Simulation and optimisation of PHB production in fed-batch culture of Ralstonia eutropha

A Review on Natural Fiber Bio-Composites, Surface Modifications and Applications

Increased environmental concerns and global warming have diverted focus from eco-friendly bio-composites. Naturals fibers are abundant and have low harvesting costs with adequate mechanical properties. Hazards of synthetic fibers, recycling issues, and toxic byproducts are the main driving factors in the research and development of bio-composites. Bio-composites are degradable, renewable, non-abrasive, and non-toxic, with comparable properties to those of synthetic fiber composites and used in many applications in various fields. A detailed analysis is carried out in this review paper to discuss developments in bio-composites. The review covers structure, morphology, and modifications of fiber, mechanical properties, degradable matrix materials, applications, and limitations of bio-composites. Some of the key sectors employing bio-composites are the construction, automobile, and packaging industries. Furthermore, bio-composites are used in the field of medicine and cosmetics.

Production of Polyhydroxybutyrate (PHB) and Factors Impacting Its Chemical and Mechanical Characteristics

Plastic pollution is fueling the grave environmental threats currently facing humans, the animal kingdom, and the planet. The pursuit of renewable resourced biodegradable materials commenced in the 1970s with the need for carbon neutral fully sustainable products driving important progress in recent years. The development of bioplastic materials is highlighted as imperative to the solutions to our global environment challenges and to the restoration of the wellbeing of our planet. Bio-based plastics are becoming increasingly sustainable and are expected to substitute fossil-based plastics. Bioplastics currently include both, nondegradable and biodegradable compositions, depending on factors including the origins of production and post-use management and conditions. Among the most promising materials being developed and evaluated is polyhydroxybutyrate (PHB), a microbial bioprocessed polyester belonging to the polyhydroxyalkanoate (PHA) family. This biocompatible and non-toxic polymer is biosynthesized and accumulated by a number of specialized bacterial strains. The favorable mechanical properties and amenability to biodegradation when exposed to certain active biological environments, earmark PHB as a high potential replacement for petrochemical based polymers such as ubiquitous high density polyethylene (HDPE). To date, high production costs, minimal yields, production technology complexities, and difficulties relating to downstream processing are limiting factors for its progression and expansion in the marketplace. This review examines the chemical, mechanical, thermal, and crystalline characteristics of PHB, as well as various fermentation processing factors which influence the properties of PHB materials.

Efficient production and characterization of homopolymeric poly(3-hydroxyvalerate) produced by Bacillus strain PJC48

Aliphatic polyester, poly(3-hydroxyvalerate) (PHV), is commonly produced as a granular component in bacterial cells of various species. Based on 16S rDNA gene sequence analysis, strain PJC48 was identified as a Bacillus species. The current study is aimed to screen for a high-yield strain that can produce PHV efficiently and to increase PHV product yield by optimizing the fermentative process. We identified a high-producer strain based on Nile red staining. Characterization of the PHV produced by PJC48 by nuclear magnetic resonance spectroscopy revealed that it consisted of (R)-3-hydroxyvalerate monomers. The suggested model was validated by response surface methodology. Optimization of the PHV yield resulted in an increase of 32.75% compared to control, with a maximum production of 1.64 g/L after 48 H.

Production and characterization of poly(3-hydroxybutyrate) generated by Alcaligenes latus using lactose and whey after acid protein precipitation process

Whey after acid protein precipitation was used as substrate for PHB production in orbital shaker using Alcaligenes latus. Statistical analysis determined the most appropriate hydroxide for pH neutralization of whey after protein precipitation among NH4OH, KOH and NaOH 10%w/v. The results were compared to those of commercial lactose. A scale-up test in a 4L bioreactor was done at 35°C, 750rpm, 7L/min air flow, and 6.5 pH. The PHB was characterized through Fourier Transform Infrared Spectroscopy, thermogravimetry and differential scanning calorimetry. NH4OH provided the best results for productivity (p), 0.11g/L.h, and for polymer yield, (YP/S), 1.08g/g. The bioreactor experiment resulted in lower p and YP/S. PHB showed maximum degradation temperature (291°C), melting temperature (169°C), and chemical properties similar to those of standard PHB. The use of whey as a substrate for PHB production did not affect significantly the final product quality.

