Fed-Batch Enzymatic Saccharification of High Solids Pretreated Lignocellulose for Obtaining High Titers and High Yields of Glucose

Efficient enzymatic hydrolysis of sweet potato residue by fed-batch method to prepare high- concentration glucose

China is the largest producer and exporter of sweet potato in the world. Sweet potato residue (SPR) separated after starch extraction account for more than 10% of the total dry matter of sweet potatoes. However, large amounts of unutilized SPR can cause environmental pollution. SPR is rich in starch and cellulose, both of which can be converted into glucose, making it a good carbon source for microbial fermentation. Therefore, an efficient SPR enzymatic process needs to be developed. The technological conditions of high-solid enzymatic hydrolysis of SPR by fed-batch was investigated in detail. Cellulase, amylase, and pectinase had synergistic effects on SPR enzymatic digestion. The experiments were first conducted to optimize the total enzyme addition of 15 mg enzyme protein/g substrate. The experiments were designed using Design-Expert (10.0) to optimize the enzyme proportions to 42%, 31.8%, and 26.2% for cellulase, amylase, and pectinase, respectively. The fed-batch enzymatic hydrolysis of SPR was investigated. The feed time and amount were optimized. The results showed that the initial SPR enzymatic hydrolysis concentration was 14% (w/v), 9% (w/v) was added at 3 h, 6 h and 12 h, respectively and the final substrate concentration was 41% (w/v). After 24 h of enzymatic hydrolysis, the glucose concentration obtained was 194.57 g/L and the glucan conversion was 63.58%. The fed-batch enzymatic hydrolysis of SPR described in this study has great potential for the whole chain utilization of sweet potato and in the microbial fermentation industry as it is environmentally friendly, economical and efficient.

Preparation of cellulose microfibrils from Gelidium amansii relieving ocular endoplasmic reticulum stress and inflammatory responses in human retinal pigmented epithelial cells

This study investigated the physicochemical properties of cellulose microfibrils (CMFs) derived from Gelidium amansii (GA) and their potential functionality in preventing retinal pathologies. GA was subjected to microwave-assisted extraction, microfibrillation, centrifugation, and autoclave sterilization, yielding G, GM, GC, and GS, respectively. Each processing steps induced distinct microstructural modifications affecting the final functional properties of the CMFs. To explore their protective effects against anti-endoplasmic reticulum (ER) stress and anti-inflammatory effects, ARPE-19 cells were pretreated with these processed CMFs before exposure to either thapsigargin or lipopolysaccharide. Among the variants, GS most effectively alleviated ocular ER stress by suppressing unfolded protein responses, reducing vascular endothelial growth factor gene and protein expressions, and lowering intracellular calcium levels. Moreover, GS significantly mitigated ocular inflammatory responses by inhibiting the translocation of nuclear factor-kappa B (NF-κB) into the nucleus; consequently preserving tight-junction integrity and downregulating inflammatory cytokine gene expressions. These findings highlight the potential of GS as a protective agent against retinal stress and inflammation.

Co-production of high-concentration fermentable sugar and lignin-based bio-adhesive from corncob residue via an enhanced enzymatic hydrolysis

Xylose plants (produce xylose from corncob through dilute acid treatment) generate a large amount of corncob residue (CCR), most of which are burned and lacked of valorization. Herein, to address this issue, CCR was directly used as starting material for high-solid loading enzymatic hydrolysis via a simple strategy by combining PFI homogenization (for sufficient mixing) with batch-feeding. A maximum glucose concentration of 187.1 g/L was achieved after the saccharification with a solid loading of 25 wt% and enzyme dosage of 10 FPU/g-CCR. Furthermore, the residue of enzymatic hydrolysis (REH) was directly used as a bio-adhesive for plywood production with both high dry (1.7 MPa) and wet (1.1 MPa) surface bonding strength (higher than the standard (0.7 MPa)), and the excellent adhesion was due to the interfacial crosslinking between the REH adhesive (containing lignin, free glucose, and nanosized fibers) and cell wall of woods. Compared with traditional reported adhesives, the REH bio-adhesive has advantages of formaldehyde-free, good moisture resistance, green process, relatively low cost and easy realization. This study presents a simple and effective strategy for better utilization of CCR, which also provides beneficial reference for the valorization of other kinds of lignocellulosic biomass.

