Resource recovery from sugarcane vinasse by anaerobic digestion - A review

Effective Exploitation of Sugarcane Byproducts and Industrial Effluents for Strategic Energy Applications: A Review on Recent Developments and Approaches with Special Reference to Microbial Fuel Cells

Apart from its role in agriculture, the contribution of the sugarcane industry and its related sectors toward the global economy is seemingly great. Hence, it is imperative to adopt the maximum possible ways to completely recover the stored chemical energy in sugarcane to generate additional revenue and thereby to ensure the sustainability of sugarcane-related industries by surmounting the regional/seasonal limitations associated with sugarcane cultivation. So, the present Review aims to highlight the importance of sugarcane crops in the global economy by comprehensively discussing the energy value of byproducts and industrial waste generated during the processing of sugarcane. The various possible strategies reported so far for the effective recovery of bioenergy from sugarcane components are discussed with a special emphasis on technologies capable of converting the stored chemical energy into electrical energy or fuel. As the fraction of waste components generated during the harvesting or processing of sugarcane is high, the bioenergy recovery strategies standing close to the "waste-to-energy" concept are the most rewarding ones, suitable for complete bioenergy recovery. Hence, the microbial fuel cell (MFC) technology that offers dual benefits in terms of waste management and power generation is receiving much attention. The status of technological developments in MFCs and the possibilities for developing hybrid technologies through their integration with existing sugar industry waste processing strategies, to further enhance the effective exploitation of the energy value of sugarcane byproducts, are discussed rigorously by focusing on their commercialization possibilities.

Sustainable treatment of sugarcane vinasse using Chlorella sp. in scalable airlift flat-panel photobioreactors: nutrient removal and biomass valorization

The global production of sugarcane ethanol generates vast amounts of vinasse, a liquid waste by-product requiring treatment to mitigate environmental impacts. Using vinasse as a feedstock for microalgae cultivation offers a sustainable alternative. This study evaluates the performance of the native strain Chlorella sp. MC18 in internal-loop airlift flat-panel photobioreactors (PBR) for treating industrial raw sugarcane vinasse (SCV) while producing biomass. Cultures were grown in diluted, centrifugation-pretreated SCV (5-25% v/v) as the sole nutrient source, with CO2 supplied by aeration. The best results were obtained with 10% SCV. Nutrient removal efficiencies reached up to 99% for nitrates and 90% for phosphates, with reduction in chemical oxygen demand (COD) exceeding 75% at 5-10% SCV. The highest specific growth rate (0.711 day-1) and biomass productivity (116 mg L-1 day-1) occurred at 10% SCV, maintaining stable pH control (8.2-8.5). The PBR design enabled scalable, reproducible growth kinetics while minimising biofouling. Biomass from 10% SCV holds significant potential for energy recovery (20.24 kJ g-1) and production of high-value product pools (lipids, carbohydrates, proteins, and carotenoids). These results demonstrate the feasibility of scaling up the PBR design for integrated vinasse treatment with Chlorella and biomass valorisation, reinforcing the concept of an agro-industrial sector biorefinery.

Vinasses valorization into short-chain fatty acids: microbiome robustness against process variations

The valorization of vinasses into short-chain fatty acids (SCFAs) via anaerobic fermentation (AF) is an emerging approach that remains under research. Given the diverse microbial metabolisms simultaneously occurring in AF, the control of operational parameters is essential to avoid process destabilization. To unravel their effect, the novelty of this investigation relied on the evaluation of the robustness of AF process against operational perturbation deliberately set (i.e. hydraulic retention time (HRT) and temperature increase). Regardless the applied perturbation, similar yields (0.5-0.6 g COD-SCFAs/g VSin) were attained. However, the selected perturbations exerted an effect on microbiome development. Whereas the temperature increase mediated a 49.70% microbiome dissimilarity, only a 21.91% dissimilarity was caused by the HRT increase. Microbial analysis revealed Clostridiales, Prevotella and Megasphaera as key bacteria in vinasses degradation. The similar bioconversion obtained despite the different microbiomes developed after each perturbation suggested a functional redundancy highlighting the AF robustness. These findings evidenced AF as a feasible biotechnology to further valorize vinasse into SCFAs, demonstrating the process stability against common perturbations that might be encountered at industrial scale.

