Advanced bioprocessing strategies for biobutanol production from biomass

A critical assessment on scalable technologies using high solids loadings in lignocellulose biorefinery: challenges and solutions

The pretreatment and the enzymatic saccharification are the key steps in the extraction of fermentable sugars for further valorization of lignocellulosic biomass (LCB) to biofuels and value-added products via biochemical and/or chemical conversion routes. Due to low density and high-water absorption capacity of LCB, the large volume of water is required for its processing. Integration of pretreatment, saccharification, and co-fermentation has succeeded and well-reported in the literature. However, there are only few reports on extraction of fermentable sugars from LCB with high biomass loading (>10% Total solids-TS) feasible to industrial reality. Furthermore, the development of enzymatic cocktails can overcome technology hurdles with high biomass loading. Hence, a better understanding of constraints involved in the development of technology with high biomass loading can result in an economical and efficient yield of fermentable sugars for the production of biofuels and bio-chemicals with viable titer, rate, and yield (TRY) at industrial scale. The present review aims to provide a critical assessment on the production of fermentable sugars from lignocelluloses with high solid biomass loading. The impact of inhibitors produced during both pretreatment and saccharification has been elucidated. Moreover, the limitations imposed by high solid loading on efficient mass transfer during saccharification process have been elaborated.

A holistic approach for process intensification of nicotinamide mononucleotide production via high cell density cultivation under exponential feeding strategy

Nicotinamide mononucleotide (NMN) subsists in all living organisms and has drawn tremendous attention as a nutraceutical and pharmaceutical product for several diseases such as Alzheimer's, cancer, aging, and vascular dysfunction. Here, NMN was produced intracellularly in a high cell density bioreactor using an engineered Escherichiacoli strain via exponential feeding of co-substrates. Fed-batch culture via exponential feeding of co-substrate (glucose) and continuous feeding of substrate (nicotinamide) were performed using different cumulative nicotinamide concentrations. The highest concentration of 19.3 g/L NMN with a dry cell weight of 117 g/L was acquired from a cumulative nicotinamide concentration of 7.2 g/L with a conversion of 98 % from nicotinamide in 28 h. Further, liquid chromatography-mass spectrometry analysis validated the NMN production. This approach will be beneficial in achieving simultaneously low cost and ensuring high quality and quantity of NMN production.

Optimization of the culture of Chlorella sorokiniana PA.91 by RSM: effect of temperature, light intensity, and MgAC-NPs

The unique physicochemical properties of magnesium amino clay nanoparticles (MgAC-NPs) tends to be beneficial in the application as a co-additive in treating microalgae. Also, MgAC-NPs can create oxidative stress in the environment, concurrently elective control bacteria in mixotrophic culture, and stimulate CO₂ biofixation. The condition of the cultivation of newly isolated strains, Chlorella sorokiniana PA.91, was optimized for the first time for MgAC-NPs at various temperatures and light intensities in the culture medium of municipal wastewater (MWW) by central composite design in the response surface methodology (RSM-CCD). This study examined synthesized MgAC-NP with their FE-SEM, EDX, XRD, and FT-IR characteristics. The synthesized MgAC-NPs were naturally stable, cubic shaped, and within the size range of 30-60 nm. The optimization results show that at culture conditions of 20 °C, 37 μmol m^-2 s^-1, and 0.05 g L^-1, microalga MgAC-NPs have the best growth productivity and biomass performance. Maximum dry biomass weight (55.41%), specific growth rate (30.26%), chlorophyll (81.26%), and carotenoids (35.71%) were achieved under the optimized condition. Experimental results displayed that C.S. PA.91 has a high capacity for lipid extraction (1.36 g L^-1) and significant lipid efficiency (45.1%). Also, in 0.2 and 0.05 g L^-1 of the MgAC-NPs, COD removal efficiency 91.1% and 81.34% from C.S. PA.91 showed, respectively. These results showed the potential of C.S. PA.91-MgAC-NPs for nutrient removal in wastewater treatment plants and their quality as sources of biodiesel.

