Polyhydroxyalkanoate production as a side stream process on a municipal waste water treatment plant

Polyhydroxyalkanoates production from laboratory to industrial scale: A review

Environmental issues related to fossil-based plastics are getting the attention of the media and legislative authorities, addressing the need to improve the plastics' design, collection, and circular economy. In this regard, polyhydroxyalkanoates (PHAs) represent a promising alternative to the conventional polymers, given their biological origin, biodegradability, and biocompatibility. To date, their commercialization covers only a little percentage of the biodegradable plastic application, mainly due to their high cost. However, new production strategies are being investigated and patented, enhancing the PHA market competitiveness. This review tries to fill the gap about the critical investigation on innovative and up-to-date process strategies in PHA production field, deeply evaluating them from a plant-engineering point of view. Several aspects are considered regarding the reduction of the production costs and the increase in the overall PHA productivity and recovery. Among them, the feeding of pre-treated carbon sources derived from food and agro-industrial wastes, the use of mixed microbial cultures as convenient substitutes to the pure ones, and optimized downstream processes are widely discussed. The overlook of the topic is completed by evaluating the innovative technologies existing at pilot and industrial scale, able to achieve improved production yields. Finally, PHA economic and market current conditions are investigated.

Integrated selection of PHA-storing biomass and nitrogen removal via nitrite from sludge reject water: a mathematical model

One of the most recent innovations to promote a circular economy during wastewater treatment is the production of biopolymers. It has recently been demonstrated that it is possible to integrate the production of biopolymers in the form of polyhydroxyalkanoates (PHA) with nitrogen removal via nitrite during the treatment of sludge reject water. In the present study, simulation of a new process for bioresource recovery was conducted by an appropriate modification of the Activated Sludge Model 3. The process consists of the integrated nitrogen removal via nitrite from sludge reject water and the selection of PHA-storing biomass by inducing a feast and famine regime under aerobic and anoxic conditions. According to the results, it is anticipated that simulation data matched very satisfactorily with the experimental data and confirmed the main experimental observation, showing that during the famine period the PHA depletion was almost complete due to the availability of nitrite as the electron acceptor. Simulation results indicate that the selection of the volumetric organic loading rate and of the relative duration of the aerobic feast/anoxic famine duration is critical in order to allow for the effective denitritation of the internally stored PHA during the famine phase.

Efficient and economical production of polyhydroxyalkanoate from sustainable rubber wood hydrolysate and xylose as co-substrate by mixed microbial cultures

Using co-substrate to accumulate polyhydroxyalkanoate (PHA) is an efficient approach to reduce production cost and improve yield of PHA. In the study, PHA was biosynthesized under full aerobic mode by using rubber wood hydrolysate and xylose co-substrate as the carbon source. The effects of co-substrate on PHA production, microbial community and carbon conversion were explored. The results showed that proper addition of xylose was beneficial for the synthesis of PHA and monomer 3-hydroxyvalerate (3HV). Higher conversion yield of substrate-to-PHA (Y_PHA/S) of 0.933 g COD PHA/g COD S and PHA content of 43.6 g PHA/100 g VSS were gained at co-substrate ratio of 1:1. Likewise, under this condition, PHA production also reached the highest value of 1849 mg COD/L (1088 mg/L). Moreover, the addition of xylose created a favorable screening of PHA dominant strains, improved the conversion of carbon source, and saved 72.3% of feedstock consumption.

Beyond PHA: Stimulating intracellular accumulation of added-value compounds in mixed microbial cultures

This review compiled and analyzed the operational conditions (dissolved oxygen, feast and famine ratio, sequential batch reactor cycle length, organic loading rate (OLR), pH, C/N, and temperature) established during the feast and famine culture strategy for the mixed microbial cultures (MMC) selection to understand how these variables could affect the synthesis of polyhydroxyalkanoates, polyglucose, triacylglycerides, levulinic acid and adipic acid from non-fermented substrates. According to the reported information, the dissolved oxygen has a greater impact on the type and amount of produced compound. In a lesser extent, the OLR and the cycle length were identified to have an impact on the accumulation of polyhydroxyalkanoates, whose accumulation was favored at lower OLR and longer cycle lengths. Thereby, the information of this work will allow the design of future strategies for the simultaneous accumulation of compounds of interest other than the polyhydroxyalkanoates or understand the operational conditions that would optimize the polyhydroxyalkanoates production.

