Utilization of pentoses from sugarcane biomass: techno-economics of biogas vs. butanol production

Utilization of lignocellulosic biofuel conversion residue by diverse microorganisms

BACKGROUND

Lignocellulosic conversion residue (LCR) is the material remaining after deconstructed lignocellulosic biomass is subjected to microbial fermentation and treated to remove the biofuel. Technoeconomic analyses of biofuel refineries have shown that further microbial processing of this LCR into other bioproducts may help offset the costs of biofuel generation. Identifying organisms able to metabolize LCR is an important first step for harnessing the full chemical and economic potential of this material. In this study, we investigated the aerobic LCR utilization capabilities of 71 Streptomyces and 163 yeast species that could be engineered to produce valuable bioproducts. The LCR utilization by these individual microbes was compared to that of an aerobic mixed microbial consortium derived from a wastewater treatment plant as representative of a consortium with the highest potential for degrading the LCR components and a source of genetic material for future engineering efforts.

RESULTS

We analyzed several batches of a model LCR by chemical oxygen demand (COD) and chromatography-based assays and determined that the major components of LCR were oligomeric and monomeric sugars and other organic compounds. Many of the Streptomyces and yeast species tested were able to grow in LCR, with some individual microbes capable of utilizing over 40% of the soluble COD. For comparison, the maximum total soluble COD utilized by the mixed microbial consortium was about 70%. This represents an upper limit on how much of the LCR could be valorized by engineered Streptomyces or yeasts into bioproducts. To investigate the utilization of specific components in LCR and have a defined media for future experiments, we developed a synthetic conversion residue (SynCR) to mimic our model LCR and used it to show lignocellulose-derived inhibitors (LDIs) had little effect on the ability of the Streptomyces species to metabolize SynCR.

CONCLUSIONS

We found that LCR is rich in carbon sources for microbial utilization and has vitamins, minerals, amino acids and other trace metabolites necessary to support growth. Testing diverse collections of Streptomyces and yeast species confirmed that these microorganisms were capable of growth on LCR and revealed a phylogenetic correlation between those able to best utilize LCR. Identification and quantification of the components of LCR enabled us to develop a synthetic LCR (SynCR) that will be a useful tool for examining how individual components of LCR contribute to microbial growth and as a substrate for future engineering efforts to use these microorganisms to generate valuable bioproducts.

Sugarcane bagasse: a biomass sufficiently applied for improving global energy, environment and economic sustainability

Sugarcane (Saccharum officinarum) bagasse (SCB) is a biomass of agricultural waste obtained from sugarcane processing that has been found in abundance globally. Due to its abundance in nature, researchers have been harnessing this biomass for numerous applications such as in energy and environmental sustainability. However, before it could be optimally utilised, it has to be pre-treated using available methods. Different pre-treatment methods were reviewed for SCB, both alkaline and alkali-acid process reveal efficient and successful approaches for obtaining higher glucose production from hydrolysis. Procedures for hydrolysis were evaluated, and results indicate that pre-treated SCB was susceptible to acid and enzymatic hydrolysis as > 80% glucose yield was obtained in both cases. The SCB could achieve a bio-ethanol (a biofuel) yield of > 0.2 g/g at optimal conditions and xylitol (a bio-product) yield at > 0.4 g/g in most cases. Thermochemical processing of SCB also gave excellent biofuel yields. The plethora of products obtained in this regard have been catalogued and elucidated extensively. As found in this study, the SCB could be used in diverse applications such as adsorbent, ion exchange resin, briquettes, ceramics, concrete, cement and polymer composites. Consequently, the SCB is a biomass with great potential to meet global energy demand and encourage environmental sustainability.