A critical assessment on scalable technologies using high solids loadings in lignocellulose biorefinery: challenges and solutions

The pretreatment and the enzymatic saccharification are the key steps in the extraction of fermentable sugars for further valorization of lignocellulosic biomass (LCB) to biofuels and value-added products via biochemical and/or chemical conversion routes. Due to low density and high-water absorption capacity of LCB, the large volume of water is required for its processing. Integration of pretreatment, saccharification, and co-fermentation has succeeded and well-reported in the literature. However, there are only few reports on extraction of fermentable sugars from LCB with high biomass loading (>10% Total solids-TS) feasible to industrial reality. Furthermore, the development of enzymatic cocktails can overcome technology hurdles with high biomass loading. Hence, a better understanding of constraints involved in the development of technology with high biomass loading can result in an economical and efficient yield of fermentable sugars for the production of biofuels and bio-chemicals with viable titer, rate, and yield (TRY) at industrial scale. The present review aims to provide a critical assessment on the production of fermentable sugars from lignocelluloses with high solid biomass loading. The impact of inhibitors produced during both pretreatment and saccharification has been elucidated. Moreover, the limitations imposed by high solid loading on efficient mass transfer during saccharification process have been elaborated.

Addressing two major limitations in high-solids enzymatic hydrolysis by an ordered polyethylene glycol pre-incubated strategy: Rheological properties and lignin adsorption for enzyme

High-solids enzymatic hydrolysis for biomass has currently received considerable interest. However, the solid effect during the process limits its economic feasibility. This work presented an ordered polyethylene glycol (PEG) pre-incubated strategy for enhancing the auxiliary effect of PEG in a high-solids enzymatic hydrolysis system. The substrate and enzyme were separately pre-incubated with PEG in this strategy. The ordered PEG pre-incubated strategies yielded a maximum glucose concentration of 166.6 g/L from 32 % (w/v) pretreated corncob with an enzymatic yield of 94.1 % by 72 h hydrolysis. Using this method, PEG not only lessened the lignin adsorption to cellulase but also altered particle rheological characteristics in the high-solids enzymatic hydrolysis system as a viscosity modifier. This study offered a new insight into the mechanism behind the PEG synergistic effect and would make it possible to achieve efficient high-solids loading hydrolysis in the commercial manufacture of cellulosic ethanol.

Enzymatic Hydrolysis Strategies for Cellulosic Sugars Production to Obtain Bioethanol from Eucalyptus globulus Bark

Cellulosic sugars production for the valorization of lignocellulosic biomass residues in an industrial site has economic benefits and is promising if integrated into a biorefinery. Enzymatic hydrolysis (EH) of pretreated Eucalyptus globulus bark, an industrial residue of low-economic value widely available in Portuguese pulp and paper mills, could be an excellent approach to attain resource circularity and pulp mill profitability. This work evaluated the potential for improving cellulosic sugars concentrations by operating with high solids loading and introducing the additives Triton X-100, PEG 4000 and Tween 80 using a commercial enzymatic consortium with a dosage of 25 FPU gcarbohydrates−1. Additives did not improve enzymatic hydrolysis performance, but the effect of increasing solids loading to 14% (w/v) in batch operation was accomplished. The fed-batch operation strategy was investigated and, when starting with 11% (w/v) solids loading, allowed the feeding of 3% (w/v) fresh feedstock sequentially at 2, 4 and 6 h, attaining 20% (w/v) total solids loading. After 24 h of operation, the concentration of cellulosic sugars reached 161 g L−1, corresponding to an EH conversion efficiency of 76%. Finally, the fermentability of the fed-batch hydrolysate using the Ethanol Red® strain was evaluated in a 5 L bioreactor scale. The present results demonstrate that Eucalyptus globulus bark, previously pretreated by kraft pulping, is a promising feedstock for cellulosic sugars production, allowing it to become the raw material for feeding a wide range of bioprocesses.