Use of residual banana for polyhydroxybutyrate (PHB) production: case of study in an integrated biorefinery

Polyhydroxybutyrate is a type of biopolymer that can be produced from hydrolyzed polysaccharide materials and could eventually replace polypropylene and polyethylene, being biodegradable, biocompatible and produced from renewable carbon sources. However, polyhydroxybutyrate is not still competitive compared to petrochemical polymers due to their high production costs. The improvement of the production processes requires a search for new alternative raw materials, design of the pretreatment technique and improvement in the fermentation and separation steps. In addition, if the polyhydroxybutyrate production is coupled into a multiproduct biorefinery it could increase the economic and environmental availability of the process through energy and mass integration strategies. In this work alternatives of energy and mass integrations for the production of polyhydroxybutyrate into a biorefinery from residual banana (an agro-industrial waste) were analyzed. The results show that the energetic integration can reduce up to 30.6% the global energy requirements of the process and the mass integration allows a 35% in water savings. Thus, this work demonstrates that energy and mass integration in a biorefinery is a very important way for the optimal use of energy and water resources hence decreasing the production cost and the negative environmental impacts.

In silico optimization and low structured kinetic model of poly[(R)-3-hydroxybutyrate] synthesis by Cupriavidus necator DSM 545 by fed-batch cultivation on glycerol

Glycerol was utilized by Cupriavidus necator DSM 545 for production of poly-3-hydroxybutyrate (PHB) in fed-batch fermentation. Maximal specific growth rates (0.12 and 0.3h(-1)) and maximal specific non-growth PHB production rate (0.16 g g(-1)h(-1)) were determined from two experiments (inocula from exponential and stationary phase). Saturation constants for nitrogen (0.107 and 0.016 g L(-1)), glycerol (0.05 g L(-1)), non-growth related PHB synthesis (0.011 g L(-1)) and nitrogen/PHB related inhibition constant (0.405 g L(-1)), were estimated. Five relations for specific growth rate were tested using mathematical models. In silico performed optimization procedures (varied glycerol/nitrogen ratio and feeding) has resulted in a PHB content of 70.9%, shorter cultivation time (23 h) and better PHB yield (0.347 g g(-1)). Initial concentration of biomass 16.8 g L(-1) and glycerol concentration in broth between 3 and 5 g L(-1) were decisive factors for increasing of productivity.

Techno-economic analysis for a sugarcane biorefinery: Colombian case

In this paper a techno-economic analysis for a sugarcane biorefinery is presented for the Colombian case. It is shown two scenarios for different conversion pathways as function of feedstock distribution and technologies for sugar, fuel ethanol, PHB, anthocyanins and electricity production. These scenarios are compared with the Colombian base case which simultaneously produce sugar, fuel ethanol and electricity. A simulation procedure was used in order to evaluate biorefinery schemes for all the scenarios, using Aspen Plus software, that include productivity analysis, energy calculations and economic evaluation for each process configuration. The results showed that the configuration with the best economic, environmental and social performance is the one that considers fuel ethanol and PHB production from combined cane bagasse and molasses. This result served as the basis to draw recommendations on technological and economic feasibility as well as social aspects for the implementation of such type of biorefinery in Colombia.

