C1-Gas Fermentation for fuel and
chemical production at scale
Dr. Christophe Mihalcea
Director Fermentation
2014 LanzaTech. All rights reserved.
Use Carbon where Required
A 2-degree carbon budget will require countries to leave
80 % of coal, 50 % of gas and 33 % of global oil untouched.
The LanzaTech Process is Driving Innovation
Novel gas fermentation
technology captures CO-rich
gases and converts the carbon
to fuels and chemicals
Proprietary
Microbe
Gas Feed Stream
Gas Reception
Compression
Fermentation
• Process recycles waste carbon into fuels
and chemicals
• Process brings underutilized carbon into
the fuel pool via industrial symbiosis
• Potential to make material impact on the
future energy pool (>100s of billions of
gallons per year)
Recovery
Product
Tank
Company Profile
• Founded in January 2005 in Auckland, NZ
• New Global HQ in Chicago, IL
• Operations in US, NZ, China, Taiwan, India
• Funding
– Series A: Khosla Ventures - $US 12M in 2007
– Series B: Qiming Ventures - $US 18M in 2010
– Series C: Burrill MLSCF - $US 60M in 2012, Petronas as Strategic Investor
– Series D: Mitsui & Co.- $US 60M in 2014, Mitsui and Siemens as Strategic Investor
• Team
CEO: Dr. Jennifer Holmgren
CSO/Founder: Dr. Sean Simpson
– Over 100 staff
• IP Portfolio
– >250 Patents pending; 100 granted
– 3 proprietary microbe families
4
Waste carbon streams as a Resource
Industrial
Waste Gas
Biogas
Solid Waste
Steel, PVC, Ferroalloys
LFG, Methane
Industrial, MSW, DSW
~184.2T M3 *
>2B MTA *
~ 1.4B MTA (Steel only) *
Reforming
CO
CO + H2
Biomass
CO2
>1.3B MTA (US Alone) *
Gasification
CO + H2 + CO2
Renewable H2
CO2 + H2
CO2 + H2O + e-
Gas Fermentation
 Available
High Volume/Low Intrinsic Value
 Non-Food
*2010 global production; 2012 proven gas reserves data (IEA, UNEP, IndexMundi, US DOE Billion Ton Update)
Renewable
Electricity
Most Point Sourced
Steel Gases: 300Bn Gal Ethanol Capacity
Iceland
RUSSIA
1,830
USA
W. EUROPE
925
4,870
United
States
Russia
Kazakhistan
E. EUROPE
CHINA
S. KOREA
10,800
1,270
China
1,300
Mexico
JAPAN
Thailand
BRAZIL
INDIA
955
Brazil
3,750
Indonesia
1,315
Australia
Argentina
Country
Potential Ethanol Production Capacity (MMGPY)
Steel Mills (>5 MT/year)
TOTAL
27,015 MMGPY
6
Why does it matter?
CO2
5.2 barrels of gasoline
are displaced by every
tonne of ethanol
produced
1 tonne ethanol produced
as CO averted from flare
The LanzaTech Process
Gas Feed Stream
Gas reception CompressionFermentation
CO
Recovery Product
tank
Per tonne of LanzaTech Ethanol
CO2 MT
kg PM
kg NOx
Averted from flare
2.1
0.6
4.1
Displaced gasoline
+0.5
+2.5
+7.4
Energy required for
LanzaTech Process
-0.8
-0.2
-0.8
Avoided per
tonne of ethanol
1.8
2.9
10.7
LanzaTech Ethanol Life Cycle Assessment
Third Party Study – EU Basis
LanzaTech ethanol achieves a 76.6%
reduction in greenhouse gas emissions
over baseline fossil fuel
Lifecycle GHG emissions following RED methodology
90
83.8
80
70
• Cradle-to-pump lifecycle of ethanol
60
• EU’s Renewal Energy Directive methodology
• BOF gas considered as waste gas by steel
industry and as residue by RSB.
