The IBUS Process – Lignocellulosic Bioethanol Close to a Commercial Reality

Enhanced ethanol production from paper sludge waste under high-solids conditions with industrial and cellulase-producing strains of Saccharomyces cerevisiae

Reported ethanol titres from hydrolysis-fermentation of the degraded fibres in paper sludge (PS) waste, generally obtained under fed-batch submerged conditions, can be improved through fermentation processes at high solids loadings, as demonstrated in the present study with two industrial PS wastes at enzyme dosages appropriate for solids loadings up to 40% (w/w). The industrial yeast,Saccharomyces cerevisiaestrain Ethanol Red®, was compared to two genetically engineeredS. cerevisiaestrains, namely Cellusec® 1.0 and Cellusec® 2.0, capable of xylose utilisation, and xylose utilisation and cellulase production, respectively. High-solids batch fermentations were conducted in 3 L horizontal rotating reactors and ethanol titres of 100.8 and 73.3 g/L were obtained for virgin pulp and corrugated recycle PS, respectively, at 40% (w/w) solids loading using Ethanol Red®. Xylose utilisation by Cellusec® 1.0 improved ethanol titres by up to 10.3%, while exogenous cellulolytic enzyme requirements were reduced by up to 50% using cellulase-producing Cellusec® 2.0.

Highly efficient, processive and multifunctional recombinant endoglucanase RfGH5_4 from Ruminococcus flavefaciens FD-1 v3 for recycling lignocellulosic plant biomasses

Gene encoding endoglucanase, RfGH5_4 from R. flavefaciens FD-1 v3 was cloned, expressed in Escherichia coli BL21(DE3) cells and purified. RfGH5_4 showed molecular size 41 kDa and maximum activity at pH 5.5 and 55 °C. It was stable between pH 5.0-8.0, retaining 85% activity and between 5 °C-45 °C, retaining 75% activity, after 60 min. RfGH5_4 displayed maximum activity (U/mg) against barley β-D-glucan (665) followed by carboxymethyl cellulose (450), xyloglucan (343), konjac glucomannan (285), phosphoric acid swollen cellulose (86), beechwood xylan (21.7) and carob galactomannan (16), thereby displaying the multi-functionality. Catalytic efficiency (mL.mg^-1 s^-1) of RfGH5_4 against carboxymethyl cellulose (146) and konjac glucomannan (529) was significantly high. TLC and MALDI-TOF-MS analyses of RfGH5_4 treated hydrolysates of cellulosic and hemicellulosic polysaccharides displayed oligosaccharides of degree of polymerization (DP) between DP2-DP11. TLC, HPLC and Processivity-Index analyses revealed RfGH5_4 to be a processive endoglucanase as initially, for 30 min it hydrolysed cellulose to cellotetraose followed by persistent release of cellotriose and cellobiose. RfGH5_4 yielded sufficiently high Total Reducing Sugar (TRS, mg/g) from saccharification of alkali pre-treated sorghum (72), finger millet (62), sugarcane bagasse (38) and cotton (27) in a 48 h saccharification reaction. Thus, RfGH5_4 can be considered as a potential endoglucanase for renewable energy applications.

Recent advances in commercial biorefineries for lignocellulosic ethanol production: Current status, challenges and future perspectives

Cellulosic ethanol production has received global attention to use as transportation fuels with gasoline blending virtue of carbon benefits and decarbonization. However, due to changing feedstock composition, natural resistance, and a lack of cost-effective pretreatment and downstream processing, contemporary cellulosic ethanol biorefineries are facing major sustainability issues. As a result, we've outlined the global status of present cellulosic ethanol facilities, as well as main roadblocks and technical challenges for sustainable and commercial cellulosic ethanol production. Additionally, the article highlights the technical and non-technical barriers, various R&D advancements in biomass pretreatment, enzymatic hydrolysis, fermentation strategies that have been deliberated for low-cost sustainable fuel ethanol. Moreover, selection of a low-cost efficient pretreatment method, process simulation, unit integration, state-of-the-art in one pot saccharification and fermentation, system microbiology/ genetic engineering for robust strain development, and comprehensive techno-economic analysis are all major bottlenecks that must be considered for long-term ethanol production in the transportation sector.

Enzymatic hydrolysis for the systematic production of second-generation glucose from the dual polysaccharide reserves of an anti-pollutant plant

In this study, the anti-pollutant macrophyte Typha domingensis is exploited for the production of highly concentrated second-generation glucose. A two-stage starch and cellulose enzymatic hydrolysis process is compared for the first time with a single-stage simultaneous starch and cellulose hydrolysis approach, with the former achieving enhanced glucose production, making it more promising for large-scale deployment. The proposed two-stage process is optimized via the Box-Behnken response surface methodology achieving glucose yield values of 74.4% and 71.7% with respect to the starch and cellulose fraction, respectively. Elevated shaking rates are shown to exert a positive effect on both starch and cellulose enzymatic hydrolysis only under high initial substrate concentrations and high initial enzyme to substrate ratios, indicating the importance of accounting for the synergies between key process variables when aiming to increase glucose production. The findings of the presented experimental framework aspire to support future scale-up studies and techno-economic assessments.

