From wheat straw to bioethanol: integrative analysis of a separate hydrolysis and co-fermentation process with implemented enzyme production

Structural changes and cellulose ultrastructure mapped with electron microscopy and SAXS after enzymatic hydrolysis of mildly steam pretreated Norway spruce

BACKGROUND

The efficient use of softwood in biorefineries requires harsh pretreatment conditions to overcome biomass recalcitrance. While this allows the solubilization of hemicellulose, it also leads to the formation of compounds that act inhibitory against microorganisms during the fermentation step. To improve the efficacy of biomass utilization and identify optimal processing conditions, we evaluated the microstructural alterations occurring during pretreatment and enzymatic hydrolysis in Norway spruce. The biomass was steam pretreated at six different severities defined by two different temperatures (180 °C and 210 °C), with and without the addition of various acids (HAc, H3PO4, H2SO4, SO2). After pretreatment, the materials were enzymatically hydrolysed using a cellulolytic cocktail (Celluclast + Novozym188) supplemented with a hemicellulolytic cocktail (Ultraflo). Scanning electron microscopy and small angle X-ray scattering were utilized to evaluate the structural changes, of the differently steam pretreated materials, before and after the enzymatic hydrolysis.

RESULTS

Scanning electron microscopy revealed increased surface roughness and pore enlargement in all the materials after enzymatic hydrolysis. The higher the severity of the pretreatment, the more the surface was rough since it was easier for the enzymes to access the binding site. As revealed by small angle X-ray scattering (SAXS), increasing the enzymatic hydrolysis of hemicellulose did not result in further collapse of cellulose. In line with the SAXS result, a qualitative evaluation of the cellulose surface using Congo red showed a larger exposed cellulose surface area after enzymatic hydrolysis.

CONCLUSIONS

The present study reports the microstructural changes caused by pretreatment and enzymatic hydrolysis of Norway spruce. By enzymatically increasing the hemicellulose hydrolysis, the exposed cellulose surface area increases meaning that the cellulose might be easier to access for the enzymes. Structural analysis of biomass after enzymatic hydrolysis can direct the choice of enzymes for improved saccharification efficiency.

Production of Cellulosic Ethanol from Enzymatically Hydrolysed Wheat Straws

The aim of this study is to find the optimal pretreatment conditions and hydrolysis in order to obtain a high yield of bioethanol from wheat straw. The pretreatments were performed with different concentrations of sulphuric acid 1, 2 and 3% (v/v), and were followed by an enzymatic hydrolysis that was performed by varying the solid-to-liquid ratio (1/20, 1/25 and 1/30 g/mL) and the enzyme dose (30/30 µL/g, 60/60 µL/g and 90/90 µL/g Viscozyme® L/Celluclast® 1.5 L). This mix of enzymes was used for the first time in the hydrolysis process of wheat straws which was previously pretreated with dilute sulfuric acid. Scanning electron microscopy indicated significant differences in the structural composition of the samples because of the pretreatment with H2SO4 at different concentrations, and ATR-FTIR analysis highlighted the changes in the chemical composition in the pretreated wheat straw as compared to the untreated one. HPLC-RID was used to identify and quantify the carbohydrates content resulted from enzymatic hydrolysis to evaluate the potential of using wheat straws as a raw material for production of cellulosic ethanol in Romania. The highest degradation of lignocellulosic material was obtained in the case of pretreatment with 3% H2SO4 (v/v), a solid-to-liquid ratio of 1/30 and an enzyme dose of 90/90 µL/g. Simultaneous saccharification and fermentation were performed using Saccharomyces cerevisiae yeast, and for monitoring the fermentation process a BlueSens equipment was used provided with ethanol, O2 and CO2 cap sensors mounted on the fermentation flasks. The highest concentration of bioethanol was obtained after 48 h of fermentation and it reached 1.20% (v/v).

Potential of Straw for Energy Purposes in Poland—Forecasts Based on Trend and Causal Models

The mitigation of climate change poses a major challenge to the legal framework which aims to stimulate the development of renewable energy sources. The European Union’s direction for the use of renewable energy is distributed generation and an increased use of by-products and organic waste, especially in the production of next-generation biofuels. The main aim of this study is to evaluate the production potential of straw in Poland and the possibility of its use for energy purposes, including a forecast for 2030, on the assumption that the management of this resource is in accordance with the provisions of the Polish Code for Good Agriculture Practice. In Poland, in the years 1999–2018, the average annual surplus of straw harvested over agricultural consumption equalled 12.5 million tons (4.2 Mtoe). Its largest surpluses were in the Dolnośląskie, Kujawsko-Pomorskie, Lubelskie, Wielkopolskie, and Zachodniopomorskie voivodeships (NUTS2). Based on the developed panel models, forecasts for straw surpluses in Poland are presented in three perspectives: realistic, pessimistic, and optimistic. The forecasts show regional differentiation until 2030. Each of the three perspectives indicate a slow increase in these surpluses, and depending on the adopted version, it will range from 10.6% to 21.9%.