Harnessing the Energy Potential and Value-Added Products from the Treatment of Sugarcane Vinasse: Maximizing Methane Production Through Co-Digestion with Sugarcane Molasses and Enhanced Organic Loading

This study assessed the impact of organic loading rate (OLR) on methane (CH4) production in the anaerobic co-digestion (AcoD) of sugarcane vinasse and molasses (SVM) (1:1 ratio) within a thermophilic fluidized bed reactor (AFBR). The OLR ranged from 5 to 27.5 kg COD.m-3.d-1, with a fixed hydraulic retention time (HRT) of 24 h. Organic matter removal varied from 56 to 84%, peaking at an OLR of 5 kg COD.m-3.d-1. Maximum CH4 yield (MY) (272.6 mL CH4.g-1CODrem) occurred at an OLR of 7.5 kg COD.m-3.d-1, while the highest CH4 production rate (MPR) (4.0 L CH4.L-1.d-1) and energy potential (E.P.) (250.5 kJ.d-1) were observed at an OLR of 20 kg COD.m-3.d-1. The AFBR exhibited stability across all OLR. At 22.5 kg COD.m-3.d-1, a decrease in MY indicated methanogenesis imbalance and inhibitory organic compound accumulation. OLR influenced microbial populations, with Firmicutes and Thermotogota constituting 43.9% at 7.5 kg COD.m-3.d-1, and Firmicutes dominating (52.7%) at 27.5 kg COD.m-3.d-1. Methanosarcina (38.9%) and hydrogenotrophic Methanothermobacter (37.6%) were the prevalent archaea at 7.5 kg COD.m-3.d-1 and 27.5 kg COD.m-3.d-1, respectively. Therefore, this study demonstrates that the organic loading rate significantly influences the efficiency of methane production and the stability of microbial communities during the anaerobic co-digestion of sugarcane vinasse and molasses, indicating that optimized conditions can maximize energy yield and maintain methanogenic balance.

Two-Stage and One-Stage Anaerobic Co-digestion of Vinasse and Spent Brewer Yeast Cells for Biohydrogen and Methane Production

This study aimed to evaluate the two-stage and one-stage anaerobic co-digestion of vinasse and spent brewer yeast cells (SBY) for biohydrogen and methane production. Optimization of the vinasse-to-SBY ratio and fly ash concentration of the two-stage and one-stage production processes was investigated. In the two-stage process, the vinasse-to-SBY ratio and fly ash concentration were optimized, and the leftover effluent was used for methane production. The optimum conditions for biohydrogen production were a vinasse-to-SBY ratio of 7:3% v/w and fly ash concentration of 0.4% w/v, in which the maximum hydrogen yield was 43.7 ml-H2/g-VSadded. In contrast, a vinasse-to-SBY ratio of 10:0% v/w and fly ash concentration of 0.2% w/v were considered optimal for methane production, and resulted in a maximum methane yield of 214.6 ml-CH4/g-VSadded. For the one-stage process, a vinasse-to-SBY ratio of 10:0% v/w and fly ash concentration of 0.1% w/v were considered optimal, and resulted in a maximum methane yield of 243.6 ml-CH4/g-VSadded. In the two-stage process, the energy yield from hydrogen (0.05-0.47 kJ/g-VSadded) was 0.62%-11.78%, and the major fraction was approximately 88.22%-99.38% gain from methane (3.19-7.73 kJ/g-VSadded). For the one-stage process, the total energy yield distribution ranged from 4.20 to 8.77 kJ/g-VSadded.

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.