High solids loading biorefinery for the production of cellulosic sugars from bioenergy sorghum

A novel process applying high solids loading in chemical-free pretreatment and enzymatic hydrolysis was developed to produce sugars from bioenergy sorghum. Hydrothermal pretreatment with 50% solids loading was performed in a pilot scale continuous reactor followed by disc refining. Sugars were extracted from the enzymatic hydrolysis at 10% to 50% solids content using fed-batch operations. Three surfactants (Tween 80, PEG 4000, and PEG 6000) were evaluated to increase sugar yields. Hydrolysis using 2% PEG 4000 had the highest sugar yields. Glucose concentrations of 105, 130, and 147 g/L were obtained from the reaction at 30%, 40%, and 50% solids content, respectively. The maximum sugar concentration of the hydrolysate, including glucose and xylose, obtained was 232 g/L. Additionally, the glucose recovery (73.14%) was increased compared to that of the batch reaction (52.74%) by using two-stage enzymatic hydrolysis combined with fed-batch operation at 50% w/v solids content.

Engineered Saccharomyces cerevisiae for lignocellulosic valorization: a review and perspectives on bioethanol production

The biorefinery concept, consisting in using renewable biomass with economical and energy goals, appeared in response to the ongoing exhaustion of fossil reserves. Bioethanol is the most prominent biofuel and has been considered one of the top chemicals to be obtained from biomass. Saccharomyces cerevisiae, the preferred microorganism for ethanol production, has been the target of extensive genetic modifications to improve the production of this alcohol from renewable biomasses. Additionally, S. cerevisiae strains from harsh industrial environments have been exploited due to their robust traits and improved fermentative capacity. Nevertheless, there is still not an optimized strain capable of turning second generation bioprocesses economically viable. Considering this, and aiming to facilitate and guide the future development of effective S. cerevisiae strains, this work reviews genetic engineering strategies envisioning improvements in ^2nd generation bioethanol production, with special focus in process-related traits, xylose consumption, and consolidated bioprocessing. Altogether, the genetic toolbox described proves S. cerevisiae to be a key microorganism for the establishment of a bioeconomy, not only for the production of lignocellulosic bioethanol, but also having potential as a cell factory platform for overall valorization of renewable biomasses.

Techno-Economic Evaluation of Biorefineries Based on Low-Value Feedstocks Using the BioSTEAM Software: A Case Study for Animal Bedding

Biofuels are still too costly to compete in the energy market and it has been suggested that low-value feedstocks could provide an opportunity for the production of low-cost biofuels; however, the lower quality of these feedstocks requires the introduction of a conditioning step in the biorefinery process. The aim of this study was to evaluate whether feedstock savings cover the cost of conditioning in the case of animal bedding. The BioSTEAM software was used to simulate a wheat straw biorefinery and an animal bedding biorefinery, whose economic performance was compared. The wheat straw biorefinery could deliver ethanol at a minimum selling price of USD 0.61 per liter, which is similar to prices in the literature. The cost of producing ethanol in the animal bedding biorefinery without water recycling was almost 40% higher, increasing the minimum selling price to USD 1.1 per liter of ethanol. After introducing water recycling in the conditioning step, the animal bedding biorefinery could deliver ethanol at a minimum selling price of USD 0.38 per liter, which is 40% lower than in the case of the wheat straw biorefinery. This demonstrates that low-value feedstocks can be used to reduce the biofuel price, as feedstock savings easily cover the additional conditioning cost.

Engineering aspects of hydrothermal pretreatment: From batch to continuous operation, scale-up and pilot reactor under biorefinery concept

Different pretreatments strategies have been developed over the years mainly to enhance enzymatic cellulose degradation. In the new biorefinery era, a more holistic view on pretreatment is required to secure optimal use of the whole biomass. Hydrothermal pretreatment technology is regarded as very promising for lignocellulose biomass fractionation biorefinery and to be implemented at the industrial scale for biorefineries of second generation and circular bioeconomy, since it does not require no chemical inputs other than liquid water or steam and heat. This review focuses on the fundamentals of hydrothermal pretreatment, structure changes of biomass during this pretreatment, multiproduct strategies in terms of biorefinery, reactor technology and engineering aspects from batch to continuous operation. The treatise includes a case study of hydrothermal biomass pretreatment at pilot plant scale and integrated process design.