Pretreatment Strategies to Enhance Enzymatic Hydrolysis and Cellulosic Ethanol Production for Biorefinery of Corn Stover

There is a rising interest in bioethanol production from lignocellulose such as corn stover to decrease the need for fossil fuels, but most research mainly focuses on how to improve ethanol yield and pays less attention to the biorefinery of corn stover. To realize the utilization of different components of corn stover in this study, different pretreatment strategies were used to fractionate corn stover while enhancing enzymatic digestibility and cellulosic ethanol production. It was found that the pretreatment process combining dilute acid (DA) and alkaline sodium sulfite (ASS) could effectively fractionate the three main components of corn stover, i.e., cellulose, hemicellulose, and lignin, that xylose recovery reached 93.0%, and that removal rate of lignin was 85.0%. After the joint pretreatment of DA and ASS, the conversion of cellulose at 72 h of enzymatic hydrolysis reached 85.4%, and ethanol concentration reached 48.5 g/L through fed-batch semi-simultaneous saccharification and fermentation (S-SSF) process when the final concentration of substrate was 18% (w/v). Pretreatment with ammonium sulfite resulted in 83.8% of lignin removal, and the conversion of cellulose and ethanol concentration reached 86.6% and 50 g/L after enzymatic hydrolysis of 72 h and fed-batch S-SSF, respectively. The results provided a reference for effectively separating hemicellulose and lignin from corn stover and producing cellulosic ethanol for the biorefinery of corn stover.

Advances and Challenges in Biocatalysts Application for High Solid-Loading of Biomass for 2nd Generation Bio-Ethanol Production

Growth in population and thereby increased industrialization to meet its requirement, has elevated significantly the demand for energy resources. Depletion of fossil fuel and environmental sustainability issues encouraged the exploration of alternative renewable eco-friendly fuel resources. Among major alternative fuels, bio-ethanol produced from lignocellulosic biomass is the most popular one. Lignocellulosic biomass is the most abundant renewable resource which is ubiquitous on our planet. All the plant biomass is lignocellulosic which is composed of cellulose, hemicellulose and lignin, intricately linked to each other. Filamentous fungi are known to secrete a plethora of biomass hydrolyzing enzymes. Mostly these enzymes are inducible, hence the fungi secrete them economically which causes challenges in their hyperproduction. Biomass’s complicated structure also throws challenges for which pre-treatments of biomass are necessary to make the biomass amorphous to be accessible for the enzymes to act on it. The enzymatic hydrolysis of biomass is the most sustainable way for fermentable sugar generation to convert into ethanol. To have sufficient ethanol concentration in the broth for efficient distillation, high solid loading ~<20% of biomass is desirable and is the crux of the whole technology. High solid loading offers several benefits including a high concentration of sugars in broth, low equipment sizing, saving cost on infrastructure, etc. Along with the benefits, several challenges also emerged simultaneously, like issues of mass transfer, low reaction rate due to water constrains in, high inhibitor concentration, non-productive binding of enzyme lignin, etc. This article will give an insight into the challenges for cellulase action on cellulosic biomass at a high solid loading of biomass and its probable solutions.

Emerging trends in high-solids enzymatic saccharification of lignocellulosic feedstocks for developing an efficient and industrially deployable sugar platform

For the techno-commercial success of any lignocellulosic biorefinery, the cost-effective production of fermentable sugars for the manufacturing of bio-based products is indispensable. High-solids enzymatic saccharification (HSES) is a straightforward approach to develop an industrially deployable sugar platform. Economic incentives such as reduced capital and operational expenditure along with environmental benefits in the form of reduced effluent discharge makes this strategy more lucrative for exploitation. However, HSES suffers from the drawback of non-linear and disproportionate sugar yields with increased substrate loadings. To overcome this bottleneck, researchers tend to perform HSES at high enzyme loadings. Nonetheless, the production costs of cellulases are one of the key contributors that impair the entire process economics. This review highlights the relentless efforts made globally to attain a high-titer of sugars and their fermentation products by performing efficient HSES at low cellulase loadings. In this context, technical innovations such as advancements in new pretreatment strategies, next-generation cellulase cocktails, additives, accessory enzymes, novel reactor concepts and enzyme recycling studies are especially showcased. This review further covers new insights, learnings and prospects in the area of lignocellulosic bioprocessing.

