for improving the conversion efficiency of cellulose‐rich fraction and the properties of lignin fraction. Chemical composition, enzymatic digestibility, degree of polymerization of cellulose and physicochemical properties of lignin were used to evaluate the impact of each third constituent on biomass processing. Ternary ChCl‐DHBA DESs exhibited better performances in delignification, fermentable sugar production, and preservation of β‐O‐4 ether linkage in lignin compared with binary ChCl‐DHBA DES.

09 BIOMASS FUELS↗

DOE OSTI2024

Simultaneous optimization of simulated moving bed adsorption and distillation for 2,3‐butanediol recovery

Abstract A combined simulated moving bed (SMB) and distillation separation scheme is developed to recover 2,3‐butanediol (BDO) from a dilute fermentation broth. The scheme was integrated into a lignocellulosic biorefinery that produces hydrocarbon fuels from corn stover with BDO as an intermediate. BDO recovery is one of the most challenging processes in this biorefinery; and given the high associated energy duties, direct distillation is considered cost‐prohibitive. An alternative separation is SMB adsorption in nanoporous materials, which can reject 90% of the water and reduce subsequent distillation costs. Rigorous models were used to optimize the SMB and distillation simultaneously. The separation can be added to the biorefinery while keeping the projected minimum fuel selling price (MFSP) below $0.66 USD (US dollars) per liter gasoline‐equivalent ($2.50/GGE, gallon gasoline equivalent). Finally, sensitivity analyses were conducted to assess the effects of cost and lifetime of the adsorbent, titer concentration, and BDO purity.

09 BIOMASS FUELS↗

DOE OSTI2025

An argument for using anaerobes as microbial cell factories to advance synthetic biology and biomanufacturing

Anaerobes thrive in the absence of oxygen and are an untapped reservoir of biotechnological potential. Therefore, bioprospecting efforts focused on anaerobic microbial diversity could rapidly uncover new enzymes, pathways, and chassis organisms to drive biotechnology innovation. Despite their potential utility, anaerobic fermenters are viewed as inefficient from a biochemical perspective because their metabolisms produce fewer ATP (~2) per molecule of glucose processed than heterotrophic respirers (~32–38 ATP). While aerobes excel at ATP generation, they are often less efficient than anaerobes at processes that compete with ATP generation for cellular resources. This perspective highlights how anaerobic adaptations are advantageous for synthetic biology and biomanufacturing applications through the engineering of microbial cell factories. We further highlight emerging applications of anaerobic bioprocessing, including the use of anaerobic metabolisms for lignocellulosic bioprocessing, human and environmental health, and value-added bioproduction.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Reshaping the 2‐Pyrone Synthase Active Site for Chemoselective Biosynthesis of Polyketides

Abstract Engineering enzymes with novel reactivity and applying them in metabolic pathways to produce valuable products are quite challenging due to the intrinsic complexity of metabolic networks and the need for high in vivo catalytic efficiency. Triacetic acid lactone (TAL), naturally generated by 2‐pyrone synthase (2PS), is a platform molecule that can be produced via microbial fermentation and further converted into value‐added products. However, these conversions require extra synthetic steps under harsh conditions. We herein report a biocatalytic system for direct generation of TAL derivatives under mild conditions with controlled chemoselectivity by rationally engineering the 2PS active site and then rewiring the biocatalytic pathway in the metabolic network of E. coli to produce high‐value products, such as kavalactone precursors, with yields up to 17 mg/L culture. Computer modeling indicates sterics and hydrogen‐bond interactions play key roles in tuning the selectivity, efficiency and yield.

Zhou, Yu↗

DOE OSTI2022

Reshaping the 2‐Pyrone Synthase Active Site for Chemoselective Biosynthesis of Polyketides

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Harnessing the potential of oilcane waste mud for recovering biobased waxes

Abstract Oilcane is an engineered sugarcane with the ability to hyper‐accumulate vegetative lipids. It is processed to obtain juice and bagasse as a potential substrate for the production of biofuels and biochemicals. The juice comprises solid particles that are separated as waste mud before the fermentation of the juice. In this study, the oilcane waste mud (OWM) generated from 1000 liters of oilcane juice was quantified and evaluated as a potential resource for recovering biobased waxes. Hexane and ethyl acetate were evaluated as two different solvents for extracting waxes from OWM followed by its purification using acetone. The extracted biobased wax samples were characterized for their chemical and thermal profiles which were then compared with commercial natural waxes. Detailed mass balance shows that 53.6 ± 2.6 kg (dry basis) of solid OWM gets generated upon processing 1000 L (~1068 kg) of oilcane juice. Hexane and ethyl acetate led to a crude wax yield of 25.6 ± 0.2% and 16.6 ± 0.4% (wt/wt, dry basis) respectively from OWM at the end of 8 h. The relative purification of the wax samples was reported in the range of 58%–65% (wt/wt). The purified OWM wax has a melting point of 74.7°C. The waste mud was valorized as a source of biobased waxes with characteristic chemical and thermal profiles comparable to commercial natural waxes (carnauba and beeswax). Considering the decline in the supply of petroleum wax in the future coupled with the switch to “greener” alternative products by consumers, OWM could be a valuable source of natural wax in the industrial sector reducing the dependence on petroleum waxes. Eventually, recovering biobased wax as a co‐product from OWM would bring in an additional stream of revenue leading to the development of a zero‐waste biorefinery based on bioenergy crops.

