Process for producing low molecular weight hydrocarbons from renewable resources

• US 8,110,093 B2
• Filed: 03/14/2008
• Issued: 02/07/2012
• Est. Priority Date: 03/14/2007
• Status: Active Grant

• Current Assignee: Genomatica Incorporated
• Original Assignee: LS9, Inc.
• Inventors: Friedman, Lisa, Rude, Mathew
• Primary Examiner(s): McAvoy, Ellen
• Application Number:
  US12/278,961
• Publication Number:
  US 20100170826A1
• Time in Patent Office: 1,425 Days
• Field of Search: 208/106, 208/118, 208/120.01, 435/166, 435/167
• US Class Current: 208/118
• CPC Class Codes: C10G 11/00 Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils cracking in direct contact with molten metals or salts C10G9/34
• CPC Class Codes: C10G 11/05 Crystalline alumino-silicates, e.g. molecular sieves
• CPC Class Codes: C10G 11/18 according to the "fluidised-bed" technique
• CPC Class Codes: C10G 2300/1011 Biomass
• CPC Class Codes: C10G 2300/301 Boiling range
• CPC Class Codes: C10G 2400/02 Gasoline
• CPC Class Codes: C10G 2400/04 Diesel oil
• CPC Class Codes: C10G 2400/08 Jet fuel
• CPC Class Codes: C10L 1/00 Liquid carbonaceous fuels
• CPC Class Codes: C10L 1/023 for spark ignition
• CPC Class Codes: C10L 1/026 for compression ignition
• CPC Class Codes: C10L 1/06 for spark ignition
• CPC Class Codes: C10L 1/08 for compression ignition
• CPC Class Codes: C12N 9/1025 Acyltransferases (2.3)
• CPC Class Codes: C12N 9/1029 transferring groups other than amino-acyl groups (2.3.1)
• CPC Class Codes: C12P 7/649 Biodiesel, i.e. fatty acid alkyl esters
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02P 30/20 using bio-feedstock

Abstract

Described herein are methods for cracking a biocrude, particularly catalytically cracking a biocrude that primarily includes olefmic hydrocarbons. Also described herein are compositions and methods of producing such compositions that are useful as fuels or fuel production feedstock.

Claims

1. A method for making low molecular weight hydrocarbons from a biocrude, which method comprises:

(a) obtaining a recombinant microorganism comprising one or more polynucleotides encoding one or more polypeptides having acetyl-CoA carboxylase (accABCD) activity (EC 6.4.1.2, 6.3.4.14), wherein the one or more polynucleotides are exogenous to the recombinant microorganism or wherein one or more endogenous polynucleotides encoding one or more polypeptides having accABCD activity are overexpressed in the recombinant microorganism;

(b) culturing the recombinant microorganism in a culture medium containing a carbohydrate as the carbon source under conditions effective to express the one or more polynucleotides, wherein the recombinant microorganism produces a biocrude; and

(c) cracking the biocrude resulting in low molecular weight hydrocarbons.

2. The method of claim 1,

wherein the recombinant microorganism further comprises one or more polynucleotides encoding a polypeptide having OleABCD activity, thioesterase activity (EC 3.1.2.14 or EC 3.1.1.5), acyl-CoA synthetase (fadD) activity (EC 2.3.1.86), fatty alcohol foaming acyl-CoA reductase (FAR) activity (EC 1.1.1.*), acyl-CoA reductase activity (EC 1.2.1.42) and ester synthase activity (EC 2.3.1.-, 2.3.1.20).

3. The method of claim 2,

wherein the biocrude is substantially free of any compounds that include oxygen.

4. The method of claim 2,

wherein the biocrude includes greater than about 90 wt % alkene compounds, based on the total weight of the biocrude.

5. The method of claim 2, which method comprises catalytically cracking the biocrude at a temperature of 350°

C. or lower.

6. The method of claim 2, wherein the cracking comprises catalytic cracking.

7. The method of claim 2, wherein the cracking does not include hydrocracking or steam cracking.

8. The method of claim 6, wherein the cracking comprises contacting the biocrude with a catalyst selected from zeolite, aluminum hydrosilicate, treated bentonite clay, fuller'"'"'s earth, bauxite, amorphous silica-alumina and mixtures or combinations thereof.

9. The method of claim 8, wherein the catalyst is an amorphous silica-alumina.

10. The method of claim 2, wherein the cracking is performed at a temperature of 350°

C. or lower.

11. The method of claim 2, wherein the cracking is performed at a temperature of 300°

C. or lower.

12. The method of claim 2, wherein the cracking converts C₁₉ to C₃₁ hydrocarbons in the biocrude to C₁ to C₁₈ hydrocarbons.

13. The method of claim 2, wherein the cracking converts about 65 to about 75 wt. % of hydrocarbons in the biocrude to low molecular weight hydrocarbons.

14. The method of claim 1, wherein the recombinant microorganism further comprises a polynucleotide encoding a polypeptide having ester synthase activity (EC 2.3.1.-, 2.3.1.20), wherein the recombinant microorganism over expresses the ester synthase.

15. The method of claim 2, wherein the cracked product includes a C₅ to C₁₀ fraction having a boiling point range of about 30 to about 180°

C. at 1 atm.

16. The method of claim 2, wherein the cracked product includes a C₈ to C₁₄ fraction having a boiling point range of about 120 to about 260°

C. at 1 atm.

17. The method of claim 2, wherein the cracked product includes a C₁₄ to C₁₈ fraction having a boiling point range of about 230 to about 320°

C. at 1 atm.

18. The method of claim 2, further comprising mixing the biocrude with petroleum crude prior to cracking, and then cracking the resulting biocrude/petroleum crude mixture.

19. The method of claim 2, wherein the biocrude includes at least about 99 wt % alkene compounds, based on the total weight of the biocrude.

20. The method according to claim 2, further comprising separating the hydrocarbons.

21. The method of claim 20, wherein culturing and separating is continuous.

22. The method of claim 20, wherein separating comprises contacting the fermentation media with an organic composition and allowing the hydrocarbon to separate into the organic composition.

23. The method of claim 2, wherein the recombinant microorganism is E. coli, S. maltophilia, K. radiotolerans, Rhodococcus, Saccharomyces cerevisiae, Aspergillus, Trichoderma, Neurospora, Fusarium or Chrysosporium.

24. The method of claim 6,

wherein the biocrude comprises a hydrocarbon feedstock including greater than about 50 wt % C₁₉-C₃₁ compounds, based on the total weight of the biocrude.

25. The method of claim 24, wherein the hydrocarbon feedstock includes greater than about 80 wt % C₁₉-C₃₁ compounds.

26. The method for cracking of claim 2,

wherein the biocrude comprises a hydrocarbon feedstock including C₁₉ to C₃₁ hydrocarbons having at least one alkene moiety.

27. The method of claim 26, wherein the hydrocarbon feedstock includes C₂₂ to C₃₁ hydrocarbons having at least one alkene moiety.