Chemical and biological combined treatment for sugarcane vinasse: selection of parameters and performance studies

Sugarcane vinasse has been reported as a high strength industrial wastewater that could cause severe environmental pollution due to its complex and bio-refractory compounds. Thus, the combined coagulation and sequencing batch biofilm reactor (SBBR) system was employed for the sugarcane vinasse treatment. This study aims to determine the recommended conditions of various parameters under coagulation and SBBR and investigate the effectiveness of combined processes. First, the approach of the coagulation process could achieve the maximum COD reduction and decolorization efficiencies of 79.0 ± 3.4% and 94.1 ± 1.9%, respectively, under the recommended conditions. Next, SBBR as an integrated biofilm reactor showed excellent synergistic biodegradability, removing 86.6 ± 4.3% COD concentration and 94.6 ± 3.8% color concentration at 3.0 g·COD/L of substrate loading concentration. The kinetic studies of SBBR revealed that the first-order kinetic model was the best fit for COD reduction efficiency. In contrast, the second-order kinetic model was the best fit for decolorization efficiency. The SBBR reaction was further investigated by ultraviolet-visible spectrophotometry (UV-Vis). In the combined processes, SBBR followed by the coagulation process (SBBR-CP) showed greater COD reduction and decolorization efficiencies (97.5 ± 0.3 and 99.4 ± 0.1%) when compared to the coagulation process followed by SBBR (CP-SBBR). This study demonstrated the removal performance and potential application of the combined sequential process to produce effluent that can be reused for bioethanol production and fertigation. This finding provides additional insight for developing effective vinasse treatment using combined chemical and biological processes.

High-retention membrane bioreactors for sugarcane vinasse treatment: Opportunities for environmental impact reduction and wastewater valorization

Ethanol production has increased over the years, and Brazil ranking second in the world using sugarcane as the main raw material. However, 10-15 L of vinasse are generated per liter of ethanol produced. Besides large volumes, this wastewater has high polluting potential due to its low pH and high concentrations of organic matter and nutrients. Given the high biodegradability of the organic matter, the treatment of this effluent by anaerobic digestion and membrane separation processes results in the generation of high value-added byproducts such as volatile fatty acids (VFAs), biohydrogen and biogas. Membrane bioreactors have been widely evaluated due to the high efficiency achieved in vinasse treatment. In recent years, high retention membrane bioreactors, in which high retention membranes (nanofiltration, reverse osmosis, forward osmosis and membrane distillation) are combined with biological processes, have gained increasing attention. This paper presents a critical review focused on high retention membrane bioreactors and the challenges associated with the proposed configurations. For nanofiltration membrane bioreactor (NF-MBR), the main drawback is the higher fouling propensity due to the hydraulic driving force. Nonetheless, the development of membranes with high permeability and anti-fouling properties is uprising. Regarding osmotic membrane bioreactor (OMBR), special attention is needed for the selection of a proper draw solution, which desirably should be low cost, have high osmolality, reduce reverse salt flux, and can be easily reconcentrated. Membrane distillation bioreactor (MDBR) also exhibit some shortcomings, with emphasis on energy demand, that can be solved with the use of low-grade and residual heat, or renewable energies. Among the configurations, MDBR seems to be more advantageous for sugarcane vinasse treatment due to the lower energy consumption provided by the use of waste heat from the effluent, and due to the VFAs recovery, which has high added value.

Microbial Behavior and Influencing Factors in the Anaerobic Digestion of Distiller: A Comprehensive Review

Anaerobic digestion technology is regarded as the most ideal technology for the treatment of a distiller in terms of environmental protection, resource utilization, and cost. However, there are some limitations to this process, the most prominent of which is microbial activity. The purpose of this paper is to provide a critical review of the microorganisms involved in the anaerobic digestion process of a distiller, with emphasis on the archaea community. The effects of operating parameters on microbial activity and process, such as pH, temperature, TAN, etc., are discussed. By understanding the activity of microorganisms, the anaerobic treatment technology of a distiller can be more mature. Aiming at the problem that anaerobic treatment of a distiller alone is not effective, the synergistic effect of different substrates is briefly discussed. In addition, the recent literature on the use of microorganisms to purify a distiller was collected in order to better purify the distiller and reduce harm. In the future, more studies are needed to elucidate the interactions between microorganisms and establish the mechanisms of microbial interactions in different environments.