Comparison of Three Xylose Pathways in Pseudomonas putida KT2440 for the Synthesis of Valuable Products

Pseudomonas putida KT2440 is a well-established chassis in industrial biotechnology. To increase the substrate spectrum, we implemented three alternative xylose utilization pathways, namely the Isomerase, Weimberg, and Dahms pathways. The synthetic operons contain genes from Escherichia coli and Pseudomonas taiwanensis. For isolating the Dahms pathway in P. putida KT2440 two genes (PP_2836 and PP_4283), encoding an endogenous enzyme of the Weimberg pathway and a regulator for glycolaldehyde degradation, were deleted. Before and after adaptive laboratory evolution, these strains were characterized in terms of growth and synthesis of mono-rhamnolipids and pyocyanin. The engineered strain using the Weimberg pathway reached the highest maximal growth rate of 0.30 h-1. After adaptive laboratory evolution the lag phase was reduced significantly. The highest titers of 720 mg L-1 mono-rhamnolipids and 30 mg L-1 pyocyanin were reached by the evolved strain using the Weimberg or an engineered strain using the Isomerase pathway, respectively. The different stoichiometries of the three xylose utilization pathways may allow engineering of tailored chassis for valuable bioproduct synthesis.

The effect of continuous tubular reactor technologies on the pretreatment of lignocellulosic biomass at pilot-scale for bioethanol production

A pilot-scale continuous tubular reactor increases enzymatic digestibility of four different feedstocks by removing xylan and effectively achieving economically viable ethanol concentrations.

High-solids enzymatic hydrolysis of ball-milled corn stover with reduced slurry viscosity and improved sugar yields

BACKGROUND

High-solids enzymatic hydrolysis has attracted increasing attentions for the production of bioethanol from lignocellulosic biomass with its advantages of high product concentration, water saving, and low energy and capital costs. However, the increase of solids content would worsen the rheological properties, resulting in heat/mass transfer limitation and higher mixing energy. To address these issues, ball milling was applied to corn stover prior to enzymatic hydrolysis, and the rheological behaviors and digestibility of ball-milled corn stover under high-solids loading were investigated.

RESULTS

Ball milling significantly modified the physicochemical properties of corn stover. The apparent viscosity of slurries at 30% solid loading decreased by a factor of 500 after milling for 60 min, and the yield stress was less than 10 Pa. The dramatic decrease of viscosity and yield stress enabled the hydrolysis process to be conducted in shake flask, and remained good mixing. Meanwhile, the estimated energy consumption for mixing during saccharification decreased by 400-fold compared to the untreated one. The resultant hydrolysate using 10 FPU g^-1 solids was determined to contain 130.5 g L^-1 fermentable sugar, and no fermentation inhibitors were detected.

CONCLUSIONS

The proposed ball milling pretreatment improved rheological behavior and sugar yield of high-solids corn stover slurry. Ball milling enables high-solids slurry to maintain low viscosity and yield stress while obtaining a non-toxic high-concentration fermentable syrup, which is undoubtedly of great significance for inter-unit processing, mixing and downstream process. In addition, the energy input for ball milling could be balanced by the reduced mixing energy. Our study indicates ball milling a promising pretreatment process for industrial bioethanol production.

Laccase-mediated hydrophilization of lignin decreases unproductive enzyme binding but limits subsequent enzymatic hydrolysis at high substrate concentrations

One of the predominant mechanisms by which lignin restricts effective enzymatic deconstruction of lignocellulosic materials is the unproductive adsorption of enzymes. Although this inhibition can be partially mitigated through hydrophilization of lignin during thermochemical pretreatment, these types of treatments could potentially worsen slurry rheology, consequently making it more difficult to process the material at high substrate concentrations. In the work reported here, laccases were used to specifically modify lignin hydrophilicity within steam-pretreated substrate via in situ phenolic compound grafting. While lignin hydrophilization reduced unproductive enzyme adsorption, high-solids hydrolysis efficiency decreased significantly due to mass transfer limitations. It was apparent that low-solids hydrolysis experiments were a poor predictor of substrate digestibility at high-solids conditions and that substrate-water interactions impacted both substrate digestibility and slurry rheology.

Economic Analysis of Cellulosic Ethanol Production from Sugarcane Bagasse Using a Sequential Deacetylation, Hot Water and Disk-Refining Pretreatment

A new process for conversion of sugarcane bagasse to ethanol was analyzed for production costs and energy consumption using experimental results. The process includes a sequential three-stage deacetylation, hot water, and disk-refining pretreatment and a commercial glucose-xylose fermenting S. cerevisiae strain. The simultaneous saccharification and co-fermentation (SScF) step used was investigated at two solids loadings: 10% and 16% w/w. Additionally, a sensitivity analysis was conducted for the major operating parameters. The minimum ethanol selling price (MESP) varied between $4.91and $4.52/gal ethanol. The higher SScF solids loading (16%) reduced the total operating, utilities, and production costs by 9.5%, 15.6%, and 5.6%, respectively. Other important factors in determining selling price were costs for fermentation medium and enzymes (e.g. cellulases). Hence, these findings support operating at high solids and producing enzymes onsite as strategies to minimize MESP.

