Bioprocess engineering for biohythane production from low-grade waste biomass: technical challenges towards scale up

Biohythane production via anaerobic digestion process: fundamentals, scale-up challenges, and techno-economic and environmental aspects

Biohythane, a balanced mixture comprising bioH2 (biohydrogen) and bioCH4 (biomethane) produced through anaerobic digestion, is gaining recognition as a promising energy source for the future. This article provides a comprehensive overview of biohythane production, covering production mechanisms, microbial diversity, and process parameters. It also explores different feedstock options, bioreactor designs, and scalability challenges, along with techno-economic and environmental assessments. Additionally, the article discusses the integration of biohythane into waste management systems and examines future prospects for enhancing production efficiency and applicability. This review serves as a valuable resource for researchers, engineers, and policymakers interested in advancing biohythane production as a sustainable and renewable energy solution.

Biohythane: a Potential Biofuel of the Future

Today, the world is becoming more dependent on fossil fuels. The major drawbacks of these non-renewable energy resources include an extreme environmental pollution and an extinction threat. Several technologies including microalgal biodiesel production, biomass gasification, and bioethanol production have been explored for the generation of renewable energy especially, biofuels. One such promising research has been carried out in the generation of biohythane which has the potential to become an alternative fuel to the existing non-renewable ones. It has been reported that biohydrogen can be produced from organic wastes or agricultural feedstocks with the help of acidogens. Dark fermentation can be carried out by acidogens to produce biohydrogen under anaerobic conditions by utilizing lignocellulosic biomass or sugarcane feedstocks in the absence of light. The spent medium contains volatile short-chain fatty acids like acetate, butyrate, and propionate that can serve as substrates for acetogenesis followed by methane biosynthesis by methanogens. Therefore, the sequential two-stage anaerobic digestion (AD) involves a production of biohydrogen followed by the biosynthesis of methane. This combined process is termed as a single eponym "Biohythane" (hydrogen + methane). Several studies have demonstrated about the effectiveness of biofuel, and it is believed to have a greater energy recovery, environmental friendliness, and shorter fermentation time. Biohythane can serve as an alternative future green biofuel and solve the present energy crisis in India as well as the entire world.

Two-stage biohydrogen and methane production from sugarcane-based sugar and ethanol industrial wastes: A comprehensive review

The transition to renewable energy sources is crucial to ensure a sustainable future. Although the sugar and ethanol industries benefit from this transition, there are untapped opportunities to utilize the waste generated from the sugar and ethanol process chains through two-stage anaerobic digestion (TSAD). This review comprehensively discusses the utilization of various sugarcane-based industrial wastes by TSAD for sequential biohydrogen and methane production. Factors influencing TSAD process performance, including pH, temperature, hydraulic retention time, volatile fatty acids and alkalinity, nutrient imbalance, microbial population, and inhibitors, were discussed in detail. The potential of TSAD to reduce emissions of greenhouse gases is demonstrated. Recent findings, implications, and promising future research related to TSAD, including the integration of meta-omics approaches, gene manipulation and bioaugmentation, and application of artificial intelligence, are highlighted. The review can serve as important literature for the implementation, improvement, and advancements in TSAD research.

Emerging microalgae-based biofuels: Technology, life-cycle and scale-up

Microalgae biomass is a versatile feedstock with a variable composition that can be submitted to several conversion routes. Considering the increasing energy demand and the context of third-generation biofuels, algae can fulfill the increasing global demand for energy with the additional benefit of environmental impact mitigation. While biodiesel and biogas are widely consolidated and reviewed, emerging algal-based biofuels such as biohydrogen, biokerosene, and biomethane are cutting-edge technologies in earlier stages of development. In this context, the present study covers their theoretical and practical conversion technologies, environmental hotspots, and cost-effectiveness. Scaling-up considerations are also addressed, mainly through Life Cycle Assessment results and interpretation. Discussions on the current literature for each biofuel directs researchers towards challenges such as optimized pretreatment methods for biohydrogen and optimized catalyst for biokerosene, besides encouraging pilot and industrial scale studies for all biofuels. While presenting studies for larger scales, biomethane still needs continuous operation results to consolidate the technology further. Additionally, environmental improvements on all three routes are discussed in light of life-cycle models, highlighting the ample research opportunities on wastewater-grown microalgae biomass.