Resource recovery in aerobic granular sludge systems: is it feasible or still a long way to go?

Lately, wastewater treatment plants are much often being designed as wastewater-resource factories inserted in circular cities. Among biological treatment technologies, aerobic granular sludge (AGS), considered an evolution of activated sludge (AS), has received great attention regarding its resource recovery potential. This review presents the state-of-the-art concerning the influence of operational parameters on the recovery of alginate-like exopolysaccharides (ALE), tryptophan, phosphorus, and polyhydroxyalkanoates (PHA) from AGS systems. The carbon to nitrogen ratio was identified as a parameter that plays an important role for the optimal production of ALE, tryptophan, and PHA. The sludge retention time effect is more pronounced for the production of ALE and tryptophan. Additionally, salinity levels in the bioreactors can potentially be manipulated to increase ALE and phosphorus yields simultaneously. Some existing knowledge gaps in the scientific literature concerning the recovery of these resources from AGS were also identified. Regarding industrial applications, tryptophan has the longest way to go. On the other hand, ALE production/recovery could be considered the most mature process if we take into account that existing alternatives for phosphorus and PHA production/recovery are optimized for activated sludge rather than granular sludge. Consequently, to maintain the same effectiveness, these processes likely could not be applied to AGS without undergoing some modification. Therefore, investigating to what extent these adaptations are necessary and designing alternatives is essential.

Effects of chemical oxygen demand concentration, pH and operation cycle on polyhydroxyalkanoates synthesis with waste sludge

To reduce the cost of polyhydroxyalkanoate (PHA) production and dispose the amount of waste sludge simultaneously, chemical oxygen demand (COD) concentration, pH and operation cycle were investigated to find the optimal PHA synthesis conditions with waste sludge in this study. The maximum PHA content (31.3% of the cell dry weight (CDW)), as well as the highest PHA conversion rate (0.30 mg COD/mg COD) and PHA-specific synthesis rate (6.12 mg COD/mg CDW·h), was achieved with initial COD concentration, pH value and operation cycle: 6000 mg/L, 8.5 and 24 h. In order to further investigate the process of PHA synthesis, COD removal rate and CDW were also introduced. This study could provide valuable information for increasing the production of PHA with waste sludge.

What Has Been Trending in the Research of Polyhydroxyalkanoates? A Systematic Review

Over the past decades, enormous progress has been achieved with regard to research on environmentally friendly polymers. One of the most prominent families of such biopolymers are bacterially synthesized polyhydroxyalkanoates (PHAs) that have been known since the 1920s. However, only as recent as the 1990s have extensive studies sprung out exponentially in this matter. Since then, different areas of exploration of these intriguing materials have been uncovered. However, no systematic review of undertaken efforts has been conducted so far. Therefore, we have performed an unbiased search of up-to-date literature to reveal trending topics in the research of PHAs over the past three decades by data mining of 2,227 publications. This allowed us to identify eight past and current trends in this area. Our study provides a comprehensive review of these trends and speculates where PHA research is heading.

Recent developments in Polyhydroxyalkanoates (PHAs) production - A review

Polyhydroxyalkanoates (PHAs) are inevitably a key biopolymer that has the potential to replace the conventional petrochemical based plastics that pose jeopardy to the environment globally. Even then the reach of PHA in the common market is so restricted. The economy of PHA is such that, even after several attempts the overall production cost seems to be high and this very factor surpasses PHAs usage when compared to the conventional polymers. The major focus of the review relies on the synthesis of PHA from Mixed Microbial Cultures (MMCs), through a 3-stage process most probably utilizing feedstocks from waste streams or models that mimic them. Emphasis was given to the works carried out in the past decade and their coherence with each and every individual criteria (Aeration, Substrate and bioprocess parameters) such that to understand their effect in enhancing the overall production of PHA.