Three-stage repeated-batch immobilized cell fermentation to produce butanol from non-detoxified sugarcane bagasse hemicellulose hydrolysates

To enable the production of butanol with undiluted, non-detoxified sugarcane bagasse hemicellulose hydrolysates, this study developed a three-staged repeated-batch immobilized cell fermentation in which the efficiency of a 3D-printed nylon carrier to passively immobilize Clostridium saccharoperbutylacetonicum DSM 14923 was compared with sugarcane bagasse. The first stage consisted of sugarcane molasses fermentation, and in the second stage, non-detoxified sugarcane bagasse hemicellulose hydrolysates (SBHH) was pulse-fed to sugarcane molasses fermentation. In the next four batches, immobilized cells were fed with undiluted SBHH supplemented with molasses, and SBHH-derived xylose accounted for approximately 50% of the sugars. Bagasse was a superior carrier, and the average xylose utilization (33%) was significantly higher than the treatment with the 3D-printed carrier (16%). Notably, bagasse allowed for 43% of the butanol to be SBHH-derived. Overall, cell immobilization on lignocellulosic materials can be an efficient strategy to produce butanol from repeated-batch fermentation of non-detoxified hemicellulose hydrolysates.

Energy potential of agricultural residues generated in Mexico and their use for butanol and electricity production under a biorefinery configuration

In this article, the geographical location and availability of the most important crop residues generated in Mexico over the last 10 years (2008-2017) were determined. This study estimates the gross number of residues for the four most important cultivars in Mexico named conventional residues (CRs) such as corn, wheat, sorghum, and barley, and estimates were also made for regionally important crops identified as nonconventional residues (NCRs) such as coffee, sugarcane, and beans. The total and sustainable energy potentials (TEP and SEP) for agricultural residues were calculated, in similar way the butanol and electricity production potentials were also calculated if these residues were processed under a nonconventional biorefinery scheme; the calculated availability of crop residues was 59,059,666 t/year, thus demonstrating that Mexico could have great potential for bioenergy production. The estimated TEP was 1,787,241,249 PJ/year, and the SEP was 78,724,689 PJ/year. The production of butanol and its production cost were calculated for the main crop residues; the butanol volume ranged from 7348 to 161,610 t/day, and the volume of crops of regional importance ranged from 6461.9 to 151,389 t/day. The minimum butanol production cost was 2000 t/day of feedstock. The surplus electricity was determined for all crop residues.

Application of Static Magnetic Fields on the Mixotrophic Culture of Chlorella minutissima for Carbohydrate Production

Magnetic field (MF) can interact with the metabolism of microalgae and has an effect (positive or negative) on the synthesis of molecules. In addition to MF, the use of pentose as a carbon source for cultivating microalgae is an alternative to increase carbohydrate yield. This study aimed at evaluating the MF application on the mixotrophic culture of Chlorella minutissima in order to produce carbohydrates. MF of 30 mT was generated by ferrite magnets and applied diurnally for 12 days. The addition of 5% pentose, MF application of 30 mT, and nitrogen concentration reduced (1.25 mM of KNO₃) was the best conditions to obtain higher carbohydrate concentrations. MF application of 30 mT increased biomass and carbohydrate contents in 30% and 163.1%, respectively, when compared with the assay without MF application. The carbohydrate produced can be used for bioethanol production.

Neither 1G nor 2G fuel ethanol: setting the ground for a sugarcane-based biorefinery using an iSUCCELL yeast platform

First-generation (1G) fuel ethanol production in sugarcane-based biorefineries is an established economic enterprise in Brazil. Second-generation (2G) fuel ethanol from lignocellulosic materials, though extensively investigated, is currently facing severe difficulties to become economically viable. Some of the challenges inherent to these processes could be resolved by efficiently separating and partially hydrolysing the cellulosic fraction of the lignocellulosic materials into the disaccharide cellobiose. Here, we propose an alternative biorefinery, where the sucrose-rich stream from the 1G process is mixed with a cellobiose-rich stream in the fermentation step. The advantages of mixing are 3-fold: (i) decreased concentrations of metabolic inhibitors that are typically produced during pretreatment and hydrolysis of lignocellulosic materials; (ii) decreased cooling times after enzymatic hydrolysis prior to fermentation; and (iii) decreased availability of free glucose for contaminating microorganisms and undesired glucose repression effects. The iSUCCELL platform will be built upon the robust Saccharomyces cerevisiae strains currently present in 1G biorefineries, which offer competitive advantage in non-aseptic environments, and into which intracellular hydrolyses of sucrose and cellobiose will be engineered. It is expected that high yields of ethanol can be achieved in a process with cell recycling, lower contamination levels and decreased antibiotic use, when compared to current 2G technologies.