Modified Activated Carbon: A Supporting Material for Improving Clostridium beijerinckii TISTR1461 Immobilized Fermentation

This study aimed to investigate the effect of activated carbon (AC) as an immobilization material in acetone-butanol-ethanol fermentation. The AC surface was modified with different physical (orbital shaking and refluxing) and chemical (nitric acid, sodium hydroxide and, (3-aminopropyl)triethoxysilane (APTES)) treatments to enhance the biobutanol production by Clostridium beijerinckii TISTR1461. The effect of surface modification on AC was evaluated using Fourier-transform infrared spectroscopy, field emission scanning electron microscopy, surface area analyses, and X-ray photoelectron spectroscopy, while the fermented broth was examined by high-performance liquid chromatography. The chemical functionalization significantly modified the physicochemical properties of the different treated ACs and further enhanced the butanol production. The AC treated with APTES under refluxing provided the best fermentation results at 10.93 g/L of butanol, 0.23 g/g of yield, and 0.15 g/L/h of productivity, which were 1.8-, 1.5-, and 3.0-fold higher, respectively, than that in the free-cell fermentation. The obtained dried cell biomass also revealed that the treatment improved the AC surface for cell immobilization. This study demonstrated and emphasized the importance of surface properties to cell immobilization.

Challenges in Using Ionic Liquids for Cellulosic Ethanol Production

The growing need to expand the use of renewable energy sources in a sustainable manner, providing greater energy supply security and reducing the environmental impacts associated with fossil fuels, finds in the agricultural by-product bioethanol an economically viable alternative with significant expansion potential. In this regard, a dramatic boost in the efficiency of processes already in place is required, reducing costs, industrial waste, and our carbon footprint. Biofuels are one of the most promising alternatives to massively produce energy sustainably in a short-term period. Lignocellulosic biomass (LCB) is highly recalcitrant, and an effective pretreatment strategy should also minimize carbohydrate degradation by diminishing enzyme inhibitors and other products that are toxic to fermenting microorganisms. Ionic liquids (ILs) have been playing an important role in achieving cleaner processes as a result of their excellent physicochemical properties and outstanding performance in the dissolution and fractionation of lignocellulose. This review provides an analysis of recent advances in the production process of biofuels from LCB using ILs as pretreatment and highlighting techniques for optimizing and reducing process costs that should help to develop robust LCB conversion processes.

An updated review on advancement in fermentative production strategies for biobutanol using Clostridium spp

A significant concern of our fuel-dependent era is the unceasing exhaustion of petroleum fuel supplies. In parallel to this, environmental issues such as the greenhouse effect, change in global climate, and increasing global temperature must be addressed on a priority basis. Biobutanol, which has fuel characteristics comparable to gasoline, has attracted global attention as a viable green fuel alternative among the many biofuel alternatives. Renewable biomass could be used for the sustainable production of biobutanol by the acetone-butanol-ethanol (ABE) pathway. Non-extinguishable resources, such as algal and lignocellulosic biomass, and starch are some of the most commonly used feedstock for fermentative production of biobutanol, and each has its particular set of advantages. Clostridium, a gram-positive endospore-forming bacterium that can produce a range of compounds, along with n-butanol is traditionally known for its biobutanol production capabilities. Clostridium fermentation produces biobased n-butanol through ABE fermentation. However, low butanol titer, a lack of suitable feedstock, and product inhibition are the primary difficulties in biobutanol synthesis. Critical issues that are essential for sustainable production of biobutanol include (i) developing high butanol titer producing strains utilizing genetic and metabolic engineering approaches, (ii) renewable biomass that could be used for biobutanol production at a larger scale, and (iii) addressing the limits of traditional batch fermentation by integrated bioprocessing technologies with effective product recovery procedures that have increased the efficiency of biobutanol synthesis. Our paper reviews the current progress in all three aspects of butanol production and presents recent data on current practices in fermentative biobutanol production technology.

Fed-batch simultaneous saccharification and fermentation including in-situ recovery for enhanced butanol production from rice straw

This paper describes a study of fed-batch SSFR (simultaneous saccharification, fermentation and recovery) for butanol production from alkaline-pretreated rice straw (RS) in a 2-L stirred tank reactor. The initial solid (9.2% w/v) and enzyme (19.9 FPU g-dw^-1) loadings were previously optimized by 50-mL batch SSF assays. Maximum butanol concentration of 24.80 g L^-1 was obtained after three biomass feedings that doubled the RS load (18.4% w/v). Butanol productivity (0.344 g L^-1h^-1) also increased two-fold in comparison with batch SSF without recovery (0.170 g L^-1h^-1). Although fed-batch SSFR was able to operate with a single initial enzyme dosage, an extra dosage of nutrients was required with the biomass additions to achieve this high productivity. The study showed that SSFR can efficiently improve butanol production from a lignocellulosic biomass accompanied by the efficient use of the enzyme.