Genome expansion by allopolyploidization in the fungal strain Coniochaeta 2T2.1 and its exceptional lignocellulolytic machinery

BACKGROUND

Particular species of the genus Coniochaeta (Sordariomycetes) exhibit great potential for bioabatement of furanic compounds and have been identified as an underexplored source of novel lignocellulolytic enzymes, especially Coniochaeta ligniaria. However, there is a lack of information about their genomic features and metabolic capabilities. Here, we report the first in-depth genome/transcriptome survey of a Coniochaeta species (strain 2T2.1).

RESULTS

The genome of Coniochaeta sp. strain 2T2.1 has a size of 74.53 Mbp and contains 24,735 protein-encoding genes. Interestingly, we detected a genome expansion event, resulting ~ 98% of the assembly being duplicated with 91.9% average nucleotide identity between the duplicated regions. The lack of gene loss, as well as the high divergence and strong genome-wide signatures of purifying selection between copies indicates that this is likely a recent duplication, which arose through hybridization between two related Coniochaeta-like species (allopolyploidization). Phylogenomic analysis revealed that 2T2.1 is related Coniochaeta sp. PMI546 and Lecythophora sp. AK0013, which both occur endophytically. Based on carbohydrate-active enzyme (CAZy) annotation, we observed that even after in silico removal of its duplicated content, the 2T2.1 genome contains exceptional lignocellulolytic machinery. Moreover, transcriptomic data reveal the overexpression of proteins affiliated to CAZy families GH11, GH10 (endoxylanases), CE5, CE1 (xylan esterases), GH62, GH51 (α-l-arabinofuranosidases), GH12, GH7 (cellulases), and AA9 (lytic polysaccharide monoxygenases) when the fungus was grown on wheat straw compared with glucose as the sole carbon source.

CONCLUSIONS

We provide data that suggest that a recent hybridization between the genomes of related species may have given rise to Coniochaeta sp. 2T2.1. Moreover, our results reveal that the degradation of arabinoxylan, xyloglucan and cellulose are key metabolic processes in strain 2T2.1 growing on wheat straw. Different genes for key lignocellulolytic enzymes were identified, which can be starting points for production, characterization and/or supplementation of enzyme cocktails used in saccharification of agricultural residues. Our findings represent first steps that enable a better understanding of the reticulate evolution and "eco-enzymology" of lignocellulolytic Coniochaeta species.

Introducing low-quality feedstocks in bioethanol production: efficient conversion of the lignocellulose fraction of animal bedding through steam pretreatment

BACKGROUND

Animal bedding remains an underutilized source of raw material for bioethanol production, despite the economic and environmental benefits of its use. Further research concerning the optimization of the production process is needed, as previously tested pretreatment methods have not increased the conversion efficiency to the levels necessary for commercialization of the process.

RESULTS

We propose steam pretreatment of animal bedding, consisting of a mixture of straw and cow manure, to deliver higher ethanol yields. The temperature, residence time and pH were optimized through response-surface modeling, where pretreatment was evaluated based on the ethanol yield obtained through simultaneous saccharification and fermentation of the whole pretreated slurry. The results show that the best conditions for steam pretreatment are 200 °C, for 5 min at pH 2, at which an ethanol yield of about 70% was obtained. Moreover, the model also showed that the pH had the greatest influence on the ethanol yield, followed by the temperature and then the residence time.

CONCLUSIONS

Based on these results, it appears that steam pretreatment could unlock the potential of animal bedding, as the same conversion efficiencies were achieved as for higher-quality feedstocks such as wheat straw.

