Production of Chemical Derivatives from Renewables (1996)

The purpose of this Cooperative Research and Development Agreement (CRADA) between Lockheed Martin Energy Research Corp., (LMER), Argonne National Laboratory (ANL), National Renewable Energy Laboratory (NREL), and Battelle Memorial Institute, operator of Pacific Northwest National Laboratory (PNNL), (collectively referred to as the 'Contractor'), and Applied Carbochemicals, Inc. (Participant) was to scale-up from bench results an economically promising and competitive process for the production of chemical derivatives from biologically produced succinic acid. The products that were under consideration for production from the succinic acid platform included 1,4-butanediol, {gamma}y-butyrolactone, 2-pyrrolidinone and N-methyl pyrrolidinone. Preliminary economic analyses indicated that this platform was competitive with the most recent petrochemical routes. The Contractors and participant are hereinafter jointly referred to as the 'Parties.' Research to date in succinic acid fermentation, separation and genetic engineering resulted in a potentially economical process based on the use of an Escherichia coli strain AFP111 with suitable characteristics for the production of succinic acid from glucose. Economic analysis has shown that higher value commodity chemicals can be economically produced from succinic acid based on preliminary laboratory findings and predicted catalytic parameters. At the time, the current need was to provide the necessary laboratory follow-up information to properly optimize, design and operate a pilot scale process. The purpose of the pilot work was to validate the integrated process, assure 'robustness' of the process, define operating conditions, and provide samples for potential customer evaluation. The data from the pilot scale process was used in design and development of a full scale production facility. A new strain, AFP111 (patented), discovered at ANL was tested and developed for process use at the Oak Ridge National Laboratory (ORNL) and ANL. The operability and product formation are attractive for this strain and effort was being directed at process development and optimization. Key to the transition from the fermentative production unit operation to the chemical catalysis is the 'clean-up' of fermentation broth, succinic acid formation from the salt, and succinic acid concentration. These steps are accomplished by a two-stage membrane ED separation process developed at AWL. Although the current process is well developed, possible modifications and optimization may be called for as development work continues in both the fermentation and catalysis areas. Research to date performed at PNNL has demonstrated that succinic acid can be converted to value added chemicals such as 1,4-butanediol, {gamma}-butyrolactone, N-methyl pyrrolidinone, and 2 pyrrolidinone with high conversion and selectivities. Continued research will be performed in catalyst development and reaction condition optimization to move this work from the bench scale to the pilot scale. All development of the process was guided by the NREL technoeconomic model. The model showed that direct aqueous phase catalysis of succinic acid to 1,4-butanediol, {gamma}-butyrolactone, and N-methyl pyrrolidinone provided significant economical advantages in the market, the margin, and the return on capital investment over existing petrochemical processes for production of these compounds. The model also provided the baseline for evaluating current laboratory research. As data from the bench and pilot work were made available the model was modified and appropriate sensitivities ran to determine impact of the process changes and optimization. The report will present the planned CRADA tasks followed by the results. The results section has an overall project summary follwed by more detailed reports from the participants. This is a nonproprietary report; additional proprietary information may be made available subject to acceptance of the appropriate proprietary information agreements.