09 BIOMASS FUELS↗

DOE OSTI2016

Techno-economic analysis of biodiesel and ethanol co-production from lipid-producing sugarcane: Biodiesel and Ethanol Co-Production from Lipid-Producing Sugarcane

Biodiesel production from vegetable oils has progressively increased over the past two decades. However, due to the low amounts of oil produced per hectare from temperate oilseed crops (e.g. soybean), the opportunities for further increasing biodiesel production are limited. Genetically modified lipid-producing sugarcane (lipid-cane) possesses great potential for producing biodiesel as an alternative feedstock because of sugarcane’s much higher productivity compared with soybean. In this study, techno-economic models were developed for biodiesel and ethanol coproduction from lipid-cane, assuming 2, 5, 10, or 20% lipid concentration in the harvested stem (dry mass basis). The models were compared with a conventional soybean biodiesel process model to assess lipid-cane’s competiveness. In the lipid-cane process model, the extracted lipids were used to produce biodiesel by transesterifi cation, and the remaining sugar was used to produce ethanol by fermentation. The results showed that the biodiesel production cost from lipid-cane decreased from $0.89/L to $0.59 /L as the lipid content increased from 2 to 20%; this cost was lower than that obtained for soybeans ($1.08/L). The ethanol production costs from lipid-cane were between $0.40/L and $0.46/L. The internal rate of return (IRR) for the soybean biodiesel process was 15.0%, and the IRR for the lipid-cane process went from 13.7 to 24.0% as the lipid content increased from 2 to 20%. Because of its high productivity, lipid-cane with 20% lipid content can produce 6700 L of biodiesel from each hectare of land, whereas soybean can only produce approximately 500 L of biodiesel from each hectare of land. This would indicate that continued efforts to achieve lipid-producing sugarcane could make large-scale replacement of fossil-fuel-derived diesel without unrealistic demands on land area.

09 BIOMASS FUELS↗

DOE OSTI2017

Strengths, challenges, and opportunities for hydrothermal pretreatment in lignocellulosic biorefineries

Pretreatment prior to or during biological conversion is required to achieve high sugar yields essential to economic production of fuels and chemicals from low cost, abundant lignocellulosic biomass. Aqueous thermochemical pretreatments achieve this performance objective from pretreatment coupled with subsequent enzymatic hydrolysis, but chemical pretreatment can also suffer from additional costs for exotic materials of construction, the need to recover or neutralize the chemicals, introduction of compounds that inhibit downstream operations, and waste disposal, as well as for the chemicals themselves. The simplicity of hydrothermal pretreatment with just hot water offers the potential to greatly improve the cost of the entire conversion process if sugar degradation during pretreatment, production of un-fermentable oligomers, and the amount of expensive enzymes needed to obtain satisfactory yields from hydrothermally pretreated solids can be reduced. Biorefinery economics would also benefit if value could be generated from lignin and other components that are currently fated to be burned for power. However, achieving these goals will no doubt require development of advanced hydrothermal pretreatment configurations. For example, passing water through a stationary bed of lignocellulosic biomass in a flowthrough configuration achieves very high yields of hemicellulose sugars, removes more than 75% of the lignin for potential valorization, and improves sugar release from the pretreated solids with lower enzyme loadings. Unfortunately, the large quantities of water needed to achieve this performance result in very dilute sugars, high energy costs for pretreatment and product recover, and large amounts of oligomers. Furthermore, improving our understanding of hydrothermal pretreatment fundamentals is needed to gain insights into R&D opportunities to improve performance, and help identify novel configurations that lower capital and operating costs and achieve higher yields.