Mixed culture polyhydroxyalkanoate (PHA) synthesis from nutrient rich wet oxidation liquors

Organic waste residues can be hydrothermally treated to produce organic acid rich liquors. These hydrothermal liquors are a potential feedstock for polyhydroxyalkanoate (PHA) production. We investigated the effect of dissolved oxygen concentration and substrate feeding regimes on PHA accumulation and yield using two hydrothermal liquors derived from a mixture of primary and secondary municipal wastewater treatment sludge and food waste. The enriched culture accumulated a maximum of 41% PHA of cell dry weight within 7 h; which is among the highest reported for N and P rich hydrothermal liquors. Recovered PHA was 77% polyhydroxybutyrate and 23% polyhydroxyvalerate by mass. The families Rhodocyclaceae (84%) and Saprospiraceae (20.5%) were the dominant Proteobacteria (73%) in the enriched culture. The third most abundant bacterial genus, Bdellovibrio, includes species of known predators of PHA producers which may lead to suboptimal PHA accumulation. The PHA yield was directly proportional to DO concentration for ammonia stripped liquor (ASL) and inversely proportional to DO concentration for low strength liquor (LSL). The highest yield of 0.50 Cmol PHA/Cmol substrate was obtained for ASL at 25% DO saturation. A progressively increasing substrate feeding regime resulted in increased PHA yields. These findings demonstrate that substrate feeding regime and oxygen concentration can be used to control the PHA yield and accumulation rate thereby enhancing PHA production viability from nutrient rich biomass streams.

Polyhydroxyalkanoate Production on Waste Water Treatment Plants: Process Scheme, Operating Conditions and Potential Analysis for German and European Municipal Waste Water Treatment Plants

This work describes the production of polyhydroxyalkanoates (PHA) as a side stream process on a municipal waste water treatment plant (WWTP) and a subsequent analysis of the production potential in Germany and the European Union (EU). Therefore, tests with different types of sludge from a WWTP were investigated regarding their volatile fatty acids (VFA) production-potential. Afterwards, primary sludge was used as substrate to test a series of operating conditions (temperature, pH, retention time (RT) and withdrawal (WD)) in order to find suitable settings for a high and stable VFA production. In a second step, various tests regarding a high PHA production and stable PHA composition to determine the influence of substrate concentration, temperature, pH and cycle time of an installed feast/famine-regime were conducted. Experiments with a semi-continuous reactor operation showed that a short RT of 4 days and a small WD of 25% at pH = 6 and around 30 °C is preferable for a high VFA production rate (PR) of 1913 mg_VFA/(L×d) and a stable VFA composition. A high PHA production up to 28.4% of cell dry weight (CDW) was reached at lower substrate concentration, 20 °C, neutral pH-value and a 24 h cycle time. A final step a potential analysis, based on the results and detailed data from German waste water treatment plants, showed that the theoretically possible production of biopolymers in Germany amounts to more than 19% of the 2016 worldwide biopolymer production. In addition, a profound estimation regarding the EU showed that in theory about 120% of the worldwide biopolymer production (in 2016) could be produced on European waste water treatment plants.

Resource Recovery from Wastewater by Biological Technologies: Opportunities, Challenges, and Prospects

Limits in resource availability are driving a change in current societal production systems, changing the focus from residues treatment, such as wastewater treatment, toward resource recovery. Biotechnological processes offer an economic and versatile way to concentrate and transform resources from waste/wastewater into valuable products, which is a prerequisite for the technological development of a cradle-to-cradle bio-based economy. This review identifies emerging technologies that enable resource recovery across the wastewater treatment cycle. As such, bioenergy in the form of biohydrogen (by photo and dark fermentation processes) and biogas (during anaerobic digestion processes) have been classic targets, whereby, direct transformation of lipidic biomass into biodiesel also gained attention. This concept is similar to previous biofuel concepts, but more sustainable, as third generation biofuels and other resources can be produced from waste biomass. The production of high value biopolymers (e.g., for bioplastics manufacturing) from organic acids, hydrogen, and methane is another option for carbon recovery. The recovery of carbon and nutrients can be achieved by organic fertilizer production, or single cell protein generation (depending on the source) which may be utilized as feed, feed additives, next generation fertilizers, or even as probiotics. Additionlly, chemical oxidation-reduction and bioelectrochemical systems can recover inorganics or synthesize organic products beyond the natural microbial metabolism. Anticipating the next generation of wastewater treatment plants driven by biological recovery technologies, this review is focused on the generation and re-synthesis of energetic resources and key resources to be recycled as raw materials in a cradle-to-cradle economy concept.

