Presentation on theme: "Bioprocess Technology"— Presentation transcript:
1Bioprocess Technology Upgrading the Value of Shale Gas on-site with Innovative Syngas Bioreactors(215)
2Calyx Bioprocess Technology Scalable, low-capital cost bioconversion of syngas to chemicalsUtilizing patented plastic-lined bioreactorHigh-value products for enhanced revenueTargeting unique biochemicalsHigh Quality Lubricants (wax-esters)Petrochemical substitutesCosmeticsTargeting stranded gas and remote shale wellsAreas where gas infrastructure is uneconomicalProfit from current gas flaring sitesOn-site gas liquefaction processRemotely monitored bioreactorNo gas distribution infrastructure neededWax EstersPotential increase in NG value per Billion cu. Ft.$3,000 (Transport Fuels: 167%)$60,000 (High Value Lubricants: 1,300%)$200,000+ (Cosmetics: 4,400%)Curtis WR, Growing cells in areservoir formed of a flexible sterile plastic liner,U.S. Patent #6,709,862, March 23, 2004.
3How big is the opportunity? Market CharacteristicsOil/gas Shale BoomVolatile market and record-low natural gas pricesExpansive shale reservesTcf recoverableEstimated 7 billion cubic feet of natural gas flared in US (2011)Current wells out of productionMany wells are not bringing gas to market due to economicsDecentralized and Remote well sitesTopography and vast area of PA prevents new gas distribution infrastructureeia.govRemote gas reserveslacking infrastructure
4Experienced TeamManagement Team (Chemical, Industrial, Biotech, Energy Engineers)Dr. Wayne R. Curtis– President and CEO25+ years algae and plant biotechnology experiencePI on ARPA-E funded “Electrofuels” ProjectRyan Johnson– Engineering Manager, Biz DevelopmentBioreactor Scale-up, Process ControlInvolved in CALYX entrepreneurial activities since 2011.Product Quality CharacterizationDr. Alex Rajangam– Molecular Biotechnologist12+ Years experience in biomass energy, metabolic engineering of wax-ester biosynthetic pathwaysNymul Khan– InternBioreactor Design ChallengesGenetic ScreeningTechnical AdvisorsDr. Harold Schobert– Renowned expert in gasification reactors and syngas conversion
5Why are we doing it?Leveraging technology developed under ARPA-E Electrofuels program fixing biofuels from H2 and CO2High-efficiency conversion of gas phase to high quality biofuelsHigh-throughput chemical screening of genetically tailored organismsCurrent syngas to liquids is based on 100 year old technologyFischer-Tropsch liquefaction requires large-scale, high cost equipmentCurrent syngas bioreactor systems produce alcoholsDifficult product separation, lower value product lineOur group has experience with fatty acid wax estersWax esters are currently being marketed for high-value lubricants and cosmeticsRapidly developing oil-shale with un-utilized “producer gas”Flared gas in the U.S. is exponentially increasing (increased by $315 Million in potential revenue from 2010 to 2011)
697%+ Syngas Yield Requires Technology OverviewA low-cost trickle-bed bioreactor is poised to be the only leading technology capable of upgrading natural gas to liquids at such a small scaleGenetic modifcation of Clostridium ljungdahlii with Jojoba wax ester pathway97+% biological conversion of gas87+% Conversion to product13% used for biological functions97%+ Syngas Yield Requires1 ) Zero outputs except BioFuel“Dead End Fermentation”2) Ultra-Low Dilution Rate“Growth Disassociated Fuel Production”3) Secreted Hydrophobic ProductPlastic-Lined Lab-scale Trickle Bed Fermenter 100 Liter for scale-up parameters
7High-value Product Line Highest Conversion Efficiency Who else is doing this?Fischer Tropsch /Thermochemical$150,000CoskataINEOS (Bio)Alcohol ProductLanzaTechSyngas / MethaneFermentersQatar GTLPlastic-LinedTrickle BedOn-Site ConversionHigh-value Product LineHighest Conversion EfficiencyCarbonSciencesCapEx($/BPD)High Temp$10,00010010,000100,000Capacity (BBL/day)
8Our Competitive Advantage Centralized, large-scale processing still requires natural gas distribution infrastructureOn-site liquefaction requires minimal gas handlingProduction of alcohol requires distillationOur continuous process phase separates our product through decantationTrickle-bed fermenters have ultra efficient gas-to-liquid mass transfer with minimal operational costTrickle-beds are much larger (90%) than conventional stirred tank fermentersOur patent allows us to have maximum efficiency with minimal capital costMinimal capital costMaximum efficiency per Energy Input
9Economic AssessmentConventional Small Scale FT-GTL CapEx is uneconomical> 120,000 $/BPD55% of CapEx for Syngas Production35% of CapEx for Fischer-Tropsch10% of CapEx for Product Upgrading100 BBL/day commercial facility analyzed using ASPEN HYSYS25,000 m^3 CH4 / day $4.54 / 1k ft^3)87% conversion of syngas to fuel$5.6 MM for “Conventional” Trickle Bed Reactor (370 m^3)Plastic Lined Reactor CapEx < $0.75 MMHigh-value product line enables strong ROIOperational + Fixed + Capital = $126/bblHigh-value lubricant product lines allow for ROR of > 322%Does not include operational / capital of syngas reforming.
10Business Model and Strategy StagesTimeframeDeliverableFundingMilestonesPhase I: Demonstration Scale Operation of “Showcase” Trickle-Bed FermenterSummer/Fall 2013Liters Continuous Conversion of Syngas$300, ,000(Grant Funding)90+ % Gas Utilization0.01 $/hr/m^3Lubricant properties of productPatent applicationsPhase II: Pilot Scale Operation with Strategic PartnersTurn-key facility for lubricant and syngas utilization.$2.5 Million(Capital Investments)Fully Automated97+% Gas Utilization0.001 $/hr/m^3Patents GrantedCommercial PrototypeFirst RevenuesCommercialization: Turn-key on-site facilities with strategic partners.2016 +Scalable product and expansive customer base.Investment cost to be determined. Depends on non-dilutive funding.Marketable product.Nationally equipped.
11Strategic Partner Possibilities Unique strategic partner for syngas production from methaneSteam reforming of Methane to syngas has been cost prohibitive at small to medium scaleReduction is CapEx for small scale autothermal methane reforming is necessary for economicsThe high specificity of transgenic bacteria allow our group to tailor products to our partners and customersWe have modified our current product lines (fuels) to include higher value lubricants.We will seek to partner with synthetic lubricant manufacturer (such as Mobil-1)Enable wax-ester product lines during scale-upFurther test product lines for higher value applications such as cosmeticsShell GTL FacilityHigh Value LubricantsCosmetics Value Chain