Ethanol production potential from AFEX™ and steam-exploded sugarcane residues for sugarcane biorefineries

Multifaced application of AFEX-pretreated biomass in producing second-generation biofuels, ruminant animal feed, and value-added bioproducts

Lignocellulosic biomass holds a crucial position in the prospective bio-based economy, serving as a sustainable and renewable source for a variety of bio-based products. These products play a vital role in displacing fossil fuels and contributing to environmental well-being. However, the inherent recalcitrance of biomass poses a significant obstacle to the efficient access of sugar polymers. Consequently, the bioconversion of lignocellulosic biomass into fermentable sugars remains a prominent challenge in biorefinery processes to produce biofuels and biochemicals. In addressing these challenges, extensive efforts have been dedicated to mitigating biomass recalcitrance through diverse pretreatment methods. One noteworthy process is Ammonia Fiber Expansion (AFEX) pretreatment, characterized by its dry-to-dry nature and minimal water usage. The volatile ammonia, acting as a catalyst in the process, is recyclable. AFEX contributes to cleaning biomass ester linkages and facilitating the opening of cell wall structures, enhancing enzyme accessibility and leading to a fivefold increase in sugar conversion compared to untreated biomass. Over the last decade, AFEX has demonstrated substantial success in augmenting the efficiency of biomass conversion processes. This success has unlocked the potential for sustainable and economically viable biorefineries. This paper offers a comprehensive review of studies focusing on the utilization of AFEX-pretreated biomass in the production of second-generation biofuels, ruminant feed, and additional value-added bioproducts like enzymes, lipids, proteins, and mushrooms. It delves into the details of the AFEX pretreatment process at both laboratory and pilot scales, elucidates the mechanism of action, and underscores the role of AFEX in the biorefinery for developing biofuels and bioproducts, and nutritious ruminant animal feed production. While highlighting the strides made, the paper also addresses current challenges in the commercialization of AFEX pretreatment within biorefineries. Furthermore, it outlines critical considerations that must be addressed to overcome these challenges, ensuring the continued progress and widespread adoption of AFEX in advancing sustainable and economically viable bio-based industries.

Green chemical and hybrid enzymatic pretreatments for lignocellulosic biorefineries: Mechanism and challenges

The greener chemical and enzymatic pretreatments for lignocellulosic biomasses are portraying a crucial role owing to their recalcitrant nature. Traditional pretreatments lead to partial degradation of lignin and hemicellulose moieties from the pretreated biomass. But it still restricts the enzyme accessibility for the digestibility towards the celluloses and the interaction of lignin-enzymes, nonproductively. Moreover, incursion of certain special chemical treatments and other lignin sulfonation techniques to the enzymatic pretreatment (hybrid enzymatic pretreatment) enhances the lignin structural modification, solubilization of the hemicelluloses and both saccharification and fermentation processes (SAF). This article concentrates on recent developments in various chemical and hybrid enzymatic pretreatments on biomass materials with their mode of activities. Furthermore, the issues on strategies of the existing pretreatments towards their industrial applications are highlighted, which could lead to innovative ideas to overcome the challenges and give guideline for the researchers towards the lignocellulosic biorefineries.

Xylooligosaccharides produced from sugarcane leaf arabinoxylan using xylanase from Aureobasidium pullulans NRRL 58523 and its prebiotic activity toward Lactobacillus spp

In an attempt to enhance the value of sugarcane leaf, xylan was extracted and used for xylooligosaccharide (XO) production via enzymatic hydrolysis using xylanase from the black yeast Aureobasidium pullulans. The xylan was extracted from sugarcane leaf using alkali extraction according to the response surface methodology. The highest xylan yield (99.42 ± 4.05 % recovery) was obtained using 14.32 % (w/v) NaOH, 13.25:1 liquid: solid ratio, at 121 °C and 15 lb.in2 for 32 min. Sugar composition and FTIR spectrum analyses confirmed its structure as arabinoxylan. The extracted arabinoxylan had a relatively high molecular weight compared to previous studies. Crude endoxylanase from A. pullulans NRRL 58523 was selected for enzymatic hydrolysis of the xylan. The enzyme hydrolyzed well at 50 °C, pH 4.0 and was relatively stable under this condition (87.38 ± 1.26 % of the activity remained after 60 h). XOs, especially xylobiose and xylotriose, were obtained at the maximum yield of 237.51 ± 17.69 mg/g xylan via endoxylanase hydrolysis under the optimum conditions (50 °C, pH 4.0, 65.31 U/g xylan, 53 h). XOs exhibited species-specific prebiotic activity toward three strains of Lactobacillus spp. but not toward Bifidobacterium spp.