09 BIOMASS FUELS↗

DOE OSTI2018

Using steam explosion or AFEX™ to produce animal feeds and biofuel feedstocks in a biorefinery based on sugarcane residues: Using Steam Explosion or AFEX™ to Produce Animal Feeds and Biofuel Feedstocks in a Biorefinery Based on Sugarcane Residues

Sustainable integration of biofuel (primarily bioethanol) and highly digestible livestock feed in production systems is a potential way to increase the economic returns to agriculture and simultaneously promote energy security, particularly in developing countries. In this work we evaluated the efficacy of steam explosion (StEx) and ammonia fiber expansion (AFEX™) as potential processes for improving the in vitro rumen digestibility, metabolizable energy, and ethanol yields from sugarcane crop residues (bagasse and cane leaf matter, CLM). Ammonia fiber expansion pretreatment enhanced the in vitro true digestibility and metabolizable energy content of sugarcane crop residues by 69% and 26%, respectively compared to untreated controls. On the other hand, StEx increased the true digestibility and metabolizable energy content of the sugarcane residues by 54% and 7%, respectively. Ammonia fiber expansion also increased the total nitrogen content of both sugarcane bagasse and CLM to more than 20.2 g kg -1 dry forage, a more than 230% improvement relative to untreated controls. High solid-loading enzymatic hydrolysis and fermentation of StEx- and AFEX™-pretreated sugarcane crop residues generated yields of up to 3368 and 4360 L of ethanol per hectare of sugarcane cultivated, respectively, at a biomass-degrading enzyme dosage of 20 mg protein per gram glucan. This research strongly suggests that the use of suitably pretreated sugarcane crop residues in integrated sugarcane biofuel-livestock production systems can increase the total per hectare agricultural output without increasing the area of sugarcane cultivated. In effect, this integrated approach promotes more sustainable biofuel production and increased food production while avoiding the potential for indirect land use change.

09 BIOMASS FUELS↗

DOE OSTI2019

Techno‐economic and greenhouse gas analyses of lignin valorization to eugenol and phenolic products in integrated ethanol biorefineries

Abstract This work presents techno‐economic and greenhouse gas (GHG) analyses of an ethanol biorefinery integrating lignin conversion into eugenol and other phenolics. Catalytic hydrogenolysis assisted by isopropanol (IPA) is used to convert the lignin recovered after ionic liquid (IL) pretreatment, saccharification, and fermentation. This process was compared to a biorefinery using lignin for energy generation and simulated in SuperPro Designer. Spatial analysis was performed to determine biorefinery locations and capacities in a Mexican state with potential for lignocellulosic biomass, including corn stover, sorghum stubble, and Jatropha fruit shells. Relative to the base case, diverting 50% of lignin to phenolics decreased the ethanol cost of production significantly due to the high market value of the co‐products. The minimum ethanol selling price (MESP) for this case was $2.02 gal −1 . The resulting cradle‐to‐gate GHG footprint of bioethanol was 21 g CO 2 ‐eq MJ −1 , a 78% reduction with respect to gasoline when system expansion is used for allocation. Using market value‐based allocation resulted in 82% GHG reduction. Analysis of scenarios showed that a biorefinery processing 3000 t day −1 biomass and diverting 80% of lignin to phenolics can potentially yield an MESP lower than $1.5 gal −1 . To achieve this, research should target a reduction in IL input by 30% and IPA input by 40%, together with more energy‐efficient separation processes. The reduction in IL and IPA can be achieved by decreasing their loading rates and increasing recycling. Sensitivity analysis showed that, for biomass prices higher than $45 t −1 , biorefinery capacities must exceed 5000 t d −1 biomass input. © 2019 Society of Chemical Industry and John Wiley & Sons, Ltd

Martinez‐Hernandez, Elias↗

DOE OSTI2022

Techno‐economic assessment of single‐stream feedstock logistics supply chain for corn stover and grain

Abstract The state‐of‐technology for corn stover harvest is a multi‐pass system that collects the stover after grain harvest. An alternative is a single‐stream system where the grain and stover are harvested as a bulk material co‐stored and preserved by anerobic fermentation, and finally, co‐transported to a biorefinery. In the present work, four single‐pass whole‐plant bulk systems were compared with a conventional multi‐pass bale system. The single‐stream systems consisted of the harvest of corn grain and a portion of the stover fraction. Four machine configurations were simulated. This work predicted that a multi‐pass bale system would result in a material cost of 111.80 $2021 Mg –1 stover DM delivered to the biorefinery gate. Alternatively, the lowest cost single‐stream system was the self‐propelled forage harvester (SPFH) configured with the whole‐plant header, which delivered feedstock for 74.76 $2021 Mg stover DM –1 . In addition to machine configuration, a sensitivity analysis was performed to understand important drivers of feedstock cost. These analyses revealed that feedstock cost increased with moisture content, fertilizer price, and biorefinery size, and decreased with harvest season length, crop yield, and grower participation. This work demonstrated that single‐stream systems could reduce corn stover feedstock costs in comparison with state‐of‐technology systems. © 2022 The Authors. Biofuels, Bioproducts and Biorefining published by Society of Industrial Chemistry and John Wiley & Sons Ltd.

