Comparative performance evaluation of conventional and two-phase hydrophobic stirred tank reactors for methane abatement: Mass transfer and biological considerations

Continuous polyhydroxybutyrate production from biogas in an innovative two-stage bioreactor configuration

Biogas biorefineries have opened up new horizons beyond heat and electricity production in the anaerobic digestion sector. Added-value products such as polyhydroxyalkanoates (PHAs), which are environmentally benign and potential candidates to replace conventional plastics, can be generated from biogas. This work investigated the potential of an innovative two-stage growth-accumulation system for the continuous production of biogas-based polyhydroxybutyrate (PHB) using Methylocystis hirsuta CSC1 as cell factory. The system comprised two turbulent bioreactors in series to enhance methane and oxygen mass transfer: a continuous stirred tank reactor (CSTR) and a bubble column bioreactor (BCB) with internal gas recirculation. The CSTR was devoted to methanotrophic growth under nitrogen balanced growth conditions and the BCB targeted PHB production under nitrogen limiting conditions. Two different operational approaches under different nitrogen loading rates and dilution rates were investigated. A balanced nitrogen loading rate along with a dilution rate (D) of 0.3 day-1 resulted in the most stable operating conditions and a PHB productivity of ~53 g PHB m-3 day-1 . However, higher PHB productivities (~127 g PHB m-3 day-1 ) were achieved using nitrogen excess at a D = 0.2 day-1 . Overall, the high PHB contents (up to 48% w/w) obtained in the CSTR under theoretically nutrient balanced conditions and the poor process stability challenged the hypothetical advantages conferred by multistage vs single-stage process configurations for long-term PHB production.

Recent advances in methanol production from methanotrophs

Methanol, the simplest aliphatic molecule of the alcohol family, finds diverse range of applications as an industrial solvent, a precursor for producing other chemicals (e.g., dimethyl ether, acetic acid and formaldehyde), and a potential fuel. There are conventional chemical routes for methanol production such as, steam reforming of natural gas to form syngas, followed by catalytic conversion into methanol; direct catalytic oxidation of methane, or hydrogenation of carbon dioxide. However, these chemical routes are limited by the requirement for expensive catalysts and extreme process conditions, and plausible environmental implications. Alternatively, methanotrophic microorganisms are being explored as biological alternative for methanol production, under milder process conditions, bypassing the requirement for chemical catalysts, and without imposing any adverse environmental impact. Methanotrophs possess inherent metabolic pathways for methanol production via biological methane oxidation or carbon dioxide reduction, thus offering a surplus advantage pertaining to the sequestration of two major greenhouse gases. This review sheds light on the recent advances in methanotrophic methanol production including metabolic pathways, feedstocks, metabolic engineering, and bioprocess engineering approaches. Furthermore, various reactor configurations are discussed in view of the challenges associated with solubility and mass transfer limitations in methanotrophic gas fermentation systems.

Enhanced removal of mixed VOCs with different hydrophobicities by Tween 20 in a biotrickling filter: Kinetic analysis and biofilm characteristics

Mass transfer limitation usually causes the poor performance of biotrickling filters (BTFs) for the treatment of hydrophobic volatile organic compounds (VOCs) during long-term operation. In this study, two identical lab-scale BTFs were established to remove a mixture of n-hexane and dichloromethane (DCM) gases using non-ionic surfactant Tween 20 by Pseudomonas mendocina NX-1 and Methylobacterium rhodesianum H13. A low pressure drop (≤110 Pa) and a rapid biomass accumulation (17.1 mg g^-1) were observed in the presence of Tween 20 during the startup period (30 d). The removal efficiency (RE) of n-hexane was enhanced by 15.0%- 20.5% while DCM was completely removed with the inlet concentration (IC) of 300 mg·m^-3 at different empty bed residence times in the Tween 20 added BTF. The viable cells and the relative hydrophobicity of the biofilm were increased under the action of Tween 20, which facilitated the mass transfer and enhanced the metabolic utilization of pollutants by microbes. Besides, Tween 20 addition enhanced the biofilm formation processes including the increased extracellular polymeric substance (EPS) secretion, biofilm roughness and biofilm adhesion. The kinetic model simulated the removal performance of the BTF with Tween 20 for the mixed hydrophobic VOCs, and the goodness-of-fit was above 0.9.