A high-value biohythane production: Feedstocks, reactor configurations, pathways, challenges, technoeconomics and applications

In recent years, the demand for high-quality biofuels from renewable sources has become an aspirational goal to offer a clean environment by alternating the depleting fossil fuels to meet future energy needs. In this aspect, biohythane production from wastes has received extensive research interest since it contains superior fuel characteristics than the promising conventional biofuel i.e. biogas. The main aim is to promote research and potentials of biohythane production by a systematic review of scientific literature on the biohythane production pathways, substrate/microbial consortium suitability, reactor design, and influential process/operational factors. Reactor configuration also decides the product yield in addition to other key factors like waste composition, temperature, pH, retention time and loading rates. Hence, a detailed emphasis on different reactor configurations with respect to the type of feedstock has also been given. The technical challenges are highlighted towards process optimization and system scale up. Meanwhile, solutions to improve product yield, technoeconomics, applications and key policy and governance factors to build a hydrogen based society have also been discussed.

Value addition through biohydrogen production and integrated processes from hydrothermal pretreatment of lignocellulosic biomass

Bioenergy production is the most sought-after topics at the crunch of energy demand, climate change and waste generation. In view of this, lignocellulosic biomass (LCB) rich in complex organic content has the potential to produce bioenergy in several forms following the pretreatment. Hydrothermal pretreatment that employs high temperatures and pressures is gaining momentum for organics recovery from LCB which can attain value-addition. Diverse bioprocesses such as dark fermentation, anaerobic digestion etc. can be utilized following the pretreatment of LCB which can result in biohydrogen and biomethane production. Besides, integration approaches for LCB utilization that enhance process efficiency and additional products such as biohythane production as well as application of solid residue obtained after LCB pretreatment were discussed. Importance of hydrothermal pretreatment as one of the suitable strategies for LCB utilization is emphasized suggesting its future potential in large scale energy recovery.

Integrative biohydrogen- and biomethane-producing bioprocesses for comprehensive production of biohythane

The production of biohythane, a combination of energy-dense hydrogen and methane, from the anaerobic digestion of low-cost organic wastes has attracted attention as a potential candidate for the transition to a sustainable circular economy. Substantial research has been initiated to upscale the process engineering to establish a hythane-based economy by addressing major challenges associated with the process and product upgrading. This review provides an overview of the feasibility of biohythane production in various anaerobic digestion systems (single-stage, dual-stage) and possible technologies to upgrade biohythane to hydrogen-enriched renewable natural gas. The main goal of this review is to promote research in biohythane production technology by outlining critical needs, including meta-omics and metabolic engineering approaches for the advancements in biohythane production technology.

Turning C1-gases to isobutanol towards great environmental and economic sustainability via innovative biological routes: two birds with one stone

BACKGROUND

The dramatic increase in greenhouse gas (GHG) emissions, which causes serious global environmental issues and severe climate changes, has become a global problem of concern in recent decades. Currently, native and/or non-native C1-utilizing microbes have been modified to be able to effectively convert C1-gases (biogas, natural gas, and CO₂) into isobutanol via biological routes. Even though the current experimental results are satisfactory in lab-scale research, the techno-economic feasibility of C1 gas-derived isobutanol production at the industrial scale still needs to be analyzed and evaluated, which will be essential for the future industrialization of C1-gas bioconversion. Therefore, techno-economic analyses were conducted in this study with comparisons of capital cost (CAPEX), operating cost (OPEX), and minimum isobutanol selling price (MISP) derived from biogas (scenario #1), natural gas (scenario #2), and CO₂ (scenario #3) with systematic economic assessment.

RESULTS

By calculating capital investments and necessary expenses, the highest CAPEX ($317 MM) and OPEX ($67 MM) were projected in scenario #1 and scenario #2, respectively. Because of the lower CAPEX and OPEX from scenario #3, the results revealed that bioconversion of CO₂ into isobutanol temporally exhibited the best economic performance with an MISP of $1.38/kg isobutanol. Furthermore, a single sensitivity analysis with nine different parameters was carried out for the production of CO₂-derived isobutanol. The annual plant capacity, gas utilization rate, and substrate cost are the three most important economic-driving forces on the MISP of CO₂-derived isobutanol. Finally, a multiple-point sensitivity analysis considering all five parameters simultaneously was performed using ideal targets, which presented the lowest MISP of $0.99/kg in a long-term case study.

CONCLUSIONS

This study provides a comprehensive assessment of the bioconversion of C1-gases into isobutanol in terms of the bioprocess design, mass/energy calculation, capital investment, operating expense, sensitivity analysis, and minimum selling price. Compared with isobutanol derived from biogas and natural gas, the CO₂-based isobutanol showed better economic feasibility. A market competitive isobutanol derived from CO₂ is predicable with lower CO₂ cost, better isobutanol titer, and higher annual capacity. This study will help researchers and decision-makers explore innovative and effective approaches to neutralizing GHGs and focus on key economic-driving forces to improve techno-economic performance.