Introducing low-quality feedstocks in bioethanol production: efficient conversion of the lignocellulose fraction of animal bedding through steam pretreatment

BACKGROUND

Animal bedding remains an underutilized source of raw material for bioethanol production, despite the economic and environmental benefits of its use. Further research concerning the optimization of the production process is needed, as previously tested pretreatment methods have not increased the conversion efficiency to the levels necessary for commercialization of the process.

RESULTS

We propose steam pretreatment of animal bedding, consisting of a mixture of straw and cow manure, to deliver higher ethanol yields. The temperature, residence time and pH were optimized through response-surface modeling, where pretreatment was evaluated based on the ethanol yield obtained through simultaneous saccharification and fermentation of the whole pretreated slurry. The results show that the best conditions for steam pretreatment are 200 °C, for 5 min at pH 2, at which an ethanol yield of about 70% was obtained. Moreover, the model also showed that the pH had the greatest influence on the ethanol yield, followed by the temperature and then the residence time.

CONCLUSIONS

Based on these results, it appears that steam pretreatment could unlock the potential of animal bedding, as the same conversion efficiencies were achieved as for higher-quality feedstocks such as wheat straw.

Effects of combined pretreatment of dilute acid pre-extraction and chemical-assisted mechanical refining on enzymatic hydrolysis of lignocellulosic biomass

An efficient enzymatic hydrolysis of lignocellulosic biomass into fermentable sugars depends greatly on the pretreatment of raw materials. In this study, a combination of dilute acid pre-extraction and chemical-assisted mechanical refining was used to pretreat wood lignocellulosic biomass for subsequent enzymatic hydrolysis. This work analyzed the surface lignin concentration, specific surface area, crystallinity, fines content, fiber length, and kink index of the resultant pulp substrates and their effects on the enzymatic hydrolysis. The results showed that the combined pretreatment significantly enhanced the enzymatic hydrolysis efficiency, and the maximum glucose conversion yield and glucose concentration were 93.32% and 21.41 g L-1, respectively. It is found that the surface lignin concentration, specific surface area, and fines content significantly affected the enzymatic hydrolysis.

Properties important for solid-liquid separations change during the enzymatic hydrolysis of pretreated wheat straw

OBJECTIVES

The biochemical conversion of lignocellulosic biomass into renewable fuels and chemicals provides new challenges for industrial scale processes. One such process, which has received little attention, but is of great importance for efficient product recovery, is solid-liquid separations, which may occur both after pretreatment and after the enzymatic hydrolysis steps. Due to the changing nature of the solid biomass during processing, the solid-liquid separation properties of the biomass can also change. The objective of this study was to show the effect of enzymatic hydrolysis of cellulose upon the water retention properties of pretreated biomass over the course of the hydrolysis reaction.

RESULTS

Water retention value measurements, coupled with ¹H NMR T₂ relaxometry data, showed an increase in water retention and constraint of water by the biomass with increasing levels of cellulose hydrolysis. This correlated with an increase in the fines fraction and a decrease in particle size, suggesting that structural decomposition rather than changes in chemical composition was the most dominant characteristic.

CONCLUSIONS

With increased water retained by the insoluble fraction as cellulose hydrolysis proceeds, it may prove more difficult to efficiently separate hydrolysis residues from the liquid fraction with improved hydrolysis.

Enzymatic hydrolysis at high dry matter content: The influence of the substrates' physical properties and of loading strategies on mixing and energetic consumption

The present work investigates the impact of the physical properties and loading strategies of wheat straw and miscanthus on enzymatic hydrolysis at high DM concentration. Three parameters have been chosen to evaluate the enzymatic hydrolysis performance: (i) the mixing time, (ii) the energetic mixing consumption and (iii) the glucose concentration. It was demonstrated that the hydrolysis of miscanthus is easy to perform and has low viscosity. On the contrary, the higher porosity grade of wheat straw than miscanthus (73% against 52%) contributed to have a very high viscosity at 20% w/w DM. The development of a fed-batch strategy allowed the reduction of viscosity inducing the energetic consumption lowering from 30 kJ to 10 kJ. It has been also proven that the miscanthus addition in wheat straw achieved to decrease mixing energy consumption at 5-8 kJ, when it represented more than 30% of the total mass of the reaction medium.

Lignin from hydrothermally pretreated grass biomass retards enzymatic cellulose degradation by acting as a physical barrier rather than by inducing nonproductive adsorption of enzymes

BACKGROUND

Lignin is known to hinder efficient enzymatic conversion of lignocellulose in biorefining processes. In particular, nonproductive adsorption of cellulases onto lignin is considered a key mechanism to explain how lignin retards enzymatic cellulose conversion in extended reactions.

