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Bioprocessing for Value-Added Products: from Prebiotics to Biofuels

Bioprocessing for Value-Added Products: from Prebiotics to Biofuels. Shang-Tian Yang Director, Ohio Bioprocessing Research Consortium Professor, Department of Chemical & Biomolecular Engineering The Ohio State University.

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Bioprocessing for Value-Added Products: from Prebiotics to Biofuels

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  1. Bioprocessing for Value-Added Products: from Prebiotics to Biofuels Shang-Tian Yang Director, Ohio Bioprocessing Research Consortium Professor, Department of Chemical & Biomolecular Engineering The Ohio State University Enhancing Linkages between Universities and Small Businesses, National NSF EPSCoR/USDA SBIR Conference, South Portland, Maine, Oct. 15-16, 2007

  2. SBIR/STTR Projects • “Production of Galacto-oligosaccharides from Lactose by Immobilized Enzyme on Cotton Cloth” USDA SBIR, Bioprocessing Innovative Co., Inc. (BIC) • “Production of Butyric Acid and Butanol from Biomass” DOE STTR, Environmental Energy, Inc. (EEI) • “Extractive Fermentation for Production of Lactic Acid from Corn Starch by Filamentous Fungi Immobilized in Fibrous Bed Bioreactor” USDA SBIR, EEI. • “Microfluidic CD Biochips for Enzyme-Linked Immunosorbent Assays” NSF STTR, BioLOC. • “A Gas-Solid Spouted Bed Bioreactor for Solid State Fermentation to Produce Enzymes and Biochemicals” NSF STTR, BIC. • “An Integrated Fermentation-Ultrafiltration Process for the Production of Xanthan Gum from Whey Lactose“ USDA SBIR, BIC.

  3. Biomass feedstock Enzyme Organisms Products Pretreatment Hydrolysis Fermentation Separation Wastewater Lignin Cells Byproducts General bioprocess flowsheet

  4. Food and Agricultural Industries • Corn refinery (wet milling) -- corn fiber and corn steep liquor • Cheese manufacturing -- cheese whey permeate and lactose • By-products - a disposal problem -- potential low-cost feedstocks

  5. US Annual Lactose Production 300,000 metric tons in 2005

  6. CH2OH CH2OH Lactose O O HO O OH OH OH Glucose Galactose OH OH Galactose Glucose IME Annual Production: 300,000 tons Galacto-Oligosaccharides (GOS) 25,000 tons worldwide Production of GOS as Prebiotic from Lactose BIC

  7. GOS formation 3-OS 4-OS Lactose 5-OS BIC

  8. Glucose, Galactose GOS, Lactose Immob. Enzyme Reactor Nano- filtration Lactose Whey Lactose Glucose GOS Galactose Production of Galacto-Oligosaccharides (GOS) from Lactose US Patent No. 7,166,451 BIC

  9. Comparisons of GOS Production from Lactose by Various Enzymes and Methods The productivity in the fibrous bed bioreactor increased by more than 250 times as compared to other studies

  10. Fibrous Bed Bioreactor Fibers as a support matrix for cell attachment and entrapment ( immobilization) • High specific surface area • High permeability compared to granular materials • High porosity (>90%) with low solid volume • Low hydrodynamic shear • Excellent mechanical strength • Three-dimensional matrix U.S. Patent No. 5563069

  11. Immobilized Cell FermentationFibrous-Bed Bioreactor High cell density: 35 – 100 g/L

  12. Fermentation • Fibrous bed bioreactor for carboxylic acids and alcohols production • Rotating fibrous bed bioreactor for viscous fermentations • Spouted bed bioreactor for solid state fermentations

  13. Biofuels • Alcohols • Ethanol • n-Butanol • Hydrogen • Biodiesels • Methane (biogas)

  14. CH3-CH2- CH2 - CH2 OH Butanol • Can be used as a transportation fuel without any modification of existing pipelines and car engines • Important industrial solvent and potentially better fuel extender than ethanol • Inexpensive feedstocks available from the agriculture industry for the fermentation process to produce butanol • Conventional acetone-butanol-ethanol (ABE) fermentation is limited by product inhibition (butanol yield < 20%, concentration < 20 g/L, productivity < 2 g/L/h) • OSU bioreactor (U.S. Patent 5,563,069) andrelated bioprocessing technologies can produce butanol from corn and other biomass with 25% more energy per bushel of corn

  15. Two-Step Process for Butanol Production Butyric acid Butanol Butanol Immobilized Cell Reactor Separation Unit Solvent Starch / Glucose Separating acidogenesis and solventogenesis into two reactors to optimize the process and increase butanol yield - U.S. Patent 5,753,474

  16. Microfluidic CD Biochipsfor Enzyme-Linked Immunosorbent Assays Revolutionary CD-ELISA Detection of cancers, immuno- and infectious diseases, food allergens, and environmental pollutants Detection of pathogens: E. coli O157: H7 Salmonella Compylobacter

  17. CD-ELISA Chip Design substrate secondary antibody (conjugate) washing solution antigen blocking protein primary antibody waste measurement • Automation • Parallel US patent Application No. 11/556,132

  18. SBIR, State fundings Private investments Ohio Bioprocessing Research Consortium Bridging Research and Development to Commercialization BIC Market

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