• GHG emissions for LanzaTech ethanol from
steel mill waste gas (BOF)
gCO2e/MJ
Key Assumptions:
50
40
30
19.6
20
10
0
Fossil Fuel
LanzaTech Ethanol
Fossil fuel comparator emissions (83.8 gCO2eq/MJ) from EU’s
FQD
Broader Environmental Impact
NOx
&
Particulates
LanzaTech Process emits ~40%
less NOx and ~80% fewer particulates
than electricity generation per MJ
energy recovered
Steel production
Electricity
Generation
Steel Mill
Waste
Gases
Electricity
Grid
LanzaTech Process emits
33% less CO2 than
electricity generation per
MJ energy recovered
LanzaTech
Process
Ethanol
Gasoline Pool
Carbon is Only Part of the Story
Steel Mill Value Proposition
0.18
US$/Cubic Meter Gas
0.16
0.14
0.12
0.1
0.08
0.06
0.04
0.02
0
Power
Ethanol
LanzaTech business case:
• Providing 2x More returns from fuel than from electricity
10
Proprietary Acetogenic Biocatalyst
 Acetogenic bacterium with ability to utilize gases as sole energy and carbon source
– CO
– CO+H2 or CO+CO2+H2
– CO2+H2
 LanzaTech has developed a proprietary
strain of Clostridium autoethanogenum
 Main Fermentation products are Ethanol
and 2,3-Butanediol
 Obtained by extensive natural selection program, having improved characteristics over parent
– High gas uptake and ethanol production rates
– Fast growth on defined minimal media
– Non-sporulating and non-motile
1
 Sequencing revealed several variations
to parent
Deletion
Variation
Insertion
Rearrangement
11
Integrated Process-wide Models in place
Strain
Genome scale model
development
• >1000 metabolic reactions
• >1000 metabolites
• Manually curated
• Validated against lab/plant data
Process
automation
Reactor design
Hydrodynamic model
Flux model
Genome scale model
•
•
•
Optimized flux to desired
products
Elimination of side products
Max yield predictions
•
•
•
•
•
Delivery of gas to the microbe
Tailoring reactor design to gas supply
Balancing growth and production
Gas and product sensitive prediction
Enables programmable operation
12
The LanzaTech Process: Ready for Deployment Today
Gas fermentation technology
converts
C-rich gases to fuels and
chemicals
Gas Feed Stream
Proprietary
Microbe
Gas Reception Compression Fermentation
Recovery
40,000 combined hours on stream
Multiple runs exceeding 2000 hours
Multiple plants at various scales
demonstrating different key aspects of process
Product
Tank
Pre commercial steel mill demonstrations
 Performance milestones
exceeded
 First commercial in design; fully
financed in China
Exceeded design capacity
Local chemicals, water
Shougang
WBT (CSC/LCY)
Mitigating Scale up Risk through
Successful Technology
Demonstration
Bao
Glenbrook
MSW to fuel
Pilot plant at gasification site
Project overview
LanzaTech has a two year partnership with a major Asian chemical company to convert livefeeds of syngas produced from municipal solid waste (MSW) into ethanol.
LanzaTech has designed, installed, and operates a pilot plant producing ethanol at a
MSW processing facility.
15
Continuous stable ethanol production from MSW
Gas utilization
efficiencyR1
Target Target
1
3
•
•
•
•
6
9
Time [days]
12
Ethanol
OD
EtOH, HAc ,Concentration
Acetate
Gas Utilization [%]
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
15
0
1
2
3
4
5
6
7
Time [Days]
8
9
10
11
12
Continuous with live feeds of MSW Syngas proven
Operation at commercial ethanol production rates and yields
Gas utilization efficiency exceeds 90%
All gas contaminant and variability issues understood and overcome.
LanzaTech is the only company to demonstrate continuous fuel production from
MSW syngas.