Closing the Nutrient Loop-The New Approaches to Recovering Biomass Minerals during the Biorefinery Processes

The recovery of plant mineral nutrients from the bio-based value chains is essential for a sustainable, circular bioeconomy, wherein resources are (re)used sustainably. The widest used approach is to recover plant nutrients on the last stage of biomass utilization processes-e.g., from ash, wastewater, or anaerobic digestate. The best approach is to recover mineral nutrients from the initial stages of biomass biorefinery, especially during biomass pre-treatments. Our paper aims to evaluate the nutrient recovery solutions from a trans-sectorial perspective, including biomass processing and the agricultural use of recovered nutrients. Several solutions integrated with the biomass pre-treatment stage, such as leaching/bioleaching, recovery from pre-treatment neoteric solvents, ionic liquids (ILs), and deep eutectic solvents (DESs) or integrated with hydrothermal treatments are discussed. Reducing mineral contents on silicon, phosphorus, and nitrogen biomass before the core biorefinery processes improves processability and yield and reduces corrosion and fouling effects. The recovered minerals are used as bio-based fertilizers or as silica-based plant biostimulants, with economic and environmental benefits.

Agro-Industrial Wastewaters for Algal Biomass Production, Bio-Based Products, and Biofuels in a Circular Bioeconomy

Recycling bioresources is the only way to sustainably meet a growing world population’s food and energy needs. One of the ways to do so is by using agro-industry wastewater to cultivate microalgae. While the industrial production of microalgae requires large volumes of water, existing agro-industry processes generate large volumes of wastewater with eutrophicating nutrients and organic carbon that must be removed before recycling the water back into the environment. Coupling these two processes can benefit the flourishing microalgal industry, which requires water, and the agro-industry, which could gain extra revenue by converting a waste stream into a bioproduct. Microalgal biomass can be used to produce energy, nutritional biomass, and specialty products. However, there are challenges to establishing stable and circular processes, from microalgae selection and adaptation to pretreating and reclaiming energy from residues. This review discusses the potential of agro-industry residues for microalgal production, with a particular interest in the composition and the use of important primary (raw) and secondary (digestate) effluents generated in large volumes: sugarcane vinasse, palm oil mill effluent, cassava processing waster, abattoir wastewater, dairy processing wastewater, and aquaculture wastewater. It also overviews recent examples of microalgae production in residues and aspects of process integration and possible products, avoiding xenobiotics and heavy metal recycling. As virtually all agro-industries have boilers emitting CO2 that microalgae can use, and many industries could benefit from anaerobic digestion to reclaim energy from the effluents before microalgal cultivation, the use of gaseous effluents is also discussed in the text.

Sugarcane vinasse as organo-mineral fertilizers feedstock: Opportunities and environmental risks

Fertigation using sugarcane vinasse is expected in the sugar and alcohol industries; however, its indiscriminate practice can trigger soil salinization and contamination of water sources. This review article appraises the vinasse use as a precursor material in producing organo-mineral fertilizers. Vinasse use could be an alternative for the increased demand for organo-mineral fertilizers. In that case, the vinasse reuse would be maintained but through controlled practices and lower environmental impact. The state-of-art points to possible advantages associated with the vinasse conversion into organo-mineral fertilizers, such as ease of transport and handling, low variability in its composition, and lower risks of soil and water resources contamination. It has been summarized and critically discussed the past ten years (2011-2021, total number papers revised: 175) of research data about vinasse composition, along with the limitations to be overcome in the near future to enable the application of organo-mineral fertilizers. Possible nutrients supplementation beyond those already present in vinasse composition would depend on the crop requirement, and the impact on the soil biota and integrity should be better understood. The aspects discussed along the manuscript would be aligned with circular economy principles, converting a residue (vinasse) into a potential resource for agricultural activities, including sugar and alcohol industries. After all, although promising, obtaining organo-mineral fertilizers from vinasse must be empirically validated and its feasibility proven by comparative studies between fertigation and the use of organo-mineral fertilizers.