Fundamentals and recent progress in bioelectrochemical system-assisted biohythane production

Biohythane, a balanced mixture of 10%-30% v/v of hydrogen and 70%-90% v/v of methane, could be the backbone of an all-purpose future energy supply. Recently, bioelectrochemical systems (BES) became a new sensation among environmental biotechnology processes with the potential to sustainably generate biohythane. Therefore, to unleash its full potential for scaling up, researchers are consistently improving microbial metabolic pathways, novel reactors, and electrode designs. This review presents a detailed analysis of recently discovered fundamental mechanisms and science and engineering intervention of different strategies to improve the biohythane composition and production rate from BES. However, several milestones are to be achieved, for instance, improving electrode kinetics using efficient catalysts, engineered microbial communities, and improved reactor configurations, for commercializing this sustainable technology. Thus, a future perspective section is included to recommend novel research lines, mainly focusing on the microbial communities and the efficient electrocatalysts, to enhance reactor performance.

Two-Phase Anaerobic Digestion of Corn Steep Liquor in Pilot Scale Biogas Plant with Automatic Control System with Simultaneous Hydrogen and Methane Production

Experimental studies of two-phase anaerobic digestion of corn steep liquor in semi-continuous automatic and semi-automatic modes of operation of a cascade of two anaerobic bioreactors with monitoring and control systems were performed. Corn steep liquor—a waste product from the process of treating corn grain for starch extraction—was used as a substrate in the process of anaerobic digestion with simultaneous hydrogen and methane production. The daily yields of biohydrogen in bioreactor 1 of the cascade (with a working volume of 8 dm3) are variable. In good operation, they are in the range of 0.7 to 1.0 L of biogas from a 1 dm3 working volume of the bioreactor, and the optimal pH is in the range of 5.0–5.5. The concentration of hydrogen in the biogas from the hydrogen bioreactor 1 is in the range of 14–34.7%. The daily yields of biomethane in bioreactor 2 of the cascade (with a working volume of 80 dm3) vary in the range 0.4 to 0.85 L of biogas from a 1 dm3 working volume of the bioreactor, and the concentration of methane in the biogas from bioreactor 2 is high and remains practically constant (in the range 65–69%). At a dilution rate of 0.4 day−1 and an organic loading rate of 20 gL for bioreactor 1, respectively, and a dilution rate of 0.05 day−1 for bioreactor 2, the best results were obtained. The computer control system is presented. Some energetical considerations were discussed.

Augmentation characteristics and microbial community dynamics of low temperature resistant composite strains LTF-27

Biogas production in the cold regions of China is hindered by low temperatures, which led to slow lignocellulose biotransformation. Cold-adapted lignocellulose degrading microbial complex community LTF-27 was used to investigate the influence of hydrolysis on biogas production. After 5 days of hydrolysis at 15 ± 1 °C, the hydrolysis conversion rate of the corn straw went up to 22.64%, and the concentration of acetic acid increased to 2596.56 mg/L. The methane production rates of total solids (TS) inoculated by LTF-27 reached 204.72 mL/g, which was higher than the biogas (161.34 mL/g), and the control group (CK) inoculated with cultural solution (121.19 mL/g), the methane production rate of volatile solids (VS) increased by 26.88% and 68.92%, respectively. Parabacteroides, Lysinibacillus, and Citrobacter were the main organisms that were responsible for hydrolysis. While numerous other bacteria genera in the gas-producing phase, Macellibacteroides were the most commonly occurring one. Methanosarcina and Methanobacteriaceae contributed 86.25% and 11.80% of the total Archaea abundance during this phase. This study proves the psychrotrophic LTF-27's applicability in hydrolysis and biomass gas production in low temperatures.

Long-term in situ bioelectrochemical monitoring of biohythane process: Metabolic interactions and microbial evolution

Microbial stability and evolution are a critical aspect for biosensors, especially in detecting dynamic and emerging anaerobic biohythane production. In this study, two upflow air-cathode chamber microbial fuel cells (UMFCs) were developed for in situ monitoring of the biohydrogen and biomethane reactors under a COD range of 1000-6000 mg/L and 150-1000 mg/L, respectively. Illumina MiSeq sequencing evidenced the dramatic shift of dominant microbial communities in UMFCs from hydrolytic and acidification bacteria (Clostridiaceae_1, Ruminococcaceae, Peptostreptococcaceae) to acetate-oxidizing bacteria (Synergistaceae, Dysgonomonadaceae, Spirochaetaceae). In addition, exoelectroactive bacteria evaluated from Enterobacteriaceae and Burkholderiaceae to Desulfovibrionaceae and Propionibacteriaceae. Especially, Hydrogenotrophic methanogens (Methanobacteriaceae) were abundant at 93.41% in UMFC (for monitoring hydrogen reactor), which was speculated to be a major metabolic pathway for methane production. Principal component analysis revealed a similarity in microbial structure between UMFCs and methane bioreactors. Microbial network analysis suggested a more stable community structure of UMFCs with 205 days' operation.