RESULTS

Lignin-rich residues (LRRs) were prepared via extensive enzymatic cellulose degradation of corn stover (Zea mays subsp. mays L.), Miscanthus × giganteus stalks (MS) and wheat straw (Triticum aestivum L.) (WS) samples that each had been hydrothermally pretreated at three severity factors (log R₀) of 3.65, 3.83 and 3.97. The LRRs had different residual carbohydrate levels-the highest in MS; the lowest in WS. The residual carbohydrate was not traceable at the surface of the LRRs particles by ATR-FTIR analysis. The chemical properties of the lignin in the LRRs varied across the three types of biomass, but monolignols composition was not affected by the severity factor. When pure cellulose was added to a mixture of LRRs and a commercial cellulolytic enzyme preparation, the rate and extent of glucose release were unaffected by the presence of LRRs regardless of biomass type and severity factor, despite adsorption of the enzymes to the LRRs. Since the surface of the LRRs particles were covered by lignin, the data suggest that the retardation of enzymatic cellulose degradation during extended reaction on lignocellulosic substrates is due to physical blockage of the access of enzymes to the cellulose caused by the gradual accumulation of lignin at the surface of the biomass particles rather than by nonproductive enzyme adsorption.

CONCLUSIONS

The study suggests that lignin from hydrothermally pretreated grass biomass retards enzymatic cellulose degradation by acting as a physical barrier blocking the access of enzymes to cellulose rather than by inducing retardation through nonproductive adsorption of enzymes.

Hydrothermal extraction of hemicellulose: from lab to pilot scale

A flow-through reactor for hemicelluloses extraction with hot pressurized water was scaled with a factor of 73. System performance was evaluated by comparing the temperature profile, extraction yield and kinetics of the two systems, performing experiments at 160 and 170°C, 11barg for 90min, using catalpa wood as raw material. Hemicellulose yields were 33.9% and 38.8% (lab scale 160°C and 170°C) and 35.7% and 41.7% (pilot scale 160°C and 170°C). The pilot reactor was upgraded by designing a manifold system capable to provide samples with different liquid residence time during the same experiment. Tests at 140, 150, 160 and 170°C were carried for 90min. Increasing yields (9.3-40.6%) and decreasing molecular weights (4078-1417Da) were obtained at increasing the temperature. Biomass/water ratio of 1/27 gave total average concentration of xylose of 0.4g/L (140°C) to 1.8g/L (170°C).

Environmental impacts of producing bioethanol and biobased lactic acid from standalone and integrated biorefineries using a consequential and an attributional life cycle assessment approach

This study evaluates the environmental impacts of biorefinery products using consequential (CLCA) and attributional (ALCA) life cycle assessment (LCA) approaches. Within ALCA, economic allocation method was used to distribute impacts among the main products and the coproducts, whereas within the CLCA system expansion was adopted to avoid allocation. The study seeks to answer the questions (i) what is the environmental impacts of process integration?, and (ii) do CLCA and ALCA lead to different conclusions when applied to biorefinery?. Three biorefinery systems were evaluated and compared: a standalone system producing bioethanol from winter wheat-straw (system A), a standalone system producing biobased lactic acid from alfalfa (system B), and an integrated biorefinery system (system C) combining the two standalone systems and producing both bioethanol and lactic acid. The synergy of the integration was the exchange of useful energy necessary for biomass processing in the two standalone systems. The systems were compared against a common reference flow: "1MJ_EtOH+1kg_LA", which was set on the basis of products delivered by the system C. Function of the reference flow was to provide service of both fuel (bioethanol) at 99.9% concentration (wt. basis) and biochemical (biobased lactic acid) in food industries at 90% purity; both products delivered at biorefinery gate. The environmental impacts of interest were global warming potential (GWP₁₀₀), eutrophication potential (EP), non-renewable energy (NRE) use and the agricultural land occupation (ALO). Regardless of the LCA approach adopted, system C performed better in most of the impact categories than both standalone systems. The process wise contribution to the obtained environmental impacts also showed similar impact pattern in both approaches. The study also highlighted that the recirculation of intermediate materials, e.g. C₅ sugar to boost bioethanol yield and that the use of residual streams in the energy conversion were beneficial for optimizing the system performance.

Comparative assessment of selected sugarcane biorefinery-centered systems in Brazil: A multi-criteria method based on sustainability indicators

This work proposes a new sustainability assessment framework aiming to compare selected options of biorefineries subject to provide the same services to a community. At this end, a concept of biorefinery-centered system helps to develop a joint resources and policy-oriented comparison. When an option of biorefinery cannot provide the given amounts of certain services from its own production, it complements its supply portfolio by purchasing the lacking amounts from complementary and conventional production systems. The proposed sustainability assessment framework includes a multi-criteria method used to compare the selected biorefinery options resulting in identifying their respective weaknesses and strengths against categories of criteria. Finally, the methodology helps finding the non-dominated option. Application to selected sugarcane-based biorefineries shows promising results that match with those obtained in a previous work. However, the new methodology allows extended and richer analyses.