A high solids field-to-fuel research pipeline to identify interactions between feedstocks and biofuel production

BACKGROUND

Environmental factors, such as weather extremes, have the potential to cause adverse effects on plant biomass quality and quantity. Beyond adversely affecting feedstock yield and composition, which have been extensively studied, environmental factors can have detrimental effects on saccharification and fermentation processes in biofuel production. Only a few studies have evaluated the effect of these factors on biomass deconstruction into biofuel and resulting fuel yields. This field-to-fuel evaluation of various feedstocks requires rigorous coordination of pretreatment, enzymatic hydrolysis, and fermentation experiments. A large number of biomass samples, often in limited quantity, are needed to thoroughly understand the effect of environmental conditions on biofuel production. This requires greater processing and analytical throughput of industrially relevant, high solids loading hydrolysates for fermentation, and led to the need for a laboratory-scale high solids experimentation platform.

RESULTS

A field-to-fuel platform was developed to provide sufficient volumes of high solids loading enzymatic hydrolysate for fermentation. AFEX pretreatment was conducted in custom pretreatment reactors, followed by high solids enzymatic hydrolysis. To accommodate enzymatic hydrolysis of multiple samples, roller bottles were used to overcome the bottlenecks of mixing and reduced sugar yields at high solids loading, while allowing greater sample throughput than possible in bioreactors. The roller bottle method provided 42-47% greater liquefaction compared to the batch shake flask method for the same solids loading. In fermentation experiments, hydrolysates from roller bottles were fermented more rapidly, with greater xylose consumption, but lower final ethanol yields and CO₂ production than hydrolysates generated with shake flasks. The entire platform was tested and was able to replicate patterns of fermentation inhibition previously observed for experiments conducted in larger-scale reactors and bioreactors, showing divergent fermentation patterns for drought and normal year switchgrass hydrolysates.

CONCLUSION

A pipeline of small-scale AFEX pretreatment and roller bottle enzymatic hydrolysis was able to provide adequate quantities of hydrolysate for respirometer fermentation experiments and was able to overcome hydrolysis bottlenecks at high solids loading by obtaining greater liquefaction compared to batch shake flask hydrolysis. Thus, the roller bottle method can be effectively utilized to compare divergent feedstocks and diverse process conditions.

Comparative study of lactic acid production from date pulp waste by batch and cyclic-mode dark fermentation

Biowaste valorization into lactic acid (LA) by treatment with indigenous microbiota has recently gained considerable attention. LA production from date pulp waste provides an opportunity for resource recovery, reduces environmental issues, and possibly turns biomass into wealth. This study aimed to compare the performance of batch and cyclic fermentation processes in LA production with and without enzymatic pretreatment. The fermentation studies were conducted in the absence of an external inoculum source (relying on indigenous microbiota) and without the addition of nutrients. The highest LA volumetric productivity (3.56 g/liter/day), yield (0.07 g/g-TS), and concentration (21.66 g/L) were attained with enzymatic pretreated date pulp in the cyclic-mode fermentation at the optimized conditions. The productivity rate of LA was enhanced in the cyclic-mode as compared to the batch process. Enzymatic pretreatment increased the digestibility of cellulose that led to higher LA yield. An Artificial Neural Network model was developed to optimize the process parameters and to predict the LA concentration from date pulp waste in both fermentation processes. The main advantage of the ANN approach is the ability to perform quick predictions without resource-consuming experiments. The model predicted optimal conditions well and demonstrated good agreement between experimental and predicted data.