Optimization of Lutein Recovery from Tetraselmis suecica by Response Surface Methodology

Microalgae have been attracting attention as feedstock for biorefinery because they have various advantages, such as carbon fixation, high growth rate and high energy yield. The bioactive compounds and lutein contained in microalgae are known to be beneficial for human health, especially eye and brain health. In this study, in order to improve the recovery of bioactive extracts including lutein from Tetraselmis suecica with higher efficiency, an effective solvent was selected, and the extraction parameters such as temperature, time and solid loading were optimized by response surface methodology. The most effective solvent for lutein recovery was identified as 100% methanol, and the optimum condition was determined (42.4 °C, 4.0 h and 125 g/L biomass loading) by calculation of the multiple regression model. The maximum content of recovered lutein was found to be 2.79 mg/mL, and the ABTS radical scavenging activity (IC50) and ferric reducing antioxidant power (FRAP) value were about 3.36 mg/mL and 561.9 μmol/L, respectively. Finally, the maximum lutein recovery from T. suecica through statistical optimization was estimated to be 22.3 mg/g biomass, which was 3.1-fold improved compared to the control group.

Improved Glucose Recovery from Sicyos angulatus by NaOH Pretreatment and Application to Bioethanol Production

As greenhouse gases and environmental pollution become serious, the demand for alternative energy such as bioethanol has rapidly increased, and a large supply of biomass is required for bioenergy production. Lignocellulosic biomass is the most abundant on the planet and a large part of it, the second-generation biomass, has the advantage of not being a food resource. In this study, Sicyos angulatus, known as an invasive plant (harmful) species, was used as a raw material for bioethanol production. In order to improve enzymatic hydrolysis, S. angulatus was pretreated with different NaOH concentration at 121 °C for 10 min. The optimal NaOH concentration for the pretreatment was determined to be 2% (w/w), and the glucan content (GC) and enzymatic digestibility (ED) were 46.7% and 55.3%, respectively. Through NaOH pretreatment, the GC and ED of S. angulatus were improved by 2.4-fold and 2.5-fold, respectively, compared to the control (untreated S. angulatus). The hydrolysates from S. angulatus were applied to a medium for bioethanol fermentation of Saccharomyces cerevisiae K35. Finally, the maximum ethanol production was found to be 41.3 g based on 1000 g S. angulatus, which was 2.4-fold improved than the control group.

Electrochemical tuning of alcohol oxidase and dehydrogenase catalysis via biosensing towards butanol-1 detection in fermentation media

A novel approach for electrochemical tuning of alcohol oxidase (AOx) and alcohol dehydrogenase (ADH) biocatalysis towards butanol-1 oxidation by incorporating enzymes in various designs of amperometric biosensors is presented. The biosensors were developed by using commercial graphene oxide-based screen-printed electrodes and varying enzyme producing strains, encapsulation approaches (layer-by-layer (LbL) or one-step electrodeposition (EcD)), layers composition and structure, operating conditions (applied potential values) and introducing mediators (Meldola Blue and Prussian Blue) or Pd-nanoparticles (Pd-NPs). Simultaneous analysis/screening of multiple crucial system parameters during the enzyme engineering process allowed to identify within a period of one month that four out of twelve proposed designs demonstrated a good signal reproducibility and linear response (up to 14.6 mM of butanol) under very low applied potentials (from -0.02 to -0.32 V). Their mechanical stability was thoroughly investigated by multi-analytical techniques prior to butanol determination in cell-free samples from an anaerobic butanol fermentation. The EcD-based biosensor that incorporates ADH, NAD⁺, Pd-NPs and Nafion showed no loss of enzyme activity after preparation and demonstrated capabilities towards low potential (-0.12 V) detection of butanol-1 in fermentation medium (4 mM) containing multiple electroactive species with almost 15 times enhanced sensitivity (0.2282 μA/mM ± 0.05) when compared to the LbL design. Furthermore, the ADH-Nafion bonding for the S. cerevisiae strain was confirmed to be 3 times higher than for E. coli.

Butanol production from cellulosic material by anaerobic co-culture of white-rot fungus Phlebia and bacterium Clostridium in consolidated bioprocessing

Butanol production from lignocelluloses is desirable. Unfortunately, the known wild-types of butanol fermenting Clostridium bacteria are not capable of delignification and saccharification. Here we analyzed butanol production from cellulosic material using anaerobic co-culture of C. saccharoperbutylacetonicum with the white-rot fungus Phlebia sp. MG-60-P2. In consolidated bioprocessing, the co-culture synergistically produced butanol and enhanced saccharification. Knockout of the pyruvate decarboxylase gene from MG-60-P2 to produce transformant line KO77 led to inhibition of ethanol fermentation and high accumulation of saccharified cellobiose and glucose from cellulose. In co-culture of KO77 with C. saccharoperbutylacetonicum, enhanced butanol production was observed (3.2 g/L, compared with 2.5 g/L in co-culture of MG-60-P2 and C. saccharoperbutylacetonicum). We believe this is the first application of co-culture between white-rot fungus and Clostridium to produce butanol from cellulose; butanol production from lignocellulose by co-culture of C. saccharoperbutylacetonicum with Phlebia sp. MG-60-P2 and its transformant should be pursued.