16
CSC Board Approval
Public Announcements
http://www.chinatimes.com/newspapers
China Steel Invest 7000 MM TWD Launch Two Projects
2015 -03-28 Economic Daily News
CSC board meeting held yesterday (27) has approved two investment project. It will
spend 5600 MM TWD to overhaul No. 2 blast furnace of the third train; meanwhile
investment 1400 MM TWD to erect a 100,000 ton per annum ethanol plant.
CSC states, trans-invested to WBT using LanzaTech (USA) fermentation technology,
built an ethanol demonstration plant, in accordance with actual operation result, all
indices were way exceed the targets, approve this technology worth for
commercialization, will begin commercial plant at the year end.
Per the decision of CSC board, it will use the land near Xiao Gang Zhong Lin Road
purchased from LCY to build the plant. The investment amount 1400 MM TWD. Starts
production after estimated 2~3 years later. Per understanding, the plant will be in two
phases, it will erect a 100,000 MT per annum production line, main application is
gasoline additives and industrial ethanol.
Project Execution Time-lines:
• Project K.O.
- May, 2015
• JV Establishment – June, 2015
• Construction start – Q4’15
17
ArcelorMittal Gent
Carbon recycling
Electricity
generation
with LanzaTech
•
•
•
•
120,000 tons/annum CO2
reduction
300.000 tons/annum CO2
captured for future reuse
60k MTA ethanol capacity
Adding value to CO
18
Downstream Conversion - Hydrocarbon Fuels Process
Key Enabler:
Price and
Availability
of Alcohol
19
Downstream Conversion – 2,3-BDO to Butadiene
Köpke and Havill, Catalyst Review 27: 7-12 (2014)
Butadiene Product Markets
Styrene Butadiene Rubber (SBR)
US $13 billion/yr
Polybutadiene Rubber
(BR)
US $8 billion/yr
Acrylonitrile Butadiene Styrene (ABS)
US $16 billion/yr
Nylon 6,6 (from Adiponitrile/HDMA)
US $7 billion/yr
20
Fixing Carbon into Plastics: Ethanol to Ethylene
 e.g. polyethylene production
Can be recycled
CSC Steel mill
CO gas
ethanol
ethylene
Polyethylene
plastic
H2O
Every ton of ethylene produced from steel mill gases
takes almost 2 tons of CO2 out of the atmosphere
GHG (kg CO2e/kg)
GHG reduction
Conventional
1.9
-
LanzaTech
-1.8
190%
Result (HDPE +LDPE)
218M tons CO2e
-207M tons CO2e
Synthetic Biology Focus: New Products
Advance the genetic toolkit
and genetic parts
for our production strain
Identify novel enzymes,
Develop a deep understanding
reactions and pathways from natural
and predictive model
and synthetic sources
of our production strain
Create synthetic microbes for
conversion of gas to high value chemicals
22
World First Genetic toolbox for a Gas Fermenting Organism
Comprehensive genetic toolbox for C. autoethanogenum developed:
1. Robust transformation protocol that supports high throughput
2. Stable, modular vector system
3. Genetic Tools
−
Proprietary methods for gene knock-out/knock-in and point mutations
4. Genetic parts library
–
Suite of marker (positive/negative) and reporter genes
–
Promoter library including inducible promoters
–
RBS calculator and Codon Usage Algorithm
5. Semi automated construct design and assembly
Promoter library covering
several log units of
expression
Promoter variant #
23
1 Organism, over 20 Products…
1 Organism, over 25 Products…
CO/H2
Discovery
Continuous
lab-scale
fermentation
Scale
Up
Biodiesel (FAEE)
3-Hydroxypropionate
Jet Fuel (3-HP)
Fatty Acids,
Terpenoids
Aromatics
Isoprene
Aromatics