Conversion of Exhausted Sugar Beet Pulp into Fermentable Sugars from a Biorefinery Approach

In this study, the production of a hydrolysate rich in fermentable sugars, which could be used as a generic microbial culture medium, was carried out by using exhausted sugar beet pulp pellets (ESBPPs) as raw material. For this purpose, the hydrolysis was performed through the direct addition of the fermented ESBPPs obtained by fungal solid-state fermentation (SSF) as an enzyme source. By directly using this fermented solid, the stages for enzyme extraction and purification were avoided. The effects of temperature, fermented to fresh solid ratio, supplementation of fermented ESBPP with commercial cellulase, and the use of high-solid fed-batch enzymatic hydrolysis were studied to obtain the maximum reducing sugar (RS) concentration and productivity. The highest RS concentration and productivity, 127.3 g·L⁻¹ and 24.3 g·L⁻¹·h⁻¹ respectively, were obtained at 50 °C and with an initial supplementation of 2.17 U of Celluclast^® per gram of dried solid in fed-batch mode. This process was carried out with a liquid to solid ratio of 4.3 mL·g⁻¹ solid, by adding 15 g of fermented solid and 13.75 g of fresh solid at the beginning of the hydrolysis, and then the same amount of fresh solid 3 times every 2.5 h. By this procedure, ESBPP can be used to produce a generic microbial feedstock, which contains a high concentration of monosaccharides.

Constraints and advances in high-solids enzymatic hydrolysis of lignocellulosic biomass: a critical review

The industrial production of sugar syrups from lignocellulosic materials requires the conduction of the enzymatic hydrolysis step at high-solids loadings (i.e., with over 15% solids [w/w] in the reaction mixture). Such conditions result in sugar syrups with increased concentrations and in improvements in both capital and operational costs, making the process more economically feasible. However, this approach still poses several technical hindrances that impact the process efficiency, known as the "high-solids effect" (i.e., the decrease in glucan conversion yields as solids load increases). The purpose of this review was to present the findings on the main limitations and advances in high-solids enzymatic hydrolysis in an updated and comprehensive manner. The causes for the rheological limitations at the onset of the high-solids operation as well as those influencing the "high-solids effect" will be discussed. The subject of water constraint, which results in a highly viscous system and impairs mixing, and by extension, mass and heat transfer, will be analyzed under the perspective of the limitations imposed to the action of the cellulolytic enzymes. The "high-solids effect" will be further discussed vis-à-vis enzymes end-product inhibition and the inhibitory effect of compounds formed during the biomass pretreatment as well as the enzymes' unproductive adsorption to lignin. This review also presents the scientific and technological advances being introduced to lessen high-solids hydrolysis hindrances, such as the development of more efficient enzyme formulations, biomass and enzyme feeding strategies, reactor and impeller designs as well as process strategies to alleviate the end-product inhibition. We surveyed the academic literature in the form of scientific papers as well as patents to showcase the efforts on technological development and industrial implementation of the use of lignocellulosic materials as renewable feedstocks. Using a critical approach, we expect that this review will aid in the identification of areas with higher demand for scientific and technological efforts.

Enhancement of high-solids enzymatic hydrolysis efficiency of alkali pretreated sugarcane bagasse at low cellulase dosage by fed-batch strategy based on optimized accessory enzymes and additives

Obtaining higher amount of final sugars with low cellulase dosage has great economic benefits for the industrial biorefinery of lignocellulosic biomass. The optimization of accessory enzymes and additives were performed using single factor and orthogonal experiment firstly, after that, fed-batch strategy was applied to enhance the high-solids enzymatic hydrolysis efficiency of alkali pretreated sugarcane bagasse (SCB). A novel enzymatic hydrolysis procedure with 22% (w/v) substrate content and cellulase dosage of only 4 FPU/g dry biomass (DM) was developed, after digested for 48 h, the achieved glucose titer, yield and productivity were 122 g/L, 80% and 2.54 g L^-1 h^-1, respectively. Results obtained in this study indicated a potential finding for the industrial application of lignocellulosic biomass.