09 BIOMASS FUELS↗

DOE OSTI2025

Carbon‐negative hydrogen from ethanol via catalytic oxidative reforming

Abstract This study evaluated a commercial technology for producing low‐ or negative‐carbon hydrogen through ethanol catalytic oxidative reforming, focusing on the life cycle greenhouse gas emissions, or carbon intensity (CI). Various scenarios were analyzed: (a) comparing corn ethanol (first‐generation or Gen1 ethanol) and cellulosic ethanol (second‐generation or Gen2 ethanol) as feedstocks; (b) assessing carbon capture and sequestration (CCS) for CO 2 from upstream fermentation; and (c) evaluating oxygen sourcing via air separation units vs. on‐site or off‐site water electrolysis using a proton exchange membrane. Findings indicate that the CI for hydrogen production using Gen2 ethanol from corn stover is lower than that of Gen1 corn ethanol. Additionally, using proton exchange membrane‐generated oxygen results in a lower CI than air separation unit‐generated oxygen, regardless of the sourcing method. Implementing CCS for the hydrogen production plant's evolved CO 2 is essential for achieving a net‐negative CI for hydrogen from Gen1 ethanol. All examined scenarios, including both ethanol generations, oxygen sources, and CCS applications, demonstrated a net‐negative carbon intensity, surpassing the life cycle greenhouse gas emissions threshold of 0.45 kg CO 2 e/kg to enable policy credits as outlined in the Inflation Reduction Act §45V. In comparison, the CI for hydrogen from steam methane reforming stands at 3.4 kg CO 2 e/kg with CCS and 9.4 kg CO 2 e/kg without CCS.

08 HYDROGEN↗

DOE OSTI2026

Harnessing plant‐based platform for low‐cost cellulosic sugar recovery from bioenergy crops

The price of pure cellulase enzyme for the recovery of fermentable cellulosic sugars is one of the major challenges that limit the commercialization of second-generation biofuels and bio-based products. This work shows a means to greatly reduce the cost of cellulases. The abundant capacity of plants to synthesize and hyperaccumulate transgenic proteins in their plastids has been demonstrated for two gene constructs using either NPT II or Tet C to regulate the expression of bacterial cellulase Cel6A. Previously, the expression of Cel6A to 20–35% of total soluble leaf protein in tobacco was shown in two consecutive field trials. Moving forward, the key challenge was the extraction of active enzymes from the transgenic tobacco leaves hyperaccumulating bacterial cellulases in a cost-effective manner. The study showed that unpurified crude extracts of NPT II and Tet C transgenic tobacco leaves recovered ~23% and ~29% w/w cellulosic sugars from energycane bagasse, respectively. A supplementation of as low as 25% of purified commercial cellulase improved the glucose recovery by 2.9 times (~85% w/w) compared to 100% crude extract, which is comparable to the glucose recovery obtained by commercial cellulases, thereby suggesting a reduced requirement of commercial cellulases leading to a cost reduction of 75% for biorefineries. Assuming a stable 40% cellulase yield in total soluble protein under field conditions and multiple harvests (one to three) a year, the study estimates that the potential cost for saccharification of 1 t of lignocellulosic biomass can be reduced to 67–200 USD by using crude leaf extracts of transgenic tobacco.

biofuel↗

DOE OSTI2019

The Transcriptome and Flux Profiling of Crabtree-Negative Hydroxy Acid-Producing Strains of Saccharomyces cerevisiae Reveals Changes in the Central Carbon Metabolism

Saccharomyces cerevisiae (S. cerevisiae) is the yeast cell factory of choice for the production of many biobased chemicals. However, it is a Crabtree-positive yeast and so shuttles a large portion of carbon into ethanol. Ethanol formation can be eliminated by deleting pyruvate decarboxylase (PDC) activity. It is not yet well understood how PDC-negative yeasts are affected when engineered to produce other products than ethanol. In this study, pathways are introduced for the production of three hydroxy acids (lactic, malic, or 3-hydroxypropionic acid [3HP]) into an evolved PDC-negative strain. These strains are characterized via transcriptome and flux profiling to elucidate the effects that the production of these hydroxy acids has on the host strain. Expression of lactic and malic acid biosynthesis pathways improved the maximum specific growth rate (μ max ) of the strain by 64% and 20%, respectively, presumably due to nicotinamide adenine dinucleotide regeneration. All strains show a very high flux (> 90% of glucose uptake) into the oxidative pentose phosphate pathway under batch fermentation conditions. The study, for the first time, directly compares the flux and transcriptome profiles of several hydroxy acid-producing strains of an evolved PDC-negative S. cerevisiae and suggests directions for future metabolic engineering.

13C-based metabolic flux analysis↗