Straw Stocks as a Source of Renewable Energy. A Case Study of a District in Poland

Biomass is playing an increasingly important role as a source of renewable energy. The aim of this study has been to identify the potential applicability of straw from agricultural crops to generate energy within the district of Braniewo, in the province Warmia and Mazury, Poland. The study covered the years 2015 to 2017. Based on statistical data, and using appropriate equations and norms, the structure of crop production and the number of livestock in the mentioned district were analysed; the potential production volume of straw was estimated, from which the amount needed for animal production (feed and bedding) was deducted, while the organic substance balance in soil was calculated. An annual average amount of straw remaining to be used for energy purposes in the district of Braniewo is about 41,531 t of straw, equivalent to about 60,222 GJ of energy (24,088 t of coal). In addition to the above analyses, a survey was conducted among local farmers, which showed their opinions about barriers to and opportunities for growing crops for energy purposes and using renewable energy resources. The survey results justify the claim that there is certain potential among farmers in the district of Braniewo to grow crops for energy purposes.

Effect of dilute acid pretreatment on the saccharification and fermentation of rye straw

This research shows the effect of dilute acid pretreatment with various sulfuric acid concentrations (0.5-2.0% [wt/vol]) on enzymatic saccharification and fermentation yield of rye straw. After pretreatment, solids of rye straw were suspended in Na citrate buffer or post-pretreatment liquids (prehydrolysates) containing sugars liberated after hemicellulose hydrolysis. Saccharification was conducted using enzymes dosage of 15 or 25 FPU/g cellulose. Cellulose saccharification rate after rye straw pretreatment was enhanced by performing enzymatic hydrolysis in sodium citrate buffer in comparison with hemicellulose prehydrolysate. The maximum cellulose saccharification rate (69%) was reached in sodium citrate buffer (biomass pretreated with 2.0% [wt/vol] H₂ SO₄ ). Lignocellulosic complex of rye straw after pretreatment was subjected to separate hydrolysis and fermentation (SHF) or separate hydrolysis and co-fermentation (SHCF). The SHF processes conducted in the sodium citrate buffer using monoculture of Saccharomyces cerevisiae (Ethanol Red) were more efficient compared to hemicellulose prehydrolysate in respect with ethanol yields. Maximum fermentation efficiency of SHF processes obtained after rye straw pretreatment at 1.5% [wt/vol] H₂ SO₄ and saccharification using enzymes dosage of 25 FPU/g in sodium citrate buffer, achieving 40.6% of theoretical yield. However, SHCF process using cocultures of pentose-fermenting yeast, after pretreatment of raw material at 1.5% [wt/vol] H₂ SO₄ and hydrolysis using enzymes dosage of 25 FPU/g, resulted in the highest ethanol yield among studied methods, achieving 9.4 g/L of ethanol, corresponding to 55% of theoretical yield.

The growth and lipid accumulation of Scenedesmus quadricauda during batch mixotrophic/heterotrophic cultivation using xylose as a carbon source

To overcome the bottlenecks of high cost and low production yields that restrict the commercial production of microalgae biodiesel, the use of xylose was evaluate by Scenedesmus quadricauda FACHB-1297, which was shown to be capable of mixotrophic and heterotrophic growth and lipid production on xylose, rich in the waste streams from pulp and paper industry, with increases in lipid productivities of 35.8-fold (mixotrophic) and 9.2-fold (heterotrophic) in comparison to photoautotrophic lipid yields. Five doses of xylose were tested to determine the effects and mechanisms of the carbon source on microalgae in mixotrophic mode. At the optimal xylose dosage of 4 g/L, the highest lipid content (38.61%) and productivity (139.55 mg/L/d) were achieved besides maximum biomass productivity (361.4 mg/L/d), nutrient removal efficiency of 68.4% (nitrogen), 97.2% (phosphorus) and 35.2% (xylose). Those indicated that S. quadricauda FACHB-1297 was suitable for further development of using xylose from certain waste streams for biofuel production.

On-site cellulase production and efficient saccharification of corn stover employing cbh2 overexpressing Trichoderma reesei with novel induction system

Although on-site cellulase production offers cost-effective saccharification of lignocellulosic biomass, low enzyme titer is still a barrier for achieving robustness. In the present study, a strain of T. reesei was developed for enhanced production of cellulase via overexpression of Cellobiohydrolase II. Furthermore, optimum enzyme production was achieved using a novel inducer mixture containing synthesized glucose-sophorose (MGD) and alkali pre-treated corn stover (APCS). Within 60h, a remarkably higher cellulase productivity and activity were achieved in the fed-batch fermentation using the optimized ratio of MGD and APCS in the inducer mixture, compared to those reported using cellulosic biomass as the sole inducer. After the enzyme production, APCS was added directly into the fermentation broth at 20% solid loading, which produced 122.5g/L glucose and 40.21g/L xylose, leading to the highest yield reported so far. The improved enzyme titers during on-site cellulase production would benefit cost-competitive saccharification of lignocellulosic biomass.