Mechanistic insights into the liquefaction stage of enzyme-mediated biomass deconstruction

Effective enzyme-mediated viscosity reduction, disaggregation, or "liquefaction," is required to overcome the rheological challenges resulting from the fibrous, hygroscopic nature of lignocellulosic biomass, particularly at the high solids loadings that will be required for an economically viable process. However, the actual mechanisms involved in enzyme-mediated liquefaction, as determined by viscosity or yield stress reduction, have yet to be fully resolved. Particle fragmentation, interparticle interaction, material dilution, and water-retention capacity were compared for their ability to quantify enzyme-mediated liquefaction of model and more realistic pretreated biomass substrates. It was apparent that material dilution and particle fragmentation occurred simultaneously and that both mechanisms contributed to viscosity/yield stress reduction. However, their relative importance was dependent on the nature of the biomass substrate. Interparticle interaction and enzyme-mediated changes to these interactions was shown to have a significant effect on slurry rheology. Liquefaction was shown to result from the combined action of material dilution, particle fragmentation, and alteration of interactions at particle surfaces. However, the observed changes in water retention capacity did not correlate with yield stress reduction. The relative importance of each mechanism was significantly influenced by the nature of the biomass substrate and its physicochemical properties. An ongoing challenge is that mechanisms, such as refining, which enhance enzyme accessibility to the cellulosic component of the substrate, are detrimental to slurry rheology and will likely impede enzyme-mediated liquefaction when high substrate concentrations are used.

Mathematical modeling of the ethanol fermentation of cashew apple juice by a flocculent yeast: the effect of initial substrate concentration and temperature

In this work, the effect of initial sugar concentration and temperature on the production of ethanol by Saccharomyces cerevisiae CCA008, a flocculent yeast, using cashew apple juice in a 1L-bioreactor was studied. The experimental results were used to develop a kinetic model relating biomass, ethanol production and total reducing sugar consumption. Monod, Andrews, Levenspiel and Ghose and Tyagi models were investigated to represent the specific growth rate without inhibition, with inhibition by substrate and with inhibition by product, respectively. Model validation was performed using a new set of experimental data obtained at 34 °C and using 100 g L^-1 of initial substrate concentration. The model proposed by Ghose and Tyagi was able to accurately describe the dynamics of ethanol production by S. cerevisiae CCA008 growing on cashew apple juice, containing an initial reducing sugar concentration ranging from 70 to 170 g L^-1 and temperature, from 26 to 42 °C. The model optimization was also accomplished based on the following parameters: percentage volume of ethanol per volume of solution (%V _ethanol/V _solution), efficiency and reaction productivity. The optimal operational conditions were determined using response surface graphs constructed with simulated data, reaching an efficiency and a productivity of 93.5% and 5.45 g L^-1 h^-1, respectively.

Using polyvinylpyrrolidone to enhance the enzymatic hydrolysis of lignocelluloses by reducing the cellulase non-productive adsorption on lignin

Polyvinylpyrrolidone (PVP) is an antifouling polymer to resist the adsorption of protein on solid surface. Effects of PVP on the enzymatic hydrolysis of pretreated lignocelluloses and its mechanism were studied. Adding 1g/L of PVP8000, the enzymatic digestibility of eucalyptus pretreated by dilute acid (Eu-DA) was increased from 28.9% to 73.4%, which is stronger than the classic additives, such as PEG, Tween and bovine serum albumin. Compared with PEG4600, the adsorption of PVP8000 on lignin was larger, and the adsorption layer was more stable and hydrophilic. Therefore, PVP8000 reduced 73.1% of the cellulase non-productive adsorption on lignin and enhanced the enzymatic hydrolysis of lignocelluloses greatly.

Pilot scale dilute acid pretreatment of rice straw and fermentable sugar recovery at high solid loadings

The aim of this work was to study the dilute acid pretreatment of rice straw (RS) and fermentable sugar recovery at high solid loadings at pilot scale. A series of pretreatment experiments were performed on RS resulting in >25wt% solids followed by enzymatic hydrolysis without solid-liquid separation at 20 and 25wt% using 10FPU/g of the pretreated residue. The overall sugar recovery including the sugars released in pretreatment and enzymatic hydrolysis was calculated along with a mass balance. Accordingly, the optimized conditions, i.e. 0.35wt% acid, 162°C and 10min were identified. The final glucose and xylose concentrations obtained were 83.3 and 31.9g/L respectively resulting in total concentration of 115.2g/L, with a potential to produce >50g/L of ethanol. This is the first report on pilot scale study on acid pretreatment of RS in a screw feeder horizontal reactor followed by enzymatic hydrolysis at high solid loadings.