Anaerobic Fungi Isolated From Bactrian Camel Rumen Contents Have Strong Lignocellulosic Bioconversion Potential

This study aims to obtain anaerobic fungi from the rumen and fecal samples and investigates their potential for lignocellulosic bioconversion. Multiple anaerobic strains were isolated from rumen contents (CR1–CR21) and fecal samples (CF1–CF10) of Bactrian camel using the Hungate roll tube technique. After screening for fiber degradability, strains from rumen contents (Oontomyces sp. CR2) and feces (Piromyces sp. CF9) were compared with Pecoramyces sp. F1 (earlier isolated from goat rumen, having high CAZymes of GHs) for various fermentation and digestion parameters. The cultures were fermented with different substrates (reed, alfalfa stalk, Broussonetia papyrifera leaves, and Melilotus officinalis) at 39°C for 96 h. The Oontomyces sp. CR2 had the highest total gas and hydrogen production from most substrates in the in vitro rumen fermentation system and also had the highest digestion of dry matter, neutral detergent fiber, acid detergent fiber, and cellulose present in most substrates used. The isolated strains provided higher amounts of metabolites such as lactate, formate, acetate, and ethanol in the in vitro rumen fermentation system for use in various industrial applications. The results illustrated that anaerobic fungi isolated from Bactrian camel rumen contents (Oontomyces sp. CR2) have the highest lignocellulosic bioconversion potential, suggesting that the Bactrian camel rumen could be a good source for the isolation of anaerobic fungi for industrial applications.

Vinasse odyssey: sugarcane vinasse remediation and laccase production by Trametes sp. immobilized in polyurethane foam

Vinasse is a high pollutant liquid residue from bioethanol production. Due to its toxicity, most vinasse is used not disposed of in water bodies but employed for the fertigation of sugarcane crops, potentially leading to soil salinization or heavy metal deposition. The anaerobic digestion of vinasse for energy production is the main alternative to fertigation, but the process cannot eliminate colored compounds such as melanoidins, caramels, or phenolic compounds. The treatment of raw vinasse with white-rot fungi could remove colored and persistent toxic compounds, but is generally considered cost-ineffective. We report the treatment of vinasse by an autochthonous Trametes sp. strain immobilized in polyurethane foam and the concomitant production of high titers of laccase, a high value-added product that could improve the viability of the process. The reuse of the immobilized biomass and the discoloration of raw vinasse, the concentration of phenolic compounds, BOD and COD, and the phytotoxicity of the treated vinasse were measured to assess the viability of the process and the potential use of treated vinasse in fertigation or as a complementary treatment to anaerobic digestion. Under optimal conditions (vinasse 0.25X, 30 °C, 21 days incubation, 2% glucose added in the implantation stage), immobilized Trametes sp. causes a decrease of 75% in vinasse color and total phenolic compounds, reaching 1082 U L^-1 of laccase. The fungi could be used to treat 0.50X vinasse (BOD 44,400 mg O₂ L^-1), causing a 26% decolorization and a 30% removal of phenolic compounds after 21 days of treatment with maximum laccase titers of 112 U L^-1, while reducing COD and BOD from 103,290 to 42,500 mg O₂ L^-1 (59%) and from 44,440 to 21,230 mg O₂ L^-1 (52%), respectively. The re-utilization of immobilized biomass to treat 0.50X vinasse proved to be successful, leading to the production of 361 U L^-1 of laccase with 77% decolorization, 61% degradation of phenolic compounds, and the reduction of COD and BOD by 75% and 80%, respectively. Trametes sp. also reduced vinasse phytotoxicity to Lactuca sativa seedlings. The obtained results show that the aerobic treatment of vinasse by immobilized Trametes sp. is an interesting technology that could be employed as a sole treatment for the bioremediation of vinasse, with the concomitant the production of laccase. Alternatively, the methodology could be used in combination with anaerobic digestion to achieve greater decolorization and reduction of phenolic compounds, melanoidins, and organic load.