Branched-chain
Amino Acids
Acetoin
2-Butanol
Pyruvate
Acetyl-CoA
1-Propanol
1,2-Propanediol
Methyl Ethyl Ketone
(MEK)
Succinate
Butyrate
Partnerships
1,3-Butadiene
Biopolymers
Butylene
Lactate
1-Butanol
1,3-Butanediol (1,3-BDO)
3-Hydroxybutyrate
(3-HB)
Isopropanol
Acetone
Acetate
Ethanol
2,3-Butanediol
(2,3-BDO)
24
New pathways: CO2 as Carbon Source
Lipid Product Markets
Hydrocarbon Transport Fuels
>US $ 3 trillion/year
Long Chain
Fatty Acids
Algae/Yeast
Biomass
Omega 3
Fatty Acids
Acetate to
Lipids
Medium/Long
Chain
Fatty Acids
Omega 3
Fatty Acids
Animal Feeds
US $370 billion/yr
Food, Nutritional Supplements
US $25 billion/yr
Oleochemicals
US $15 billion/yr
26
Conversion of Acetic Acid to Lipids
Carbon
Source
Lipid Profile of Yeast using Acetate
peak area
CO2
Energy
Source
H2
Lipid Profile of Algae using Acetate
99%
1.4E+10
1.2E+10
1E+10
8E+09
6E+09
4E+09
Lipids are
predominantly
saturated C16 &
C18
2E+09
7:0
8:0
9:0
10:0
12:0
12:0
12:0
14:0
14:0
16:0
18:1
18:1
18:0
19:1
20:1
20:0
22:1
22:0
23:0
24:1
24:0
0
Acetate
Direct feed, no purification
C:double bonds
•
•
•
Work done in a collaboration
with Prof Kent Zhao of the Dalian
Institute of Chemical Physics.
•
Strains identified that grow of
LanzaTech broth using acetate as
Yeast
algae
the sole source of carbon and
2nd fermentation
energy.
Acetate to Lipid conversion by yeast or algae •
Patent filed, optimization underway
•
Yeast accumulate lipids to >70%
of their cell mass.
•
Work done in a collaboration with Advanced BioEnergy Research Centre at Indian Oil Corporation IOC.
Strains identified that grow of LanzaTech broth
using acetate as the sole source of carbon and
energy.
Algae accumulate lipids to >50% of their cell
mass.
25% of lipids content are Omega-3 fatty acids
(Specifically DHA).
27
Acetic acid production from H2/CO2 using A. woodii in
LanzaTech’s single fermenter system setup
• Step change in achievable
acetate broth concentration
(from 2.5 to 4wt%)
• Optimized media recipe
• Stable high level production
• Acetic acid production rates at 180g/L/d at a concentration of 30g/L were
achieved in single fermenter system.
• Selectivity of acetic acid is ~95% as no other products apart from biomass is
produced
28
Lipid composition of acetate–fed algae
Acetate consumption rates: ~80g/L/d
Lipid Composition:
• Constant across dilution rates
• Consistently ~22% of lipids = DHA omega-3 fatty acid
29
“Electrosynthesis” the next step for LanzaTech
Bacteria that use gases such as CO2 as their source of carbon derive the energy needed
from electrons.
Sources of
electrons:
Wind
Solar
electrical
energy
Biomass
CO2
CO2
eLanzaTech converts CO2 and electrons to products with no run-off, land use
change, or environmental uncertainty issues associated with crops
Crops convert CO2 and solar energy in to
Biomass
• LanzaTech bacteria can ferment CO2 and H2
• LanzaTech have shown enhanced reactor performance with electron-assisted fermentation (Patent
application: US61/295,145)
• Prof. Derek Lovley at U Mass (Amherst) is the leading researcher in this “electrofuels” field
• Prof. Lovley and LanzaTech are establishing a joint research effort (government funded) in this area
• This work is a natural extension of the microbial, synthetic bio, and engineering work being undertaken
on the LanzaTech platform
Natural feedstock extension of the LanzaTech Platform technology
LanzaTech Global Partnerships