A review on characteristics of food waste and their use in butanol production

Biobutanol offers several advantages and a larger market, that make it a biofuel to be studied with great interest. In fact, butanol has an energy content similar to that of gasoline, and it can be used as an alternative fuel to gasoline. It is a biofuel that is safe for the environment. The optimization of the production of butanol thus appears as an attractive option. Butanol production from food waste (FW) is a process for carbon recovery and a method for solid waste recycling. Recently, the use of FW and food processing waste (FPW) as raw material for the production of butanol has attracted much interest. However, an efficient fermentation process is vital to improve the production of biobutanol. To the best of our knowledge, no review on butanol production from FW has been presented so far. Thus, this review focuses on the characteristics of FW and its potential to produce butanol. In addition, the main factors that affect their use for the production of butanol are also discussed.

Acetone-free biobutanol production: Past and recent advances in the Isopropanol-Butanol-Ethanol (IBE) fermentation

Production of butanol for fuel via the conventional Acetone-Butanol-Ethanol fermentation has been considered economically risky because of a potential oversupply of acetone. Alternatively, acetone is converted into isopropanol by specific solventogenic Clostridium species in the Isopropanol-Butanol-Ethanol (IBE) fermentation. This route, although less efficient, has been gaining attention because IBE mixtures are a potential fuel. The present work is dedicated to reviewing past and recent advances in microorganisms, feedstock, and fermentation equipment for IBE production. In our analysis we demonstrate the importance of novel engineered IBE-producing Clostridium strains and cell retention systems to decrease the staggering number of fermentation tanks required by IBE plants equipped with conventional technology. We also summarize the recent progress on recovery techniques integrated with fermentation, especially gas stripping. In addition, we assessed ongoing pilot-plant efforts that have been enabling IBE production from woody feedstock.

Jet fuel production in eucalyptus pulp mills: Economics and carbon footprint of ethanol vs. butanol pathway

This work assessed the economics and carbon footprint of alcohol (ethanol vs. n-butanol)-to-jet fuel production using eucalyptus for feedstock. Considering a risk-mitigating strategy of investing first in the alcohol plant (organosolv pretreatment, enzymatic hydrolysis, fermentation) and waiting five years until the second investment (alcohol-to-jet plant), the minimum jet fuel selling price was similar in both ethanol and butanol cases (2.10 and 2.08 US$/l for 20% Internal Rate of Return, IRR). In contrast, according to a stochastic decision-making framework that had carbon footprint as one of the criteria, the ethanol pathway is more promising. Nevertheless, even optimistic assumptions (regarding e.g. lignin price, and the interval between project phases) were ineffective to prevent eucalyptus jet fuel from depending on price premium (>1.00 US$/l), which is needed for better returns than those from eucalyptus ethanol plants. Therefore, the feasibility of alcohol-to-jet fuel production in eucalyptus pulp mills depends on long-term, stable premium and subsidy.

Process design and economics of a flexible ethanol-butanol plant annexed to a eucalyptus kraft pulp mill

This work proposes a strategy, from a process design standpoint, for pulp companies to enter the Brazilian ethanol market. The flexible plant converts eucalyptus-derived glucose to either ethanol or butanol (according to market conditions) and xylose only to butanol production. Depending on the biomass pretreatment technology, Monte Carlo simulations showed that the Net Present Value (NPV) of the flexible plant increases by 20-28% in relation to an ethanol-dedicated plant. Whereas the lower costs of the steam explosion technology turns the investment more attractive (NPV = 184 MMUSD; IRR = 29%), the organosolv technology provides better flexibility to the plant. This work also shows that excessive power consumption is a hurdle in the development of flash fermentation technology chosen for the flexible plant. These results indicate that conventional batch fermentation is preferable if the enzymatic hydrolysis step operates with solids loading up to 20 wt%.