Bio-hydrogen and bio-methane potential analysis for production of bio-hythane using various agricultural residues

The present study targeted towards the feasibility of various agricultural residues for bio-hythane production by anaerobic digestion (AD) process without pre-treatment. Biochemical methane potential (BMP) analysis was carried out for mixed fruit waste (MFW), mixed vegetable waste (MVW), sugarcane bagasse (SB), rice husk (RH), and wheat straw (WS). The analysis of gas was carried out in gas chromatography with a thermal conductivity detector (GC-TCD). The BMP test results in the study for SB, MFW, and MVW reveal that the average percentage value of bio-hythane production was 53.64%, 43.54%, and 40.92% and that of RH and WS was 16.74% and 29.75%, respectively. The result also shows that agricultural biomass, such as WS and RH produces less % of bio-hythane due to the presence of lignocellulosic components. The main contribution of this study is to highlight the bio-hythane potential with reference to the bio-methane and bio-hydrogen productions from the agricultural residues.

Pretreatment of polysaccharidic wastes with cellulolytic Aspergillus fumigatus for enhanced production of biohythane in a dual-stage process

Biological pretreatment of polysaccharidic wastes (PWs) is a cost-effective and environmentally friendly approach to improve the digestibility and utilization of these valuable substrates in dual-stage biohythane production. In order to reduce the prolonged incubation time and loss of carbohydrate during the pretreatment of PWs with Aspergillus fumigatus, a systematic optimization using Taguchi methodology resulted in an unprecedented recovery of soluble carbohydrates (362.84 mg g^-1) within 5 days. The disruption and fragmentation of lignocellulosic structures in PWs, and possible saccharification of cellulose and hemicellulose components, increased its digestibility. A dual-stage biohythane production with pretreated PWs showed increased yield (214.13 mL g^-1 VS_added), which was 56% higher than the corresponding value with the untreated PWs. This resulted in 47% higher energy recovery as biohythane in pretreated biomass compared to untreated biomass. Optimized fungal pretreatment is, therefore, an effective method to improve the digestibility of PWs and its subsequent conversion to biohythane.

Cohesive strategy and energy conversion efficiency analysis of bio-hythane production from corncob powder by two-stage anaerobic digestion process

In order to maximize the substrate conversion, co-production of hydrogen and methane from two-stage anaerobic digestion has attracted wide attention. In two-stage fermentation process, the cohesive strategy is considered as a key indicator for bio-hythane yield. In this work, corncob powder was utilized as raw material. The pH of fermentative broth, bio-hythane yield, gas production rate and energy conversion efficiency were taken as indexes. Under the directional control of bio-chemical reaction process, the effects of diverse coupling time nodes on the fermentation process and the bio-hythane co-production potential were investigated. The results showed that when the coupling time node was 48 h, hydrogen production potential and methane production potential were 22.29 mL/g TS and 141.14 mL/g TS, respectively. The hydrogen content in the bio-hythane was 13.64% which satisfied the hydrogen concentration requirement, and the energy conversion efficiency was 27.6%.

An innovative multistage anaerobic hythane reactor (MAHR): Metabolic flux, thermodynamics and microbial functions

Biohythane production from wastewater via anaerobic fermentation currently relies on two-stage physically separated biohydrogen and biomethane reactors, which requires closed monitoring, the implementation of a control system, and cost-intensive, complex operation. Herein, an innovative multistage anaerobic hythane reactor (MAHR) was reported via integrating two-stage fermentation into one reactor. MAHR was constructed using an internal down-flow packed bed reactor and an external up-flow sludge blanket to enhance microbial enrichment and thermodynamic feasibility of the associated bioreactions. The performance of MAHR was investigated for 160 d based on biogas production, metabolic flux and microbial structure in comparison to a typical anaerobic high-rate reactor (up-flow anaerobic sludge blanket (UASB)). A biohythane production with an optimized hydrogen volume ratio (10-20%) and a high methane content (75-80%) was achieved in the hythane zone (M_H) and methane zone (M_M) in MAHR, respectively. In addition, MAHR showed a stronger capability to accommodate a high organic loading rate (120 g COD/L/d), and it enhanced the conversion of organics leading to a methane production rate 66% higher than UASB. Thermodynamic analysis suggested that hydrogen extraction in M_H significantly decreased the hydrogen partial pressure (<0.1% vol) which favored acetogenesis in M_M. Metabolic flux and microbial function analysis further supported the superior performance of MAHR over UASB, which was primarily attributed to enhanced acetogenesis and acetoclastic methanogenesis.