Hybrid SSF/SHF Processing of SO2 Pretreated Wheat Straw-Tuning Co-fermentation by Yeast Inoculum Size and Hydrolysis Time

Wheat straw is one of the main agricultural residues of interest for bioethanol production. This work examines conversion of steam-pretreated wheat straw (using SO2 as a catalyst) in a hybrid process consisting of a short enzymatic prehydrolysis step and a subsequent simultaneous saccharification and fermentation (SSF) step with a xylose-fermenting strain of Saccharomyces cerevisiae. A successful process requires a balanced design of reaction time and temperature in the prehydrolysis step and yeast inoculum size and temperature in the SSF step. The pretreated material obtained after steam pretreatment at 210 °C for 5 min using 2.5 % SO2 (based on moisture content) showed a very good enzymatic digestibility at 45 °C but clearly lower at 30 °C. Furthermore, the pretreatment liquid was found to be rather inhibitory to the yeast, partly due to a furfural content of more than 3 g/L. The effect of varying the yeast inoculum size in this medium was assessed, and at a yeast inoculum size of 4 g/L, a complete conversion of glucose and a 90 % conversion of xylose were obtained within 50 h. An ethanol yield (based on the glucan and xylan in the pretreated material) of 0.39 g/g was achieved for a process with this yeast inoculum size in a hybrid process (10 % water-insoluble solid (WIS)) with 4 h prehydrolysis time and a total process time of 96 h. The obtained xylose conversion was 95 %. A longer prehydrolysis time or a lower yeast inoculum size resulted in incomplete xylose conversion.

Long-term variability in sugarcane bagasse feedstock compositional methods: sources and magnitude of analytical variability

BACKGROUND

In an effort to find economical, carbon-neutral transportation fuels, biomass feedstock compositional analysis methods are used to monitor, compare, and improve biofuel conversion processes. These methods are empirical, and the analytical variability seen in the feedstock compositional data propagates into variability in the conversion yields, component balances, mass balances, and ultimately the minimum ethanol selling price (MESP). We report the average composition and standard deviations of 119 individually extracted National Institute of Standards and Technology (NIST) bagasse [Reference Material (RM) 8491] run by seven analysts over 7 years. Two additional datasets, using bulk-extracted bagasse (containing 58 and 291 replicates each), were examined to separate out the effects of batch, analyst, sugar recovery standard calculation method, and extractions from the total analytical variability seen in the individually extracted dataset. We believe this is the world's largest NIST bagasse compositional analysis dataset and it provides unique insight into the long-term analytical variability. Understanding the long-term variability of the feedstock analysis will help determine the minimum difference that can be detected in yield, mass balance, and efficiency calculations.

RESULTS

The long-term data show consistent bagasse component values through time and by different analysts. This suggests that the standard compositional analysis methods were performed consistently and that the bagasse RM itself remained unchanged during this time period. The long-term variability seen here is generally higher than short-term variabilities. It is worth noting that the effect of short-term or long-term feedstock compositional variability on MESP is small, about $0.03 per gallon.

CONCLUSIONS

The long-term analysis variabilities reported here are plausible minimum values for these methods, though not necessarily average or expected variabilities. We must emphasize the importance of training and good analytical procedures needed to generate this data. When combined with a robust QA/QC oversight protocol, these empirical methods can be relied upon to generate high-quality data over a long period of time.