Pentoses and light intensity increase the growth and carbohydrate production and alter the protein profile of Chlorella minutissima

High concentrations of carbon, which is considered a necessary element, are required for microalgal growth. Therefore, the identification of alternative carbon sources available in large quantities is increasingly important. This study evaluated the effects of light variation and pentose addition on the carbohydrate content and protein profile of Chlorella minutissima grown in a raceway photobioreactor. The kinetic parameters, carbohydrate content, and protein profile of Chlorella minutissima and its theoretical potential for ethanol production were estimated. The highest cellular concentrations were obtained with a light intensity of 33.75µmol.m^-2.s^-1. Arabinose addition combined with a light intensity of 33.75µmol.m^-2.s^-1 increased the carbohydrate content by 53.8% and theoretically produced 39.1mL·100g^-1 ethanol. All of the assays showed that a lower light availability altered the protein profile. The luminous intensity affects xylose and arabinose assimilation and augments the carbohydrate content in C. minutissima, making this microalga appropriate for bioethanol production.

Assessment of different pre-treatment methods for the removal of limonene in citrus waste and their effect on methane potential and methane production rate

The objective of this study was to assess the limonene removal efficiency of three pre-treatment methods when applied to citrus waste and to evaluate their effects on the biochemical methane potential and the methane production rate using batch anaerobic tests. The methods tested were based on removal (biological pretreatment by fungi) or recovery (steam distillation and ethanol extraction) of limonene. All the treatments decreased the concentration of limonene in orange peel, with average efficiencies of 22%, 44% and 100% for the biological treatment, steam distillation and ethanol extraction, respectively. By-products from limonene biodegradation by fungi exhibited an inhibitory effect also, not making interesting the biological pretreatment. The methane potential and production rate of the treated orange peel increased significantly after applying the recovery strategies, which separated and recovered simultaneously other inhibitory components of the citrus essential oil. Apart from the high recovery efficiency of the ethanol extraction process, it presented a favourable energy balance.

Ethanol production in Brazil: a bridge between science and industry

In the last 40 years, several scientific and technological advances in microbiology of the fermentation have greatly contributed to evolution of the ethanol industry in Brazil. These contributions have increased our view and comprehension about fermentations in the first and, more recently, second-generation ethanol. Nowadays, new technologies are available to produce ethanol from sugarcane, corn and other feedstocks, reducing the off-season period. Better control of fermentation conditions can reduce the stress conditions for yeast cells and contamination by bacteria and wild yeasts. There are great research opportunities in production processes of the first-generation ethanol regarding high-value added products, cost reduction and selection of new industrial yeast strains that are more robust and customized for each distillery. New technologies have also focused on the reduction of vinasse volumes by increasing the ethanol concentrations in wine during fermentation. Moreover, conversion of sugarcane biomass into fermentable sugars for second-generation ethanol production is a promising alternative to meet future demands of biofuel production in the country. However, building a bridge between science and industry requires investments in research, development and transfer of new technologies to the industry as well as specialized personnel to deal with new technological challenges.

Nitrogen balancing and xylose addition enhances growth capacity and protein content in Chlorella minutissima cultures

This study aimed to examine the metabolic changes in Chlorella minutissima cells grown under nitrogen-deficient conditions and with the addition of xylose. The cell density, maximum photochemical efficiency, and chlorophyll and lipid levels were measured. The expression of two photosynthetic proteins, ribulose-1,5-bisphosphate carboxylase/oxygenase (Rubisco) and the beta subunit (AtpB) of adenosine triphosphate synthase, were measured. Comparison of cells grown in medium with a 50% reduction in the nitrogen concentration versus the traditional medium solution revealed that the cells grown under nitrogen-deficient conditions exhibited an increased growth rate, higher maximum cell density (12.7×10(6)cellsmL(-1)), optimal PSII efficiency (0.69) and decreased lipid level (25.08%). This study has taken the first steps toward protein detection in Chlorella minutissima, and the results can be used to optimize the culturing of other microalgae.

Investigation of uncertainties associated with the production of n-butanol through ethanol catalysis in sugarcane biorefineries

This study evaluated the viability of n-butanol production integrated within a first and second generation sugarcane biorefinery. The evaluation included a deterministic analysis as well as a stochastic approach, the latter using Monte Carlo simulation. Results were promising for n-butanol production in terms of revenues per tonne of processed sugarcane, but discouraging with respect to internal rate of return (IRR). The uncertainty analysis determined there was high risk involved in producing n-butanol and co-products from ethanol catalysis. It is unlikely that these products and associated production route will be financially attractive in the short term without lower investment costs, supportive public policies and tax incentives coupled with biofuels' production strategies.