Valorization of vinasse and whey to protein and biogas through an environmental fungi-based biorefinery

Vinasse and whey are wastewaters that are produced in large quantities in the sugar-to-ethanol and dairy industries, respectively. They pose a considerable threat to the environment due to the high concentration of nutrients and COD. In this study, the potential of producing protein-rich fungal biomass and biomethane from vinasse and whey through a two-stage biorefinery was examined. In the first stage, an edible and safe for human filamentous fungus, Neurospora intermedia, was cultivated on these wastewaters. To maximize the fungal biomass yield, the cultivation parameters, i.e., pH, vinasse to whey ratio, incubation time, and nutrients supplementation, were optimized. The highest yield of 12.0 g biomass per L of wastewaters was obtained by cultivation at pH 6.5 and vinasse to whey ratio of 25:75 (v/v) for 96 h with nitrogen source supplementation. The N. intermedia biomass contained about 45% protein and noticeable essential amino acid contents, comparable to commercial sources of protein for aquatic feed such as soybean meal and fishmeal. In the second stage, the effluent of fungal cultivation was anaerobically digested to produce 425 mL/g VS biomethane. Overall, 1 m³ of wastewater yielded 5.4 kg crude protein and 10.3 m³ methane, accompanied by 93.3% COD removal.

Improving the efficiency of anaerobic digestion of Molasses alcohol wastewater using Cassava alcohol wastewater as a mixed feedstock

Cassava alcohol wastewater (CAW) was utilized as a mixed feedstock to explore whether the addition of CAW could improve the anaerobic digestion of Molasses alcohol wastewater (MAW). The result showed that the rate of removal of the soluble chemical oxygen demand in the M treatment mixed with CAW was 70.13 ± 0.16%, which was significantly higher than that of the C treatment (only MAW), which was 61.23 ± 0.36%. Co-digestion in the M treatment resulted in higher methane production, achieving 23.89% increase in methane yield compared to C treatment. The addition of CAW helps to alleviate the accumulation of volatile fatty acids (397.06 ± 141.82 mg·L^-1), enhance the stability of system and promote the establishment of stable and active microbial communities. Microbial community structure analysis indicated that hydrolytic bacteria such as Bacteroidetes, Firmicutes, and Proteobacteria, and acetoclastic methanogens, including Methanosaeta and Methanosarcina were more abundant in the co-digests.

Metagenomic analysis of community, enzymes and metabolic pathways during corn straw fermentation with rumen microorganisms for volatile fatty acid production

Anaerobic fermentation of corn straw with rumen microorganisms as inoculum to produce volatile fatty acids (VFAs) is important for biomass valorization. In this study, dynamic variation in bacterial and fungal community composition, carbohydrate-active enzymes (CAZymes) and key functional genes related with VFA production was explored via metagenomic sequencing. Rumen microorganisms efficiently hydrolyzed and acidified corn straw, and VFA concentration reached 8.99 g/L in 72 h. Bacterial and fungal community significantly changed, but the core genera kept stable. Low pH and VFA accumulation were the main factors affecting bacterial and fungal communities. The positive correlations between bacteria were more complex than those between fungi. Most CAZyme abundance significantly decreased after 72 h fermentation, and functional gene abundance participating in VFA generation also decreased. This study provided new insights into dynamic variation of bacteria and fungi during anaerobic ruminal fermentation in vitro, promoting the application of rumen microorganisms in practice.