Challenges and Future Perspectives of Promising Biotechnologies for Lignocellulosic Biorefinery

Lignocellulose is a kind of renewable bioresource containing abundant polysaccharides, which can be used for biochemicals and biofuels production. However, the complex structure hinders the final efficiency of lignocellulosic biorefinery. This review comprehensively summarizes the hydrolases and typical microorganisms for lignocellulosic degradation. Moreover, the commonly used bioprocesses for lignocellulosic biorefinery are also discussed, including separated hydrolysis and fermentation, simultaneous saccharification and fermentation and consolidated bioprocessing. Among these methods, construction of microbial co-culturing systems via consolidated bioprocessing is regarded as a potential strategy to efficiently produce biochemicals and biofuels, providing theoretical direction for constructing efficient and stable biorefinery process system in the future.

Current understanding of the inhibition factors and their mechanism of action for the lignocellulosic biomass hydrolysis

Biorefining of lignocellulosic biomass is a relatively new concept but it has strong potential to develop and partially replace the fossil derived fuels and myriad of value products to subsequently reduce the greenhouse gas emissions. However, the energy and cost intensive process of releasing the entrapped fermentable sugars is a major challenge for its commercialization. Various factors playing a detrimental role during enzymatic hydrolysis of biomass are inherent recalcitrance of lignocellulosic biomass, expensive enzymes, sub-optimal enzyme composition, lack of synergistic activity and enzyme inhibition caused by various inhibitors. The current study investigated the mechanism of enzyme inhibition during lignocellulosic biomass saccharification especially at high solid loadings. These inhibition factors are categorized into physio-chemical factors, water-soluble and -insoluble enzyme inhibitors, oligomers and enzyme-lignin binding. Furthermore, different approaches are proposed to alleviate the challenges and improve the enzymatic hydrolysis efficiency such as supplementation with surfactants, synergistic catalytic/non-catalytic proteins, and bioprocess modifications.

Strategies to improve solid state anaerobic bioconversion of lignocellulosic biomass: an overview

Solid state anaerobic digestion (SSAD) of lignocellulosic biomass may be attractive solution for its valorisation. Compared to liquid state anaerobic digestion (LSAD), SSAD can handle higher organic loading rates (OLR), requires a less water and smaller reactor volume. It may require lower energy demand for heating or mixing and has higher volumetric methane productivity. Besides numerous benefits of SSAD processes and progress in system design, there are still obstacles, which need to be overcome for its successful implementations. This review aims to compile the recent trends in enhancing the bioconversion of agricultural stubbles in SSAD. Several pretreatment procedures used to breaking lignin and cellulose complex, method to overcome carbon to nitrogen ratio imbalance, use of carbon-based conducting materials to enhance Volatile Fatty Acids (VFA) conversion and additives for achieving nutrient balance will be discussed in this review. Leachate recirculation and its impacts on SSAD of agricultural stubbles are also discussed.

Saccharification of water hyacinth biomass by a combination of steam explosion with enzymatic technologies for bioethanol production

In the present work, bioethanol was produced by sugar fermentation obtained from water hyacinth using a novelty hybrid method composed of steam explosion and enzymatic hydrolysis, using hydrolytic enzymes produced by solid-state fermentation and water hyacinth as substrate. The highest activity, 42 U for xylanase and 2 U for cellulase per gram of dry matter, respectively, was obtained. Steam explosion pretreatment was performed at 190 ℃ for 1, 5, and 10 min, using water hyacinth sampled from the Maria Lizamba Lagoon, the Arroyo Hondo and the Amapa River. The highest amounts of reducing sugars of water hyacinth were obtained form the samples from the lagoon (5.4 g/50 g of dry matter) after 10 min of treatment. Steamed biomass was hydrolysed using the enzymes obtained by solid-state fermentation, obtained reducing sugars (maximum 15.5 g/L); the efficiency of enzymatic hydrolysis was 0.51 g of reducing sugars per gram of water hyacinth. Finally, reducing sugars were fermented using Saccharomyces cerevisiae for conversion to ethanol, with the highest ethanol concentration (7.13 g/L) and an ethanol yield of 0.23 g/g of dry matter.

