Continuous bioethanol fermentation from wheat straw hydrolysate with high suspended solid content using an immersed flat sheet membrane bioreactor

Model-based study of Yarrowia lipolytica cultivation on crude glycerol under different fermentation modes: Development of a membrane bioreactor process

Batch fermentations of the wild type Yarrowia lipolytica MUCL 28849 were performed in a bench-top bioreactor to assess crucial operating conditions. A setup of carbon to nitrogen (mol/mol) ratio equal to 34, pH = 6.0 and 52 g/L of crude glycerol showed increased lipid production and complete glycerol consumption at t = 24 h, thus, selected for further process improvement. Α semi-continuous process was implemented, where a pH drop to 4.0 at 24 h, interrupted citric acid secretion without affecting lipid production. An in-situ membrane module was employed for membrane bioreactor fermentations, where yeast cells were successfully retained with minimum fouling. The membrane bioreactor fed-batch process, resulted in a high-cell-density culture reaching 49.8 g/L of dry biomass and 4.9 g/L of lipids. An unstructured model was developed and successfully simulated operation under all fermentation modes, distinguishing diverse physiological shifts.

A Review on Opportunities and Limitations of Membrane Bioreactor Configuration in Biofuel Production

Biofuels are a clean and renewable source of energy that has gained more attention in recent years; however, high energy input and processing cost during the production and recovery process restricted its progress. Membrane technology offers a range of energy-saving separation for product recovery and purification in biorefining along with biofuel production processes. Membrane separation techniques in combination with different biological processes increase cell concentration in the bioreactor, reduce product inhibition, decrease chemical consumption, reduce energy requirements, and further increase product concentration and productivity. Certain membrane bioreactors have evolved with the ability to deal with different biological production and separation processes to make them cost-effective, but there are certain limitations. The present review describes the advantages and limitations of membrane bioreactors to produce different biofuels with the ability to simplify upstream and downstream processes in terms of sustainability and economics.

Application of Immersed Membrane Bioreactor for Semi-Continuous Production of Polyhydroxyalkanoates from Organic Waste-Based Volatile Fatty Acids

Volatile fatty acids (VFAs) appear to be an economical carbon feedstock for the cost-effective production of polyhydroxyalkanoates (PHAs). The use of VFAs, however, could impose a drawback of substrate inhibition at high concentrations, resulting in low microbial PHA productivity in batch cultivations. In this regard, retaining high cell density using immersed membrane bioreactor (iMBR) in a (semi-) continuous process could enhance production yields. In this study, an iMBR with a flat-sheet membrane was applied for semi-continuous cultivation and recovery of Cupriavidus necator in a bench-scale bioreactor using VFAs as the sole carbon source. The cultivation was prolonged up to 128 h under an interval feed of 5 g/L VFAs at a dilution rate of 0.15 (d^-1), yielding a maximum biomass and PHA production of 6.6 and 2.8 g/L, respectively. Potato liquor and apple pomace-based VFAs with a total concentration of 8.8 g/L were also successfully used in the iMBR, rendering the highest PHA content of 1.3 g/L after 128 h of cultivation. The PHAs obtained from both synthetic and real VFA effluents were affirmed to be poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a crystallinity degree of 23.8 and 9.6%, respectively. The application of iMBR could open an opportunity for semi-continuous production of PHA, increasing the feasibility of upscaling PHA production using waste-based VFAs.

Enhanced chloride-free snow-melting agent generation from organic wastewater by integrating bioconversion and synthesis

In this study, a new process for producing chloride-free snow-melting agents (CSAs) was proposed. Organic wastewater was converted to total volatile fatty acids (TVFA) by anaerobic acidogenic fermentation. The experiments for acid generation showed that the maximum TVFA concentration of 45.9 g/L was obtained at an organic loading rate of 5 g chemical oxygen demand /(L·d), and the proportion of acetic acid reached 78.8 %. Forward osmosis was used for concentrating the TVFA solution. The obtained CSAs, after evaporation and crystallization, had a better ice-melting capacity and less corrosion on metal and concrete than NaCl and CaCl₂. Additionally, the damage caused by CSAs to the germination of plant seeds was significantly lesser than that caused by chloride salts. This study proposed a feasible method for the high-value conversion of organic wastewater, providing a new direction for the reuse of organic wastewater.