Biochemical production of bioenergy from agricultural crops and residue in Iran

The present study assessed the potential for biochemical conversion of energy stored in agricultural waste and residue in Iran. The current status of agricultural residue as a source of bioenergy globally and in Iran was investigated. The total number of publications in this field from 2000 to 2014 was about 4294. Iran ranked 21st with approximately 54 published studies. A total of 87 projects have been devised globally to produce second-generation biofuel through biochemical pathways. There are currently no second-generation biorefineries in Iran and agricultural residue has no significant application. The present study determined the amount and types of sustainable agricultural residue and oil-rich crops and their provincial distribution. Wheat, barley, rice, corn, potatoes, alfalfa, sugarcane, sugar beets, apples, grapes, dates, cotton, soybeans, rapeseed, sesame seeds, olives, sunflowers, safflowers, almonds, walnuts and hazelnuts have the greatest potential as agronomic and horticultural crops to produce bioenergy in Iran. A total of 11.33million tonnes (Mt) of agricultural biomass could be collected for production of bioethanol (3.84gigaliters (Gl)), biobutanol (1.07Gl), biogas (3.15billion cubic meters (BCM)), and biohydrogen (0.90BCM). Additionally, about 0.35Gl of biodiesel could be obtained using only 35% of total Iranian oilseed. The potential production capacity of conventional biofuel blends in Iran, environmental and socio-economic impacts including well-to-wheel greenhouse gas (GHG) emissions, and the social cost of carbon dioxide reduction are discussed. The cost of emissions could decrease up to 55.83% by utilizing E85 instead of gasoline. The possible application of gaseous biofuel in Iran to produce valuable chemicals and provide required energy for crop cultivation is also studied. The energy recovered from biogas produced by wheat residue could provide energy input for 115.62 and 393.12 thousand hectares of irrigated and rain-fed wheat cultivation in Iran, respectively. The nitrogen requirement for 33.6% of the total wheat cultivation area could be supplied by the ammonia acquired from biohydrogen. A discussion of the logistics of collection and transportation of the biomass and sensitivity analysis are carried out to evaluate the effect of field cover factor, crop yield, and well-to-wheel GHG emission on collectable residue, biofuel production, and GHG emissions.

The micromorphology of Trichoderma reesei analyzed in cultivations on lactose and solid lignocellulosic substrate, and its relationship with cellulase production

BACKGROUND

Trichoderma reesei is the principal producer of cellulolytic enzymes. Because of the strong influence on the enzyme production, the morphology of the filamentous fungi is a key parameter for process optimization. For cost-effective production of cellulolytic enzymes, the cultivation of T. reesei is performed on lignocellulosic waste streams. These insoluble substrates prevent the application of the conventional light microscopy for the analysis of fungal morphology. Here, we present a novel method for the micromorphological analysis based on confocal laser-scanning microscopy (CLSM) and the computer-aided image analysis. This method enabled the quantification of the dimensions of the single cell (intercalary length and cell width) and the degree of branching in cultivations on the industrially relevant substrates wheat straw and lactose. The micromorphology of two T. reesei strains, QM9414 and a carbon catabolite derepressed cre1 knockout mutant (Δcre1), was analyzed in dependence of substrate, inoculation method, and agitation velocity.

RESULTS

Trichoderma reesei strain Δcre1 formed shorter cells (10.09 µm) on average and developed more ramified mycelia (0.36 branches/cell) than strain QM9414 (12.03 µm, 0.22 branches/cell). Cultivated on wheat straw, the average cell length of QM9414 (10.87 µm) and Δcre1 (9.74 µm) was 10 and 21 % shorter as compared to reference cultivations on lactose. When inoculation was done with spores as compared to hyphal biomass, cell lengths of QM9414 (10.97 µm) and Δcre1 (9.10 µm) were on average about 20 % shorter. Strain performance was evaluated in protein concentration and total cellulase activity, which varied between 0.69 and 2.31 FPU/mL for Δcre1 and between 0.84 and 1.64 FPU/mL for QM9414. The cell length exhibited slightly negative correlation with the protein (regression coefficient -0.04 g/(L µm), R (2) 0.33) and the cellulase (-0.30 FPU/(mL µm), R (2) 0.53) production.

CONCLUSIONS

The dimensions of the single cell of T. reesei were dependent on strain background, substrate used and process conditions applied. Micromorphological changes were correlated semi-quantitatively with the efficiency of enzyme production. In providing a process analytical tool for enzyme production by T. reesei on lignocellulosic substrate, this study has relevance for the characterization and optimization of a critical step in the overall saccharification process.

Integration of mild acid hydrolysis in γ-valerolactone/water system for enhancement of enzymatic saccharification from cotton stalk

In this study, mild acid hydrolysis using γ-valerolactone (GVL)/water system integrated with enzymatic hydrolysis was carried out for the enhancement of enzymatic saccharification efficiency. The quantitative analysis of soluble carbohydrates and structural characterizations of solid residues were conducted. Results showed that the soluble carbohydrates in the water-phase were mainly composed of monomers and oligomers from xylose and glucose, while the contents of which were depended on the ratio of GVL to water. Moreover, the inhibitors were hardly detected due to the moderate pretreatment severity. Compared with the untreated feedstock, the yields of enzymatic hydrolysis from pretreated samples increased by two-fold with the mixture of 80/20 GVL/H2O. Combined with the amount of glucose (14.6%) dissolved in the water-phase, over 92.6% of glucose in cotton stalk was released and recovered. Based on the comprehensive analysis, treatment with GVL/H2O system provided us a more effective approach for sugar production from biomass.