Oxidative production of xylonic acid using xylose in distillation stillage of cellulosic ethanol fermentation broth by Gluconobacter oxydans

An oxidative production process of xylonic acid using xylose in distillation stillage of cellulosic ethanol fermentation broth was designed, experimentally investigated, and evaluated. Dry dilute acid pretreated and biodetoxified corn stover was simultaneously saccharified and fermented into 59.80g/L of ethanol (no xylose utilization). 65.39g/L of xylose was obtained in the distillation stillage without any concentrating step after ethanol was distillated. Then the xylose was completely converted into 66.42g/L of xylonic acid by Gluconobacter oxydans. The rigorous Aspen Plus modeling shows that the wastewater generation and energy consumption was significantly reduced comparing to the previous xylonic acid production process using xylose in pretreatment liquid. This study provided a practical process option for xylonic acid production from lignocellulose feedstock with significant reduction of wastewater and energy consumption.

Micromorphological changes and mechanism associated with wet ball milling of Pinus radiata substrate and consequences for saccharification at low enzyme loading

In this work, substrates prepared from thermo-mechanical treatment of Pinus radiata chips were vibratory ball milled for different times. In subsequent enzymatic hydrolysis, percent glucan conversion passed through a maximum value at a milling time of around 120min and then declined. Scanning electron microscopy revealed breakage of fibers to porous fragments in which lamellae and fibrils were exposed during ball milling. Over-milling caused compression of the porous fragments to compact globular particles with a granular texture, decreasing accessibility to enzymes. Carbon-13 NMR spectroscopy showed partial loss of interior cellulose in crystallites, leveling off once fiber breakage was complete. A mathematical model based on observed micromorphological changes supports ball milling mechanism. At a low enzyme loading of 2FPU/g of substrate and milling time of 120min gave a total monomeric sugar yield of 306g/kg of pulp which is higher than conventional pretreatment method such as steam exploded wood.

Combination of high solids loading pretreatment and ethanol fermentation of whole slurry of pretreated rice straw to obtain high ethanol titers and yields

In cellulosic ethanol production using lignocellulose, an increase in biomass solids loading during the pretreatment process significantly affects the final ethanol titer and the production cost. In this study, pretreatment using rice straw at high solids loading (20% (w/v)) was evaluated, using maleic acid as a catalyst. After pretreatment at optimal conditions of 190°C, 20 min, and 0.2% or 5% (w/v) maleic acid, the highest enzymatic digestibility obtained was over 80%. Simultaneous saccharification and fermentation (SSF) of the whole slurry of pretreated rice straw in the presence of activated carbon to separate inhibitory compounds generated a high ethanol yield of 62.8%, based on the initial glucan in unpretreated rice straw. These findings suggest that high solids loading pretreatment using maleic acid and SSF of the whole slurry of pretreated rice straw can be combined to improve the process economics of ethanol production.

Comparative techno-economic assessment and LCA of selected integrated sugarcane-based biorefineries

This work addresses the economic and environmental performance of integrated biorefineries based on sugarcane juice and residues. Four multiproduct scenarios were considered; two from sugar mills and the others from ethanol distilleries. They are integrated biorefineries producing first (1G) and second (2G) generation ethanol, sugar, molasses (for animal feed) and electricity in the context of Brazil. The scenarios were analysed and compared using techno-economic value-based approach and LCA methodology. The results show that the best economic configuration is provided by a scenario with largest ethanol production while the best environmental performance is presented by a scenario with full integration sugar - 1G2G ethanol production.

The effect of a combined biological and thermo-mechanical pretreatment of wheat straw on energy yields in coupled ethanol and methane generation

Ethanol and biogas are energy carriers that could contribute to a future energy system independent of fossil fuels. Straw is a favorable bioenergy substrate as it does not compete with food or feed production. As straw is very resistant to microbial degradation, it requires a pretreatment to insure efficient conversion to ethanol and/or methane. This study investigates the effect of combining biological pretreatment and steam explosion on ethanol and methane yields in order to improve the coupled generation process. Results show that the temperature of the steam explosion pretreatment has a particularly strong effect on possible ethanol yields, whereas combination with the biological pretreatment showed no difference in overall energy yield. The highest overall energy output was found to be 10.86 MJ kg VS(-1) using a combined biological and steam explosion pretreatment at a temperature of 200°C.

Optimization of uncatalyzed steam explosion pretreatment of rapeseed straw for biofuel production

Rapeseed straw constitutes an agricultural residue with great potential as feedstock for ethanol production. In this work, uncatalyzed steam explosion was carried out as a pretreatment to increase the enzymatic digestibility of rapeseed straw. Experimental statistical design and response surface methodology were used to evaluate the influence of the temperature (185-215°C) and the process time (2.5-7.5min). According to the rotatable central composite design applied, 215°C and 7.5min were confirmed to be the optimal conditions, considering the maximization of enzymatic hydrolysis yield as optimization criterion. These conditions led to a maximum yield of 72.3%, equivalent to 81% of potential glucose in pretreated solid. Different configurations for bioethanol production from steam exploded rapeseed straw were investigated using the pretreated solid obtained under optimal conditions as a substrate. As a relevant result, concentrations of ethanol as high as 43.6g/L (5.5% by volume) were obtained as a consequence of using 20% (w/v) solid loading, equivalent to 12.4g ethanol/100g biomass.