Enzyme catalysis coupled with artificial membranes towards process intensification in biorefinery- a review

In this review, for the first time, the conjugation of the major types of enzymes used in biorefineries and the membrane processes to develop different configurations of MBRs, was analyzedfor the production of biofuels, phytotherapics and food ingredients. In particular, the aim is to critically review all the works related to the application of MBR in biorefinery, highlighting the advantages and the main drawbacks which can interfere with the development of this system at industrial scale. Alternatives strategies to overcome main limits will be also described in the different application fields, such as the use of biofunctionalized magnetic nanoparticles associated with membrane processes for enzyme re-use and membrane cleaning or the membrane fouling control by the use of integrated membrane process associated with MBR.

Agro-Food Residues and Bioethanol Potential: A Study for a Specific Area

Bioethanol obtained from agro-food wastes could contribute to decrease the dependency on fossil resources, reduce the impact of fossil fuels on the environment, and mitigate the food versus fuel debate. This study is aimed to investigate the availability of residual inexpensive agro-food biomasses that could feed a second-generation bioethanol plant located in a specific area of North Eastern Italy. After the identification of all crops in the area, more than 40 agro-food residues were analyzed for their availability and compositions in terms of water, polysaccharides, and sugars potentially convertible into bioethanol. 574,166 Mg of residual wet lignocellulosic biomass corresponding to 297,325 Mg of dry material were found available for bioethanol conversion. The most promising substrates were wheat straw and vine shoots. Based on the chemical composition of residues, the potential attainable ethanol was determined. Theoretical potential ethanol production was estimated at nearly 72,000 Mg per year. This quantity extensively exceeds the minimum yearly capacity of a sustainable bioethanol plant previously identified as around 50,000 Mg of ethanol. Taken together, these results demonstrate that, in the analyzed area, agro-food residues are available in an amount that could sustain bioethanol production in a specific and restricted district. Techno-economical evaluations are in progress to assess the actual feasibility of installing a second generation bioethanol production plant in the area of interest.

Membrane bioreactor-assisted volatile fatty acids production and in situ recovery from cow manure

Cow manure (CM) generation in large volumes has for long been considered a waste management challenge. However, the organic content of CM signals opportunities for the production of value-added bioproducts such as volatile fatty acids (VFAs) through anaerobic digestion (AD). However, a robust VFAs fermentation process requires effective methane formation inhibition and enhance VFAs recovery. In this study, thermal pretreatment was applied to inhibit methanogens for enhanced VFAs production and an immersed membrane bioreactor (iMBR) for in situ recovery of VFAs in a semi-continuous AD. Maximal VFAs yield of 0.41 g VFAs/g volatile solids (VS) was obtained from thermally-treated CM without inoculum addition. The CM was further fed to the iMBR operating at organic loading rates of 0.8-4.7 gVS/L.d. The VFAs concentration increased to 6.93 g/L by rising substrate loading to 4.7 g VS/L.d. The applied iMBR set-up was successfully used for stable long-term (114 days) VFAs production and recovery.

Pretreatment of Mango (Mangifera indica L. Anacardiaceae) Seed Husk for Bioethanol Production by Dilute Acid Treatment and Enzymatic Hydrolysis