Mathematical modelling and process optimization of a continuous 5-stage bioreactor cascade for production of poly[-(R)-3-hydroxybutyrate] by Cupriavidus necator

A multistage system for poly(hydroxyalkanoate) (PHA) production consisting of five continuous stirred tank reactors in series (5-CSTR) with Cupriavidus necator DSM 545 as production strain was modelled using formal kinetic relations. Partially growth-associated production of PHA under nitrogen limited growth was chosen as modelling strategy, thus the Luedeking-Piret's model of partial growth-associated product synthesis was applied as working hypothesis. Specific growth rate relations adjusted for double substrate (C and N source) limited growth according to Megee et al. and Mankad-Bungay relation were tested. The first stage of the reactor cascade was modelled according to the principle of nutrient balanced continuous biomass production system, the second one as two substrate controlled process, while the three subsequent reactors were adjusted to produce PHB under continuous C source fed and nitrogen deficiency. Simulated results of production obtained by the applied mathematical models and computational optimization indicate that PHB productivity of the whole system could be significantly increased (from experimentally achieved 2.14 g L(-1) h(-1) to simulated 9.95 g L(-1) h(-1)) if certain experimental conditions would have been applied (overall dilution rate, C and N source feed concentration). Additionally, supplemental feeding strategy for switching from batch to continuous mode of cultivation was proposed to avoid substrate inhibition.

Perspectives in the Modeling and Optimization of PHB Production by Pure and Mixed Cultures

Poly(beta-hydroxybutyrate) or PHB is an important member of the family of polyhydroxyalkanoates with properties that make it potentially competitive with synthetic polymers. In addition, PHB is biodegradable. While the biochemistry of PHB synthesis by microorganisms is well known, improvement of large-scale productivity requires good fermentation modeling and optimization. The latter aspect is reviewed here. Current models are of two types: (i) mechanistic and (ii) cybernetic. The models may be unstructured or structured, and they have been applied to single cultures and co-cultures. However, neither class of models expresses adequately all the important features of large-scale non-ideal fermentations. Model-independent neural networks provide faithful representations of observations, but they can be difficult to design. So hybrid models, combining mechanistic, cybernetic and neural models, offer a useful compromise. All three kinds of basic models are discussed with applications and directions toward hybrid model development.

A Simple Structured Mathematical Model for Biopolymer (PHB) Production

Economic production technology for a biodegradable polymer (poly-beta-hydroxybutyrate, PHB) is urgently required to replace conventional polymers, which have an inherent disadvantage of staying in the environment forever. Various approaches have been applied for improving the productivity and reducing the production cost, which are considered to be the two major problems associated with industrial production of PHB. One of the engineering approaches to improve PHB productivity could be to design and implement model-based fed-batch cultivations to provide desirable nutrient availability. In the present study, growth and intracellular biopolymer storage kinetics of Ralstonia eutropha was studied in a batch cultivation process. It featured 19.7 g/L biomass and 10.89 g/L PHB with a productivity of 0.18 g/L.h. The effect of carbon, nitrogen, and phosphate limitations and inhibitions on growth was studied in detail. A structured model featuring typical growth limitations and/or possible inhibitions was then proposed. The value of the model parameters was found by minimizing the difference between experimental value and model simulation at all data points and for all process variables. The optimal batch model parameter values obtained above were used to solve the differential equations numerically. The simulated data obtained in this way was then compared with the experimental data to establish the validity of the batch model. The proposed model was then compared with literature reported mathematical models to reconfirm its accuracy. Statistical validity of the developed model and historical models to describe the observed experimental kinetics was then investigated to reinforce the accuracy of the developed simple model.

Dispersion optimization to enhance PHB production in fed-batch cultures of Ralstonia eutropha

Despite its many useful properties, microbial production of poly-beta-hydroxybutyrate (PHB) is not yet commercially competitive with synthetic polymers. One reason is inadequate optimization of the fermentation under industrial conditions. In this study, a physiologically reasonable and experimentally validated kinetic model for PHB synthesis by Ralstonia eutropha was incorporated into a dispersion model to simulate a large fed-batch bioreactor. Solutions of the model indicated that cell growth and PHB synthesis were maximum at Peclet numbers (Pe) between 20 and 30, representing limited finite dispersion. At these Peclet numbers, the optimum feed rates also showed lower consumptions of the substrates than at Pe=0. Since complete dispersion was also difficult to achieve in production-scale bioreactors, these results pointed to the possibility of exploiting controlled dispersion for productivity enhancement.