Pretreatment and enzymatic saccharification of oak at high solids loadings to obtain high titers and high yields of sugars

Production of high-titer sugar from lignocellulose is important in terms of process economics of bio-based product industry. In this study, to obtain high titers and yields of sugars, we combined pretreatment and saccharification steps, both at high solids loadings. First, pretreatment of oak was optimized at a 30% (w/w) solids loading. The whole slurry of the pretreated oak was subjected to a fed-batch saccharification step at the final solids loading of 30%, to minimize loss of fermentable sugars and simplify the processes. As a result, high-titer sugars (157.5 g/L) consisting of 120.2 g/L of glucose and 37.3 g/L of xylose were obtained at 75.9% and 58.6%, respectively, of theoretical maximum yields, based on the initial glucan and xylan contents. Thus, through proper optimization processes of oak, the combination of pretreatment and saccharification at high solids loadings was effective in obtaining both high titers and high yields of sugars from lignocellulose.

Fractionation of Lignocellulosic Biomass over Core-Shell Ni@Al2 O3 Catalysts with Formic Acid as a Cocatalyst and Hydrogen Source

Highly dispersed, core-shell Ni@Al₂ O₃ on activated carbon (AC) catalysts were prepared to develop an effective, external-hydrogen-free fractionation process for various types of lignocellulosic biomass. In a mixture of formic acid, ethanol, and water at 190 °C, the conversion of oak wood produced 23.4 C% lignin-derived phenolic monomers (LDPMs) and highly delignified pulp-rich solid. At an early stage, formic acid acted as a cocatalyst to enhance the delignification by solvolysis, and at a later stage, it acted as a hydrogen source to stabilize the phenolic monomers by hydrodeoxygenation and hydrogenation. Based on the positive correlation between spillover hydrogen on the catalysts and LDPM yields, a new suite of catalyst design criteria was proposed to develop highly active, non-noble-metal based catalysts for realizing economically viable biorefineries. Enzymatic saccharification of the pulp-rich solid indicated that the pulp-rich solid is an excellent source of fermentable sugars.

From batch to fed-batch and to continuous packed-bed reactors: Lipase-catalyzed esterifications in low viscous deep-eutectic-solvents with buffer as cosolvent

This work explores for the first time the use of Deep Eutectic Solvents (DES) with phosphate buffer 100 mM pH 7 as cosolvent (10% v/v) in biocatalytic reactions in fed-batch and packed-bed bioreactors. The lipase-catalyzed esterification of glycerol and benzoic acid is studied, as it involves two substrates with different polarities (for which DES are needed). In the fed-batch bioreactor, the highest conversion (90%) was obtained at a substrate flow rate of 0.01 mL/min. The fed-batch operation increased the conversion by 59% compared to the batch mode. Regarding productivity, semi-continuous and continuous bioreactors showed analogous results. Upon recirculation of the reaction media in the continuous bioreactor, a conversion of 67% was achieved in 7 cycles of operation. The stability of the biocatalyst in the packed-bed bioreactor decreased only 2% in 10 days, demonstrating the attractiveness that low viscous DES-water mixtures with continuous processes may have.

Optimization of the Enzymatic Saccharification Process of Milled Orange Wastes

Orange juice production generates a very high quantity of residues (Orange Peel Waste or OPW-50–60% of total weight) that can be used for cattle feed as well as feedstock for the extraction or production of essential oils, pectin and nutraceutics and several monosaccharides by saccharification, inversion and enzyme-aided extraction. As in all solid wastes, simple pretreatments can enhance these processes. In this study, hydrothermal pretreatments and knife milling have been analyzed with enzyme saccharification at different dry solid contents as the selection test: simple knife milling seemed more appropriate, as no added pretreatment resulted in better final glucose yields. A Taguchi optimization study on dry solid to liquid content and the composition of the enzymatic cocktail was undertaken. The amounts of enzymatic preparations were set to reduce their impact on the economy of the process; however, as expected, the highest amounts resulted in the best yields to glucose and other monomers. Interestingly, the highest content in solid to liquid (11.5% on dry basis) rendered the best yields. Additionally, in search for process economy with high yields, operational conditions were set: medium amounts of hemicellulases, polygalacturonases and β-glucosidases. Finally, a fractal kinetic modelling of results for all products from the saccharification process indicated very high activities resulting in the liberation of glucose, fructose and xylose, and very low activities to arabinose and galactose. High activity on pectin was also observed, but, for all monomers liberated initially at a fast rate, high hindrances appeared during the saccharification process.