One of the targets of the Sustainable Development Goals is clean and affordable energy. This is also the aim of the Biofuels Act of 2007 in the Philippines. However, this law is confronted with challenges such as the limitation of lignocellulosic feedstock, specifically available for bioethanol production. The present study sought to address the issue by exploring the potential of mango seed husk (MSH), a by-product of the mango industry, in bioethanol production. MSH is considered a waste material and its utilization also permit value-addition as this can serve as an alternative and affordable source of feedstock in energy production. Two pretreatment strategies are employed to exploit the cellulose and hemicellulose content of MSH, namely, dilute acid treatment and enzymatic hydrolysis. Results show that the %H₂SO₄ resulting in the highest glucose concentration and yield is 4% v/v at 95 °C hydrolysis temperature, 1:10 (w/v) solid-to-solvent ratio, and 60-min hydrolysis time. For enzymatic hydrolysis using a commercial enzyme preparation, the reaction time up to 72 h did not affect glucose concentration and yield at the following conditions: 50 °C hydrolysis temperature, 150 rpm, pH 5.0, 10% solids loading, and 4% enzyme loading. This could be attributed to the lignin and non-structural compounds present in MSHs. However, a combined process strategy of dilute acid pretreatment followed by enzymatic hydrolysis in the pretreatment of MSH contributes to an increased concentration and yield of sugars in the hydrolysates, which is advantageous for bioethanol production. Graphical Abstract.

An overview on bioethanol production from lignocellulosic feedstocks

Lignocellulosic ethanol has been proposed as a green alternative to fossil fuels for many decades. However, commercialization of lignocellulosic ethanol faces major hurdles including pretreatment, efficient sugar release and fermentation. Several processes were developed to overcome these challenges e.g. simultaneous saccharification and fermentation (SSF). This review highlights the various ethanol production processes with their advantages and shortcomings. Recent technologies such as singlepot biorefineries, combined bioprocessing, and bioenergy systems with carbon capture are promising. However, these technologies have a lower technology readiness level (TRL), implying that additional efforts are necessary before being evaluated for commercial availability. Solving energy needs is not only a technological solution and interlinkage of various factors needs to be assessed beyond technology development.

Intensification of lignocellulosic bioethanol production process using continuous double-staged immersed membrane bioreactors

Processing complexities associated with different lignocellulosic bioethanol production stages have hindered reaching full commercial capacity. Therefore, in this study efforts were made to remediate some issues associated with hydrolysis and fermentation, by the integration of immersed membrane bioreactors (iMBRs) into lignocellulosic bioethanol production process. In this regards, double-staged continuous saccharification-filtration and co-fermentation-filtration of wheat straw slurry was conducted using iMBRs at filtration fluxes up to 51.0 l.m^-2.h^-1 (LMH). The results showed a stable long-term (264 h) continuous hydrolysis-filtration and fermentation-filtration with effective separation of lignin-rich solids (up to 70% lignin) from hydrolyzed sugars, and separation of yeast cells from bioethanol stream at an exceptional filtration performance at 21.9 LMH. Moreover, the effect of factors such as filtration flux, medium quality and backwashing on fouling and cake-layer formation was studied. The results confirmed the process intensification potentials of iMBRs in tackling commonly faced technical obstacles in lignocellulosic bioethanol production.

Enhanced ethanol production from industrial lignocellulose hydrolysates by a hydrolysate-cofermenting Saccharomyces cerevisiae strain

Industrial production of lignocellulosic ethanol requires a microorganism utilizing both hexose and pentose, and tolerating inhibitors. In this study, a hydrolysate-cofermenting Saccharomyces cerevisiae strain was obtained through one step in vivo DNA assembly of pentose-metabolizing pathway genes, followed by consecutive adaptive evolution in pentose media containing acetic acid, and direct screening in biomass hydrolysate media. The strain was able to coferment glucose and xylose in synthetic media with the respective maximal specific rates of glucose and xylose consumption, and ethanol production of 3.47, 0.38 and 1.62 g/g DW/h, with an ethanol titre of 41.07 g/L and yield of 0.42 g/g. Industrial wheat straw hydrolysate fermentation resulted in maximal specific rates of glucose and xylose consumption, and ethanol production of 2.61, 0.54 and 1.38 g/g DW/h, respectively, with an ethanol titre of 54.11 g/L and yield of 0.44 g/g. These are among the best for wheat straw hydrolysate fermentation through separate hydrolysis and cofermentation.