Comparative evaluation of bacterial and fungal removal of indoor and industrial polluted air using suspended and packed bed bioreactors

The abatement of indoor volatile organic compounds (VOCs) represents a major challenge due to their environmental risk, wide nature and concentration variability. Biotechnologies represent a cost-effective, robust and sustainable platform for the treatment of hazardous VOCs at low and fluctuating concentrations. However, they have been scarcely implemented for indoor air purification. Thus, little is known about the influence of the reactor configuration or the VOC nature and concentration variability on the removal, resilience and the microbial population of bioreactor configurations susceptible to be implemented, both in indoors and industrial environments. The present study aims at comparing the removal performance of four VOCs with different hydrophobicity and molecular structure -acetone, n-hexane, α-pinene and toluene-at two inlet concentrations (5 and 400 mg m^-3), which mimics the concentrations of contaminated indoor and industrial air. To this aim a stirred tank, flat biofilm and latex-based biocoated flat bioreactor were comparatively evaluated. The results demonstrated the superior performance of the stirred tank reactor for the removal of hydrophilic VOCs at high inlet concentrations, which achieved removals >99% for acetone and toluene. At low concentrations, the removal efficiencies of acetone, toluene and α-pinene were >97% regardless of the bioreactor configuration tested. The most hydrophobic gas, n-hexane, was more efficiently removed in the flat biofilm reactor without latex. The microbial community analyses showed that the presence of VOCs as the only carbon and energy source didn't promote the growth of dominant bacterial members and the populations independently evolved in each reactor configuration and operation mode. The fungal population was more diverse in the biofilm-based bioreactors, although, it was mainly dominated by uncultured fungi from the phylum Cryptomycota.

Airlift two-phase partitioning bioreactor for dichloromethane removal: Silicone rubber stimulated biodegradation and its auto-circulation

Solid non-aqueous phases (NAPs), such as silicone rubber, have been used extensively to improve the removal of volatile organic compounds (VOCs). However, the removal of VOCs is difficult to be further improved because the poor understanding of the mass transfer and reaction processes. Further, the conventional reactors were either complicated or uneconomical. In view of this, herein, an airlift bioreactor with silicone rubber was designed and investigated for dichloromethane (DCM) treatment. The removal efficiency of Reactor 1 (with silicone rubber) was significantly higher than that of Reactor 2 (without silicone rubber), with corresponding higher chloride ion and CO₂ production. It was found that Reactor 1 achieved a much better DCM shock tolerance capability and biomass stability than Reactor 2. Silicone rubber not only enhanced the mass transfer in terms of both gas/liquid and gas/microbial phases, but also decreased the toxicity of DCM to microorganisms. Noteworthily, despite the identical inoculum used, the relative abundance of potential DCM-degrading bacteria in Reactor 1 (91.2%) was much higher than that in Reactor 2 (24.3%) at 216 h. Additionally, the silicone rubber could be automatically circulated in the airlift bioreactor due to the driven effect of the airflow, resulting in a significant reduction of energy consumption.

Biochar dose determines methane uptake and methanotroph abundance in Haplic Luvisol

Biochar promotes C sequestration and improvement of soil properties. Nevertheless, the effects of biochar addition on soil condition are poorly understood, especially with respect to greenhouse gas (GHG) emissions. A large proportion of GHG emissions derive from agriculture and, thus, recognition of the effect of biochar addition to soil on GHG emissions from terrestrial ecosystems is an important issue. The purpose of our study was to evaluate the short- and long-term effects of biochar application on soil in aspects of: GHG exchange (CH₄ and CO₂), basic physicochemical soil properties and structure of microbial communities in Haplic Luvisol. Soil was collected from fallow fields enriched with three doses of wood offcuts biochar (10, 20 and 30 Mg ha^-1) and incubated at two moisture levels (60 and 100% WHC) with the addition of 1% CH₄. To evaluate the influence of biochar aging in soil, the samples were analysed directly (short-term response) and five years (long-term response) after amendment. Generally, biochar addition increased soil pH, redox potential (Eh), organic carbon (SOC) and dissolved organic carbon (DOC) contents. Under 60% WHC, direct biochar application to the soil resulted in a clear improvement in the CH₄ uptake rate. In contrast to that (at 100% WHC) methane uptake rates were twofold decreased. The positive effect was reduced due to biochar aging in the soil, but five years after application, at 60% WHC and the highest biochar dose (30 Mg ha^-1) still significantly enhanced CH₄ oxidation. From a short-term perspective, biochar application increased CO₂ emissions, but after five years this effect was not observed. Microbial tests confirmed that the improvement in CH₄ oxidation was correlated with methanotroph abundance in the soil. Moreover, an increase of Methylocystis abundance in the soil enriched with biochar along with enhanced CH₄ uptake rates confirm the positive biochar influence on methanotrophic communities.