Continuous lactose fermentation by Clostridium acetobutylicum--assessment of solventogenic kinetics

This work reports the results of a series of tests on the specific butanol production rate by Clostridium acetobutylicum continuous cultures. The tests were carried out using lactose as carbon source to mimic cheese-whey. A continuous stirred tank reactor equipped with a microfiltration unit was used. The dilution rate (D) ranged between 0.02 and 0.15h(-1) and the ratio R of the permeate stream rate to the stream fed to the reactor ranged between 14% and 95%. For each set of D and R values, the continuous cultures were characterized in terms of concentration of cells, acids and solvents. Results were processed to assess the concentration of acidogenic cells, solventogenic cells, spores and the specific butanol production rate. The max butanol productivity was 0.5gL(-1)h(-1) at D=0.1h(-1) and R=95%. The butanol productivity referred to solventogenic cells was expressed as a function of concentration of lactose, acids and butanol.

Black liquor fractionation for biofuels production - a techno-economic assessment

The hemicelluloses fraction of black liquor is an underutilized resource in many chemical pulp mills. It is possible to extract and separate the lignin and hemicelluloses from the black liquor and use the hemicelluloses for biochemical conversion into biofuels and chemicals. Precipitation of the lignin from the black liquor would consequently decrease the thermal load on the recovery boiler, which is often referred to as a bottleneck for increased pulp production. The objective of this work is to techno-economically evaluate the production of sodium-free lignin as a solid fuel and butanol to be used as fossil gasoline replacement by fractionating black liquor. The hydrolysis and fermentation processes are modeled in Aspen Plus to analyze energy and material balances as well as to evaluate the plant economics. A mathematical model of an existing pulp and paper mill is used to analyze the effects on the energy performance of the mill subprocesses.

Techno-economics of carbon preserving butanol production using a combined fermentative and catalytic approach

This paper presents a novel process for n-butanol production which combines a fermentation consuming carbon dioxide (succinic acid fermentation) with subsequent catalytic reduction steps to add hydrogen to form butanol. Process simulations in Aspen Plus have been the basis for the techno-economic analyses performed. The overall economy for the novel process cannot be justified, as production of succinic acid by fermentation is too costly. Though, succinic acid price is expected to drop drastically in a near future. By fully integrating the succinic acid fermentation with the catalytic conversion the need for costly recovery operations could be reduced. The hybrid process would need 22% less raw material than the butanol fermentation at a succinic acid fermentation yield of 0.7g/g substrate. Additionally, a carbon dioxide fixation of up to 13ktonnes could be achieved at a plant with an annual butanol production of 10ktonnes.

Consolidated conversion of protein waste into biofuels and ammonia using Bacillus subtilis

The non-recyclable use of nitrogen fertilizers in microbial production of fuels and chemicals remains environmentally detrimental. Conversion of protein wastes into biofuels and ammonia by engineering nitrogen flux in Escherichia coli has been demonstrated as a method to reclaim reduced-nitrogen and curb its environmental deposition. However, protein biomass requires a proteolysis process before it can be taken up and converted by any microbe. Here, we metabolically engineered Bacillus subtilis to hydrolyze polypeptides through its secreted proteases and to convert amino acids into advanced biofuels and ammonia fertilizer. Redirection of B. subtilis metabolism for amino-acid conversion required inactivation of the branched-chain amino-acid (BCAA) global regulator CodY. Additionally, the lipoamide acyltransferase (bkdB) was deleted to prevent conversion of branched-chain 2-keto acids into their acyl-CoA derivatives. With these deletions and heterologous expression of a keto-acid decarboxylase and an alcohol dehydrogenase, the final strain produced biofuels and ammonia from an amino-acid media with 18.9% and 46.6% of the maximum theoretical yield. The process was also demonstrated on several waste proteins. The results demonstrate the feasibility of direct microbial conversion of polypeptides into sustainable products.