High Gravity Fermentation of Sugarcane Bagasse Hydrolysate by Saccharomyces pastorianus to Produce Economically Distillable Ethanol Concentrations: Necessity of Medium Components Examined

A major economic obstacle in lignocellulosic ethanol production is the low sugar concentrations in the hydrolysate and subsequent fermentation to economically distillable ethanol concentrations. We have previously demonstrated a two-stage fermentation process that recycles xylose with xylose isomerase to increase ethanol productivity, where the low sugar concentrations in the hydrolysate limit the final ethanol concentrations. In this study, three approaches are combined to increase ethanol concentrations. First, the medium-additive requirements were investigated to reduce ethanol dilution. Second, methods to increase the sugar concentrations in the sugarcane bagasse hydrolysate were undertaken. Third, the two-stage fermentation process was recharacterized with high gravity hydrolysate. It was determined that phosphate and magnesium sulfate are essential to the ethanol fermentation. Additionally, the Escherichia coli extract and xylose isomerase additions were shown to significantly increase ethanol productivity. Finally, the fermentation on hydrolysate had only slightly lower productivity than the reagent-grade sugar fermentation; however, both fermentations had similar final ethanol concentrations. The present work demonstrates the capability to produce ethanol from high gravity sugarcane bagasse hydrolysate using Saccharomyces pastorianus with low yeast inoculum in minimal medium. Moreover, ethanol productivities were on par with pilot-scale commercial starch-based facilities, even when the yeast biomass production stage was included.

Pretreatment for biorefineries: a review of common methods for efficient utilisation of lignocellulosic materials

The implementation of biorefineries based on lignocellulosic materials as an alternative to fossil-based refineries calls for efficient methods for fractionation and recovery of the products. The focus for the biorefinery concept for utilisation of biomass has shifted, from design of more or less energy-driven biorefineries, to much more versatile facilities where chemicals and energy carriers can be produced. The sugar-based biorefinery platform requires pretreatment of lignocellulosic materials, which can be very recalcitrant, to improve further processing through enzymatic hydrolysis, and for other downstream unit operations. This review summarises the development in the field of pretreatment (and to some extent, of fractionation) of various lignocellulosic materials. The number of publications indicates that biomass pretreatment plays a very important role for the biorefinery concept to be realised in full scale. The traditional pretreatment methods, for example, steam pretreatment (explosion), organosolv and hydrothermal treatment are covered in the review. In addition, the rapidly increasing interest for chemical treatment employing ionic liquids and deep-eutectic solvents are discussed and reviewed. It can be concluded that the huge variation of lignocellulosic materials makes it difficult to find a general process design for a biorefinery. Therefore, it is difficult to define "the best pretreatment" method. In the end, this depends on the proposed application, and any recommendation of a suitable pretreatment method must be based on a thorough techno-economic evaluation.

Techno-economic analysis of chemically catalysed lignocellulose biorefineries at a typical sugar mill: Sorbitol or glucaric acid and electricity co-production

Global concerns about depletion of fossil reserves has driven countries towards bio-economies utilising mostly first generation feedstocks. The economic viability of energy self-sufficient biorefineries processing sugarcane lignocelluloses into sorbitol or glucaric acid and electricity was investigated. Aspen Plus® simulations represented glucose conversion processes via SO₂-steam explosion or dilute acid pre-treatment, followed by enzymatic hydrolysis. The most economically viable sorbitol scenario using dilute acid pretreatment with a capital investment cost per litre of US$ 3.96/L was marginally profitable having a selling price 5% below the US$ 655/t market price. To secure private investment, the sorbitol selling price should reach US$ 1283/t.

Silencing of a BAHD acyltransferase in sugarcane increases biomass digestibility

BACKGROUND

Sugarcane (Saccharum spp.) covers vast areas of land (around 25 million ha worldwide), and its processing is already linked into infrastructure for producing bioethanol in many countries. This makes it an ideal candidate for improving composition of its residues (mostly cell walls), making them more suitable for cellulosic ethanol production. In this paper, we report an approach to improving saccharification of sugarcane straw by RNAi silencing of the recently discovered BAHD01 gene responsible for feruloylation of grass cell walls.

RESULTS

We identified six BAHD genes in the sugarcane genome (SacBAHDs) and generated five lines with substantially decreased SacBAHD01 expression. To find optimal conditions for determining saccharification of sugarcane straw, we tried multiple combinations of solvent and temperature pretreatment conditions, devising a predictive model for finding their effects on glucose release. Under optimal conditions, demonstrated by Organosolv pretreatment using 30% ethanol for 240 min, transgenic lines showed increases in saccharification efficiency of up to 24%. The three lines with improved saccharification efficiency had lower cell-wall ferulate content but unchanged monosaccharide and lignin compositions.

CONCLUSIONS

The silencing of SacBAHD01 gene and subsequent decrease of cell-wall ferulate contents indicate a promising novel biotechnological approach for improving the suitability of sugarcane residues for cellulosic ethanol production. In addition, the Organosolv pretreatment of the genetically modified biomass and the optimal conditions for the enzymatic hydrolysis presented here might be incorporated in the sugarcane industry for bioethanol production.