Synthetic biology of microbes synthesizing polyhydroxyalkanoates (PHA)

Microbial polyhydroxyalkanoates (PHA) have been produced as bioplastics for various purposes. Under the support of China National Basic Research 973 Project, we developed synthetic biology methods to diversify the PHA structures into homo-, random, block polymers with improved properties to better meet various application requirements. At the same time, various pathways were assembled to produce various PHA from glucose as a simple carbon source. At the end, Halomonas bacteria were reconstructed to produce PHA in changing morphology for low cost production under unsterile and continuous conditions. The synthetic biology will advance the PHA into a bio- and material industry.

Potential for polyhydroxyalkanoate production on German or European municipal waste water treatment plants

Biopolymers, which are made of renewable raw materials and/or biodegradable residual materials present a possible alternative to common plastic. A potential analysis, based on experimental results in laboratory scale and detailed data from German waste water treatment plants, showed that the theoretically possible production of biopolymers in Germany amounts to more than 20% of the 2015 worldwide biopolymer production. In addition a profound estimation regarding all European Union member states showed that theoretically about 115% of the actual worldwide biopolymer production could be produced on European waste water treatment plants. With an upgraded biopolymer production and a theoretically reachable biopolymer proportion of around 60% of the cell dry weight a total of 1,794,656tPHAa or approximately 236% of today's biopolymer production could be produced on waste water treatment plants in the European Union, using primary sludge as raw material only.

Development of a Novel Process Integrating the Treatment of Sludge Reject Water and the Production of Polyhydroxyalkanoates (PHAs)

Polyhydroxyalkanoates (PHAs) from activated sludge and renewable organic material can become an alternative product to traditional plastics since they are biodegradable and are produced from renewable sources. In this work, the selection of PHA storing bacteria was integrated with the side stream treatment of nitrogen removal via nitrite from sewage sludge reject water. A novel process was developed and applied where the alternation of aerobic-feast and anoxic-famine conditions accomplished the selection of PHA storing biomass and nitrogen removal via nitrite. Two configurations were examined: in configuration 1 the ammonium conversion to nitrite occurred in the same reactor in which the PHA selection process occurred, while in configuration 2 two separate reactors were used. The results showed that the selection of PHA storing biomass was successful in both configurations, while the nitrogen removal efficiency was much higher (almost 90%) in configuration 2. The PHA selection degree was evaluated by the volatile fatty acid (VFA) uptake rate (-qVFAs) and the PHA production rate (qPHA), which were 239 ± 74 and 89 ± 7 mg of COD per gram of active biomass (Xa) per hour, respectively. The characterization of the biopolymer recovered after the accumulation step, showed that it was composed of 3-hydroxybutyrate (3HB) (60%) and 3-hydroxyvalerate (3HV) (40%). The properties associated with the produced PHA suggest that they are suitable for thermoplastic processing.

Sustainable multistage process for enhanced productivity of bioplastics from waste remediation through aerobic dynamic feeding strategy: Process integration for up-scaling

Polyhydroxyalkanoates (PHA) production was evaluated in a multistage operation using food waste as a renewable feedstock. The first step involved the production of bio-hydrogen (bio-H2) via acidogenic fermentation. Volatile fatty acid (VFA) rich effluent from bio-H2 reactor was subsequently used for PHA production, which was carried out in two stages, Stage II (culture enrichment) and Stage III (PHA production). PHA-storing microorganisms were enriched in a sequencing batch reactor (SBR), operated at two different cycle lengths (CL-24; CL-12). Higher polymer recovery as well as VFA removal was achieved in CL-12 operation both in Stage II (16.3% dry cell weight (DCW); VFA removal, 84%) and Stage III (23.7% DCW; VFA removal, 88%). The PHA obtained was a co-polymer [P(3HB-co-3HV)] of PHB and PHV. The results obtained indicate that this integrated multistage process offers new opportunities to further leverage large scale PHA production with simultaneous waste remediation in the framework of biorefinery.