Temperature Effects on Kinetic Parameters and Substrate Affinity of Cel7A Cellobiohydrolases

We measured hydrolytic rates of four purified cellulases in small increments of temperature (10-50 °C) and substrate loads (0-100 g/liter) and analyzed the data by a steady state kinetic model that accounts for the processive mechanism. We used wild type cellobiohydrolases (Cel7A) from mesophilic Hypocrea jecorina and thermophilic Rasamsonia emersonii and two variants of these enzymes designed to elucidate the role of the carbohydrate binding module (CBM). We consistently found that the maximal rate increased strongly with temperature, whereas the affinity for the insoluble substrate decreased, and as a result, the effect of temperature depended strongly on the substrate load. Thus, temperature had little or no effect on the hydrolytic rate in dilute substrate suspensions, whereas strong temperature activation (Q10 values up to 2.6) was observed at saturating substrate loads. The CBM had a dual effect on the activity. On one hand, it diminished the tendency of heat-induced desorption, but on the other hand, it had a pronounced negative effect on the maximal rate, which was 2-fold larger in variants without CBM throughout the investigated temperature range. We conclude that although the CBM is beneficial for affinity it slows down the catalytic process. Cel7A from the thermophilic organism was moderately more activated by temperature than the mesophilic analog. This is in accord with general theories on enzyme temperature adaptation and possibly relevant information for the selection of technical cellulases.

Hydrothermal pretreatment of several lignocellulosic mixtures containing wheat straw and two hardwood residues available in Southern Europe

This work studied the processing of biomass mixtures containing three lignocellulosic materials largely available in Southern Europe, eucalyptus residues (ER), wheat straw (WS) and olive tree pruning (OP). The mixtures were chemically characterized, and their pretreatment, by autohydrolysis, evaluated within a severity factor (logR0) ranging from 1.73 up to 4.24. A simple modeling strategy was used to optimize the autohydrolysis conditions based on the chemical characterization of the liquid fraction. The solid fraction was characterized to quantify the polysaccharide and lignin content. The pretreatment conditions for maximal saccharides recovery in the liquid fraction were at a severity range (logR0) of 3.65-3.72, independently of the mixture tested, which suggests that autohydrolysis can effectively process mixtures of lignocellulosic materials for further biochemical conversion processes.

From wheat straw to bioethanol: integrative analysis of a separate hydrolysis and co-fermentation process with implemented enzyme production

BACKGROUND

Lignocellulosic ethanol has a high potential as renewable energy source. In recent years, much research effort has been spent to optimize parameters involved in the production process. Despite that, there is still a lack of comprehensive studies on process integration. Single parameters and process configurations are, however, heavily interrelated and can affect the overall process efficiency in a multitude of ways. Here, we present an integrative approach for bioethanol production from wheat straw at a representative laboratory scale using a separate hydrolysis and co-fermentation (SHCF) process. The process does not rely on commercial (hemi-) cellulases but includes enzyme production through Hypocrea jecorina (formerly Trichoderma reesei) on the pre-treated feedstock as key unit operation. Hydrolysis reactions are run with high solid loadings of 15% dry mass pre-treated wheat straw (DM WS), and hydrolyzates are utilized without detoxification for mixed glucose-xylose fermentation with the genetically and evolutionary engineered Saccharomyces cerevisiae strain IBB10B05.

RESULTS

Process configurations of unit operations in the benchtop SHCF were varied and evaluated with respect to the overall process ethanol yield (Y Ethanol-Process). The highest Y Ethanol-Process of 71.2 g ethanol per kg raw material was reached when fungal fermentations were run as batch, and the hydrolysis reaction was done with an enzyme loading of 30 filter paper units (FPU)/gDM WS. 1.7 ± 0.1 FPU/mL were produced, glucose and xylose were released with a conversion efficiency of 67% and 95%, respectively, and strain IBB10B05 showed an ethanol yield of 0.4 g/gGlc + Xyl in 15% hydrolyzate fermentations. Based on the detailed process analysis, it was further possible to identify the enzyme yield, the glucose conversion efficiency, and the mass losses between the unit operations as key process parameters, exhibiting a major influence on Y Ethanol-Process.

CONCLUSIONS

Y Ethanol-Process is a measure for the efficiency of the lignocellulose-to-bioethanol process. Based on mass balance analysis, the correlations between single process parameters and Y Ethanol-Process were elucidated. The optimized laboratory scale SHCF process showed efficiencies similar to pilot scale plants. The herein presented process analysis can serve as effective and simple tool to identify key process parameters, bottlenecks, and future optimization targets.