Investigation of alkaline hydrogen peroxide pretreatment and Tween 80 to enhance enzymatic hydrolysis of sugarcane bagasse

BACKGROUND

Due to the intact structure of lignocellulosic biomass, pretreatment was a prerequisite to improve the enzymatic hydrolysis by disrupting the recalcitrant lignocellulose and increasing the accessibility of cellulose to enzyme. In this study, an alkaline hydrogen peroxide (AHP) pretreatment of sugarcane bagasse with various loadings of H₂O₂ (1.25-6.25 wt%) at temperatures of 60-160 °C was proposed to degrade hemicellulose/lignin and improve the enzymatic digestibility.

RESULTS

It was found that increasing H₂O₂ loadings during pretreatment lead to the enhancement of substrate digestibility, whereas the alkali (only NaOH)-pretreated solid generated higher glucose yield than that pretreated under AHP pretreatment with lower loading of H₂O₂. This enhancement of enzymatic digestibility was due to the degradation of hemicellulose and lignin. Furthermore, Tween 80 was added to promote enzymatic digestibility, however, the increased yields were different with various substrates and hydrolysis time. The highest glucose yield of 77.6% was obtained after pretreatment at 160 °C for 60 min with 6.25% H₂O₂ and the addition of Tween 80, representing 89.1% of glucose in pretreated substrate.

CONCLUSIONS

This study demonstrated that the AHP pretreatment could greatly enhance the enzymatic saccharification. The addition of Tween 80 played remarkable performances in promoting the glucose yield during enzymatic hydrolysis by stabilizing and protecting the enzyme activity. This study provided an economical feasible and gradual process for the generation of glucose, which will be subsequently converted to bioethanol and bio-chemicals.

Incorporating anaerobic co-digestion of steam exploded or ammonia fiber expansion pretreated sugarcane residues with manure into a sugarcane-based bioenergy-livestock nexus

The co-digestion of pretreated sugarcane lignocelluloses with dairy cow manure (DCM) as a bioenergy production and waste management strategy, for intensive livestock farms located in sugarcane regions, was investigated. Ammonia fiber expansion (AFEX) increased the nitrogen content and accelerated the biodegradability of sugarcane bagasse (SCB) and cane leaf matter (CLM) through the cleavage of lignin carbohydrate crosslinks, resulting in the highest specific methane yields (292-299 L CH₄/kg VSadded), biogas methane content (57-59% v/v) and biodegradation rates, with or without co-digestion with DCM. To obtain comparable methane yields, untreated and steam exploded (StEx) SCB and CLM had to be co-digested with DCM, at mass ratios providing initial C/N ratios in the range of 18 to 35. Co-digestion with DCM improved the nutrient content of the solid digestates, providing digestates that could be used as biofertilizer to replace CLM that is removed from sugarcane fields during green harvesting.

Enhancing enzymatic saccharification of sugarcane bagasse by combinatorial pretreatment and Tween 80

BACKGROUND

The recalcitrant structure of lignocellulosic biomass made it challenging for their bioconversion into biofuels and biochemicals. Pretreatment was required to deconstruct the intact structure by the removal of hemicellulose/lignin, improving the cellulose accessibility of enzyme. Combinatorial pretreatments with liquid hot water/H₂SO₄ and ethanol/NaOH of sugarcane bagasse were developed to improve enzymatic hydrolysis under mild conditions.

RESULTS

After one-step 60% ethanol containing 0.5% NaOH pretreatment with solid to liquid ratio of 1/10, the glucose yield after hydrolysis for 72 h with enzyme dosage of 20 FPU/g substrate was enhanced by 41% and 205% compared to that of NaOH or 60% ethanol pretreated solids, respectively. This improvement was correlated with the removal of hemicellulose and lignin. However, using combinatorial pretreatments with 1% H₂SO₄ followed by 60% ethanol containing 0.5% NaOH, the highest glucose yield with Tween 80 reached 76%, representing 84.5% of theoretical glucose in pretreated substrate. While retaining similar glucose yield, the addition of Tween 80 capacitated either a reduction of enzyme loading by 50% or shortening hydrolysis time to 24 h. However, the enhancement with the addition of Tween 80 decreased as hydrolysis time was extended.

CONCLUSIONS

This study demonstrated that a combinatorial pretreatment with 1% H₂SO₄ followed by 60% ethanol containing 0.5% NaOH had significant effects on improving the enzymatic hydrolysis of sugarcane bagasse. The addition of Tween 80 enabled reducing the enzyme loading or shortening the hydrolysis time. This study provided an economically feasible and mild process for the generation of glucose, which will be subsequently converted to bioethanol and biochemicals.