Food waste-derived volatile fatty acids platform using an immersed membrane bioreactor

Volatile fatty acids (VFAs) are the key intermediates from anaerobic digestion (AD) process that can be a platform to synthesize products of higher value than biogas. However, some obstacles still exist that prevent large-scale production and application of VFAs, key among them being the difficulty in recovering the acids from the fermentation medium and low product yields. In this study, a novel anaerobic immersed membrane bioreactor (iMBR) with robust cleaning capabilities, which incorporated frequent backwashing to withstand the complex AD medium, was designed and applied for production and in situ recovery of VFAs. The iMBR was fed with food waste and operated without pH control, achieving a high yield of 0.54 g VFA/g VS_added. The continuous VFA recovery process in the iMBR was investigated for 40 days at OLRs of 2 gVS/L/d and 4 gVS/L/d without significant change in the permeate flux at a maximum suspended solids concentration of 31 g/L.

Removal of Bacterial Contamination from Bioethanol Fermentation System Using Membrane Bioreactor

A major issue hindering efficient industrial ethanol fermentation from sugar-based feedstock is excessive unwanted bacterial contamination. In industrial scale fermentation, reaching complete sterility is costly, laborious, and difficult to sustain in long-term operation. A physical selective separation of a co-culture of Saccharomyces cerevisiae and an Enterobacter cloacae complex from a buffer solution and fermentation media at dilution rates of 0.1–1 1/h were examined using an immersed membrane bioreactor (iMBR). The effect of the presence of yeast, inoculum size, membrane pore size, and surface area, backwashing and dilution rate on bacteria removal were assessed by evaluating changes in the filtration conditions, medium turbidity, and concentration of compounds and cell biomass. The results showed that using the iMBR with dilution rate of 0.5 1/h results in successful removal of 93% of contaminating bacteria in the single culture and nearly complete bacteria decontamination in yeast-bacteria co-culture. During continuous fermentation, application of lower permeate fluxes provided a stable filtration of the mixed culture with enhanced bacteria washout. This physical selective separation of bacteria from yeast can enhance final ethanol quality and yields, process profitability, yeast metabolic activity, and decrease downstream processing costs.

Simultaneous glucose production from cellulose and fouling reduction using a magnetic responsive membrane reactor with superparamagnetic nanoparticles carrying cellulolytic enzymes

This work aimed at investigating simultaneous hydrolysis of cellulose and in-situ foulant degradation in a cellulose fed superparamagnetic biocatalytic membrane reactor (BMR^SP). In this reactor, a dynamic layer of superparamagnetic bionanocomposites with immobilized cellulolytic enzymes were reversibly immobilized on superparamagnetic polymeric membrane using an external magnetic field. The formation of a dynamic layer of bionanocomposites on the membrane helped to prevent direct membrane-foulant interaction. Due to in-situ biocatalysis, there was limited filtration resistance. Simultaneous separation of the product helped to avoid enzyme product inhibition, achieve constant reaction rate over time and 50% higher enzyme efficiency than batch reactor. Stable enzyme immobilization and the ability to keep enzyme in the system for long period helped to achieve continuous productivity at very low enzyme but high solid loading, while also reducing the extent of membrane fouling. Hence, the BMR^SP paves a path for sustainable production of bioethanol from the cheaply available lignocellulose.

Recent advances and strategies in process and strain engineering for the production of butyric acid by microbial fermentation

Butyric acid is an important platform chemical, which is widely used in the fields of food, pharmaceutical, energy, etc. Microbial fermentation as an alternative approach for butyric acid production is attracting great attention as it is an environmentally friendly bioprocessing. However, traditional fermentative butyric acid production is still not economically competitive compared to chemical synthesis route, due to the low titer, low productivity, and high production cost. Therefore, reduction of butyric acid production cost by utilization of alternative inexpensive feedstock, and improvement of butyric acid production and productivity has become an important target. Recently, several advanced strategies have been developed for enhanced butyric acid production, including bioprocess techniques and metabolic engineering methods. This review provides an overview of advances and strategies in process and strain engineering for butyric acid production by microbial fermentation. Additionally, future perspectives on improvement of butyric acid production are also proposed.