Co-production of ethanol, biogas, protein fodder and natural fertilizer in organic farming--evaluation of a concept for a farm-scale biorefinery

Process scale-up simulation and techno-economic assessment of ethanol fermentation from cheese whey

BACKGROUND

Production of cheese whey in the EU exceeded 55 million tons in 2022, resulting in lactose-rich effluents that pose significant environmental challenges. To address this issue, the present study investigated cheese-whey treatment via membrane filtration and the utilization of its components as fermentation feedstock. A simulation model was developed for an industrial-scale facility located in Italy's Apulia region, designed to process 539 m3/day of untreated cheese-whey. The model integrated experimental data from ethanolic fermentation using a selected strain of Kluyveromyces marxianus in lactose-supplemented media, along with relevant published data.

RESULTS

The simulation was divided into three different sections. The first section focused on cheese-whey pretreatment through membrane filtration, enabling the recovery of 56%w/w whey protein concentrate, process water recirculation, and lactose concentration. In the second section, the recovered lactose was directed towards fermentation and downstream anhydrous ethanol production. The third section encompassed anaerobic digestion of organic residue, sludge handling, and combined heat and power production. Moreover, three different scenarios were produced based on ethanol yield on lactose (YE/L), biomass yield on lactose, and final lactose concentration in the medium. A techno-economic assessment based on the collected data was performed as well as a sensitivity analysis focused on economic parameters, encompassing considerations on cheese-whey by assessing its economical impact as a credit for the simulated facility, dictated by a gate fee, or as a cost by considering it a raw material. The techno-economic analysis revealed different minimum ethanol selling prices across the three scenarios. The best performance was obtained in the scenario presenting a YE/L = 0.45 g/g, with a minimum selling price of 1.43 €/kg. Finally, sensitivity analysis highlighted the model's dependence on the price or credit associated with cheese-whey handling.

CONCLUSIONS

This work highlighted the importance of policy implementation in this kind of study, demonstrating how a gate fee approach applied to cheese-whey procurement positively impacted the final minimum selling price for ethanol across all scenarios. Additionally, considerations should be made about the implementation of the simulated process as a plug-in addition in to existing processes dealing with dairy products or handling multiple biomasses to produce ethanol.

Enhanced volatile fatty acids production from anaerobic fermentation of food waste: A mini-review focusing on acidogenic metabolic pathways

Recently, efficient disposal of food waste (FW) with potential resource recovery has attracted great attentions. Due to its easily biodegradable nature, rich nutrient availability and high moisture content, FW is regarded as favorable substrate for anaerobic digestion (AD). Both waste disposal and energy recovery can be fulfilled during AD of FW. Volatile fatty acids (VFAs) which are the products of the first-two stages of AD, are widely applied in chemical industry as platform chemicals recently. Concentration and distribution of VFAs is the result of acidogenic metabolic pathways, which can be affected by the micro-environment (e.g. pH) in the digester. Hence, the clear elucidation of the acidogenic metabolic pathways is essential for optimization of acidogenic process for efficient product recovery. This review summarizes major acidogenic metabolic pathways and regulating strategies for enhancing VFAs recovery during acidogenic fermentation of FW.

Systemic colonization of clover (Trifolium repens) by Clostridium botulinum strain 2301

In recent years, cases of botulism in cattle and other farm animals and also in farmers increased dramatically. It was proposed, that these cases could be affiliated with the spreading of compost or other organic manures contaminated with Clostridium botulinum spores on farm land. Thus, soils and fodder plants and finally farm animals could be contaminated. Therefore, the colonization behavior and interaction of the botulinum neurotoxin (BoNT D) producing C. botulinum strain 2301 and the non-toxin producing Clostridium sporogenes strain 1739 were investigated on clover (Trifolium repens) in a field experiment as well as in phytochamber experiments applying axenic and additionally soil based systems under controlled conditions. Plants were harvested and divided into root and shoot parts for further DNA isolation and polymerase chain reaction (PCR) assays; subsamples were fixed for fluorescence in situ hybridization analysis in combination with confocal laser scanning microscopy. In addition, we observed significant differences in the growth behavior of clover plants when inoculated with clostridial spores, indicating a plant growth promoting effect. Inoculated plants showed an increased growth index (shoot size, wet and dry weight) and an enlarged root system induced by the systemic colonization of clover by C. botulinum strain 2301. To target C. botulinum and C. sporogenes, 16S rDNA directed primers were used and to specifically detect C. botulinum, BoNT D toxin genes targeted primers, using a multiplex PCR approach, were applied. Our results demonstrate an effective colonization of roots and shoots of clover by C. botulinum strain 2301 and C. sporogenes strain 1739. Detailed analysis of colonization behavior showed that C. botulinum can occur as individual cells, in cell clusters and in microcolonies within the rhizosphere, lateral roots and within the roots tissue of clover.

Ethanol production from industrial hemp: effect of combined dilute acid/steam pretreatment and economic aspects

In the present study, combined steam (140-180°C) and dilute-acid pre-hydrolysis (0.0-2.0%) were applied to industrial hemp (Cannabis sativa L.), as pretreatment for lignocellulosic bioethanol production. The influence of the pretreatment conditions and cultivation type on the hydrolysis and ethanol yields was also evaluated. Pretreatment with 1% sulfuric acid at 180°C resulted in the highest glucose yield (73-74%) and ethanol yield of 75-79% (0.38-0.40 g-ethanol/g-glucose). Taking into account the costs of biomass processing, from field to ethanol facility storage, the field-dried hemp pretreated at the optimal conditions showed positive economic results. The type of hemp cultivation (organic or conventional) did not influence significantly the effectiveness of the pretreatment as well as subsequent enzymatic hydrolysis and ethanol fermentation.

Development and validation of a technoeconomic analysis tool for early-stage evaluation of bio-based chemical production processes

By using cost correlations and standard scale-factors, a spreadsheet-based early-stage cost estimation tool was developed. Named BioPET (Biorenewables Process Evaluation Tool), this tool allows users to specify up to seven primary unit operations--fermentation, separation, three catalytic stages, and purification--along with key parameters for each. BioPET then computes an estimated minimum selling price for the pathway. Model validation was conducted by selecting three molecules (ethanol, succinic acid, and adipic acid), and comparing BioPET's results to literature values and to results from a commercial process design tool. BioPET produced virtually identical prices to the process design tool, although the costs were not identically distributed amongst the categories. BioPET produced estimates that were within 40% of other literature values at low feedstock costs, and within 5% at high feedstock costs.

The environmental sustainability of anaerobic digestion as a biomass valorization technology

This paper studies the environmental sustainability of anaerobic digestion from three perspectives. First, reference electricity is compared to electricity production from domestic organic waste and energy crop digestion. Second, different digester feed possibilities in an agricultural context are studied. Third, the influence of applying digestate as fertilizer is investigated. Results highlight that biomass is converted at a rational exergy (energy) efficiency ranging from 15.3% (22.6) to 33.3% (36.0). From a life cycle perspective, a saving of over 90% resources is achieved in most categories when comparing biobased electricity to conventional electricity. However, operation without heat valorization results in 32% loss of this performance while using organic waste (domestic and agricultural residues) as feedstock avoids land resources. The use of digestate as a fertilizer is beneficial from a resource perspective, but causes increased nitrogen and methane emissions, which can be reduced by 50%, making anaerobic digestion an environmentally competitive bioenergy technology.