Biohythane production from food processing wastes - Challenges and perspectives

The food industry generates enormous quantity of food waste (FW) either directly or indirectly including the processing sector, which turned into biofuels for waste remediation. Six types of food processing wastes (FPW) such as oil, fruit and vegetable, dairy, brewery, livestock and finally agriculture based materials that get treated via dark fermentation/anaerobic digestion has been discussed. Production of both hydrogen and methane is daunting for oil, fruit and vegetable processing wastes because of the presence of polyphenols and essential oils. Moreover, acidic pH and high protein are the reasons for increased concentration of ammonia and accumulation of volatile fatty acids in FPW, especially in dairy, brewery, and livestock waste streams. Moreover, the review brought to forefront the enhancing methods, (pretreatment and co-digestion) operational, and environmental parameters that can influence the production of biohythane. Finally, the nature of feedstock's role in achieving successful circular bio economy is also highlighted.

Anaerobic digestion

Worldwide waste generation has become a topic of interest since the accumulation of this waste has prompted environmental hazards. Among which, anaerobic digestion provides green and efficient alternate solution for removal of toxic waste and energy production. Therefore, this review emphasizes on the recent data published in 2018 on topics related to anaerobic process, enhancement of biogas production, and fermentation efficiency. Furthermore, more focus was made on the factors influencing anaerobic digestion and the effect of trace elements as ionic salts as well as nanoparticles on overall biogas production, respectively. PRACTITIONER POINTS: Anaerobic digestion provide green and efficient alternate solution to deal with. This review focused on the conditions related to anaerobic process to improve biogas production and fermentation efficiency. The trace elements were focused on how to influence biogas production during anaerobic digestion.

A review of research trends in the enhancement of biomass-to-hydrogen conversion

Different types of biomass are being examined for their optimum hydrogen production potentials and actual hydrogen yields in different experimental set-ups and through different chemical synthetic routes. In this review, the observations emanating from research findings on the assessment of hydrogen synthesis kinetics during fermentation and gasification of different types of biomass substrates have been concisely surveyed from selected publications. This review revisits the recent progress reported in biomass-based hydrogen synthesis in the associated disciplines of microbial cell immobilization, bioreactor design and analysis, ultrasound-assisted, microwave-assisted and ionic liquid-assisted biomass pretreatments, development of new microbial strains, integrated production schemes, applications of nanocatalysis, subcritical and supercritical water processing, use of algae-based substrates and lastly inhibitor detoxification. The main observations from this review are that cell immobilization assists in optimizing the biomass fermentation performance by enhancing bead size, providing for adequate cell loading and improving mass transfer; there are novel and more potent bacterial and fungal strains which improve the fermentation process and impact on hydrogen yields positively; application of microwave irradiation and sonication and the use of ionic liquids in biomass pretreatment bring about enhanced delignification, and that supercritical water biomass processing and dosing with metal-based nanoparticles also assist in enhancing the kinetics of hydrogen synthesis. The research areas discussed in this work and their respective impacts on hydrogen synthesis from biomass are arguably standalone. Thence, further work is still required to explore the possibilities and techno-economic implications of combining these areas for developing robust and integrated biomass-to-hydrogen synthetic schemes.

Recent developments in biohythane production from household food wastes: A review

Biohythane is a hydrogen-methane blend with hydrogen concentration between 10 and 30% v/v. It can be produced from different organic substrates by two sequential anaerobic stages: a dark fermentation step followed by a second an anaerobic digestion step, for hydrogen and methane production, respectively. The advantages of this blend compared to either hydrogen or methane, as separate biofuels, are first presented in this work. The two-stage anaerobic process and the main operative parameters are then discussed. Attention is focused on the production of biohythane from household food wastes, one of the most abundant organic substrate available for anaerobic digestion: the main milestones and the future trends are exposed. In particular, the possibility to co-digest food wastes and sewage sludge to improve the process yield is discussed. Finally, the paper illustrates the developments of biohythane application in the automotive sector as well as its reduced environmental burden.