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.

Smart fermentation engineering for butanol production: designed biomass and consolidated bioprocessing systems

There is a renewed interest in acetone-butanol-ethanol (ABE) fermentation from renewable substrates for the sustainable and environment-friendly production of biofuel and platform chemicals. However, the ABE fermentation is associated with several challenges due to the presence of heterogeneous components in the renewable substrates and the intrinsic characteristics of ABE fermentation process. Hence, there is a need to select optimal substrates and modify their characteristics suitable for the ABE fermentation process or microbial strain. This "designed biomass" can be used to establish the consolidated bioprocessing systems. As there are very few reports on designed biomass, the main objectives of this review are to summarize the main challenges associated with ABE fermentation from renewable substrates and to introduce feasible strategies for designing the substrates through pretreatment and hydrolysis technologies as well as through the establishment of consolidated bioprocessing systems. This review offers new insights on improving the efficiency of ABE fermentation from designed renewable substrates.

Life cycle assessment of upgraded microalgae-to-biofuel chains

Two individual chains of microalgae-to-diesel and microalgae-to-butanol were upgraded through process integration and design. According to life cycle assessment (LCA) standards, the two proposed chains were compared in terms of 17 categories of LCA impacts and the sensitivity analysis of LCA impacts on two chains with different lipid or carbohydrate content of microalgae cells was performed. Based on the prescribed specifications and conditions for microalgae cultivation, pretreatment and purity level of the products, LCA analysis revealed that the annual ReCiPe end point score of producing 1 kg biobutanol is lower than that of 1 kg biodiesel by 54.4%. The upgraded microalgae-to-butanol chain could reduce the annual ReCiPe end point score of producing 100 MJ diesel/gasoline from crude oil by 5-10%. The microalgae-to-butanol chain is more ecofriendly than the microalgae-to-diesel chain due to lower LCA impacts such as Climate change human health, Climate change ecosystems, and Fossil depletion.

Strategic intensification in butanol production by exogenous amino acid supplementation: Fermentation kinetics and thermodynamic studies

Amino acids are vital precursors in many biochemical production pathways in addition to efficient nitrogen source which could enhance microbial growth yields. Therefore, in present study, the effect of amino acids from aliphatic and aromatic family was comprehensively evaluated in batch and integrated fed batch fermentation system. Clostridium acetobutylicum NRRL B-527 was able to utilize 54.15 ± 1.0 g/L glucose to produce 12.43 ± 0.10 g/L butanol under batch cultivation. Interestingly, a significant step up in butanol titer (20.82 ± 0.33 g/L) was achieved by using fed-batch fermentation process integrated with liquid-liquid extraction module. Besides, mathematical modeling studies demonstrated the best fitting of experimental data with first order reaction kinetics. Overall, an enhancement in solvent titer by induction of essential cellular components coupled with advance bioprocess strategy was successfully utilized in this study for its further applications.

Improved Biobutanol Production in 2-L Simultaneous Saccharification and Fermentation with Delayed Yeast Extract Feeding and in-situ Recovery

Simultaneous saccharification and fermentation (SSF) with delayed yeast extract feeding (DYEF) was conducted in a 2-L bioreactor equipped with in-situ recovery using a gas stripping in order to enhance biobutanol production from lignocellulosic biomass of oil palm empty fruit bunch (OPEFB). This study showed that 2.88 g/L of biobutanol has been produced from SSF with a similar yield of 0.23 g/g as compared to separate hydrolysis and fermentation (SHF). An increase of 42% of biobutanol concentration was observed when DYEF was introduced in the SSF at 39 h of fermentation operation. Biobutanol production was further enhanced up to 11% with a total improvement of 72% when in-situ recovery using a gas stripping was implemented to reduce the solvents inhibition in the bioreactor. In overall, DYEF and in-situ recovery were able to enhance biobutanol production in SSF.

Direct transformation of butenes or ethylene into propylene by cascade catalytic reactions

Catalysts and processes involved in the direct conversion of ethylene or n-butenes into propylene are reviewed.