SBIR-STTR Award

This proposed Phase I project deals with a new production method for a bulk, value added chemical, glycerol, by fermentation of glucose derived from corn starch. According to experimental data already on hand, a yeast is capable of converting glucose into glycerol giving a high yield, with a high fermentor productivity, generating a final fermented broth, containing a high concentration of glycerol. The proposed Phase I project is to apply two new techniques together to improve the glycerol productivity even further, so that the fermentation method will become the dominating method of glycerol production for years to come. The two techniques include first the use of a novel fermentor design called ALSA which is inexpensive to construct and requires a low initial investment. An ALSA does not require agitation by a mechanical agitator, which reduces electricity cost. The ALSA also has the advantage of being easily operated in a continuous, multiple stage, mode with improved process efficiency. The second new technique is called pressure pulsation or PP. This technique is capable of improving aerobic fermentation and oxygen transfer rate by 20-30% in preliminary experiments already done. With further experimental and theoretical studies, the improvement can be increased even more. This proposed project is for testing the feasibility of combined application of ALSA and PP in glycerol fermentation. Currently, glycerol is produced by chemical synthesis and also recovered as a byproduct from fatty acid industries. The new fermentation method has already been extensively studied by the PI.

Anticipated Results/Potential Commercial Applications of Research:
:Preliminary cost analysis shows the cost of production, based on the results already on hand, to be less than $0.32/lb of glycerol. The current price of glycerol is $0.50/lb. This price is much depressed by the currency crisis in Malaysia and Indonesia which are the major sources of glycerol (derived from their palm kernel oil). When the economies of these countries are well recovered in 2-3 years as knowledgeable experts expect, the glycerol price will go back to its normal price of $0.85/lb. According to a USDA report, the worldwide demand for glycerol will grow at a rate of 2-3% per year from its annual consumption of 1.2 billion pounds. Therefore, one can expect that in due time, this fermentation method of glycerol will become a big money maker and economy promoter for agriculture. This fermentation method will bring a new use for starch from corn and other crops in producing value added chemicals.MARKETING AND TRADE FUNDED PROJECTSA GUIDE FOR USDA ISO-9000 BASED (QSCP) QUALITY SYSTEM CERTIFICATION PROGRAMMARKETING HIGH VALUE HERBAL PRODUCTS FROM INDIAN COUNTRYORGANIC WOOL: DEMAND CREATION AND SUPPLY GENERATIONESTIMATING WHEAT YIELDS FROM TIME-SERIES ANALYSIS OF REMOTELY SENSED DATA

This Phase II proposal and the recently completed Phase I project deal with a new process of production of glycerol from cornstarch by a yeast fermentation. There are two current industrial processes for glycerol. Chemical syntheses are no longer competitive. The second method involves recovering glycerol as a byproduct from soap and other fatty acid industries. It suffers from the decline of the main products and also the large and thus restrictive 7 to 1 main-products to byproduct ratio. The byproduct simply cannot grow much without upsetting the market supply-demand balance of the main-products. Phase I work has improved the glycerol fermentation to a peak productivity of 4-5 g/l/h and a high average productivity of 3 g/l/h. The work has also improved the final glycerol concentration in the fermented broth to over 330 g/l, reducing reactor volume and evaporation costs. The overall yield has reached a high value of 1g/2g of cornstarch. Another important character of the yeast is the fact that the cells are stable and active, leaving no residual glucose at the end of batch operations. This makes the downstream operation of vacuum distillation for purifying the final product easy to do, avoiding otherwise problems of charring of residual carbohydrates. These results have led to this proposed Phase II project which will evaluate various reactor systems, as well as high vacuum distillation for glycerol purification, employing industrial grade raw materials, over wide ranges of process variables and oxygen supply levels. This proposed Phase II study will obtain enough practical data to prepare for a future Phase III project. ANTICIPATED RESULTS & POTENTIAL COMMERCIAL APPLICATIONS OF RESEARCH The production cost of glycerol is estimated at $0.45/lb by fermentation, comparing with a market price of $0.85lb. The large difference makes this process very profitable. It has attracted strongly industrial interests. GRT will provide follow-on funding of $275,000 from its internal resource for Phase III. Meanwhile, GRT is negotiating with two companies for licensing and for joint production ventures. Annual glycerol demand was given in an USDA report as 1.2 billion pounds. It is growing steadily. Two new potential uses will stimulate further demand growth. One is the use of glycerol in drilling mud formula for oil wells. Another is the conversion into 1,3-propanediol through a 2-step process that has been shown to be very effective. The new industry, once established, will benefit agriculture significantly.