Enhanced biodegradation of n-hexane in a two-phase partitioning bioreactor inoculated with Pseudomonas mendocina NX-1 under chitosan stimulation

Two-phase partitioning bioreactors (TPPBs) have been extensively used for volatile organic compounds (VOCs) removal. To date, most studies have focused on improving the mass transfer of gas phases/non-aqueous phases (NAPs)/aqueous phases, whereas the NAP/biological phases and gas/biological phases transfer has been neglected. Herein, chitosan was introduced into a TPPB to increase cell surface hydrophobicity (CSH) and improve the n-hexane mass transfer. The performance and stability of the TPPB with chitosan for n-hexane biodegradation were investigated, and it was found out that the TPPB with chitosan achieved maximum removal efficiency and elimination capacity of 80.6% and 26.5 g m^-3 h^-1, thereby reaching much higher values than those obtained without chitosan (61.3% and 15.2 g m^-3 h^-1). Chitosan not only obvio usly increased cell surface hydrophobicity and cell dry biomass on the surface of silicone oil, but might also allow hydrophobic cells in aqueous phases to directly capture and biodegrade n-hexane, resulting in an obvious improvement of mass transfer from the gas phase to biomass. Stability enhancement was another attractive advantage from chitosan addition. This study might provide a new strategy for the development of TPPB in the hydrophobic VOCs treatment.

Biogas valorization via continuous polyhydroxybutyrate production by Methylocystis hirsuta in a bubble column bioreactor

Creating additional value out of biogas during waste treatment has become a priority in past years. Biogas bioconversion into valuable bioproducts such as biopolymers has emerged as a promising strategy. This work assessed the operational feasibility of a bubble column bioreactor (BCB) implemented with gas recirculation and inoculated with a polyhydroxybutyrate (PHB)-producing strain using biogas as substrate. The BCB was initially operated at empty bed residence times (EBRTs) ranging from 30 to 120 min and gas recirculation ratios (R) from 0 to 30 to assess the gas-to-liquid mass transfer and bioconversion of CH₄. Subsequently, the BCB was continuously operated at a R of 30 and an EBRT of 60 min under excess of nitrogen and nitrogen feast-famine cycles of 24 h:24 h to trigger PHB synthesis. Gas recirculation played a major role in CH₄ gas-liquid transfer, providing almost fourfold higher CH₄ elimination capacities (~41 g CH₄ m^-3 h^-1) at the highest R and EBRT of 60 min. The long-term operation under N excess conditions entailed nitrite accumulation (induced by O₂ limiting conditions) and concurrent methanotrophic activity inhibition above ~60 mg N-NO₂^- L^-1. Adjusting the N-NO₃^- supply to match microbial N demand successfully prevented nitrite accumulation. Finally, the N feast-famine 24 h:24 h strategy supported a stable CH₄ conversion with a removal efficiency of 70% along with a continuous PHB production, which yielded PHB accumulations of 14.5 ± 2.9% (mg PHB mg^-1 total suspended solids × 100). These outcomes represent the first step towards the integration of biogas biorefineries into conventional anaerobic digestion plants.

Comparative assessment of two biotrickling filters for siloxanes removal: Effect of the addition of an organic phase

Biogas produced at wastewater treatment plants and landfills contains trace levels of volatile methyl siloxanes (VMS) that are responsible for abrasion, corrosion and erosion of equipment during biogas storage and combustion. This research comparatively evaluated the removal of the most common VMS (L2, L3, D4, and D5) under aerobic conditions in a conventional biotrickling filter (BTF) and a two-phase partitioning BTF (TP-BTF) with silicone oil (at 30%) as organic phase. The TP-BTF showed a superior performance compared to the conventional BTF, increasing the total VMS removal from <30% in the BTF up to ∼70% in the TP-BTF. The highest REs in the TP-BTF were recorded for D4 and D5, reaching values of 80-90%, corresponding to ECs between 0.12 and 0.17 g m^-3.h^-1. Slightly lower values were obtained for L3 (70-80%), and the lowest performance was recorded for L2 (20-60%) due to the high vapor pressure of this siloxane and therefore its lower affinity by the organic phase. Surprisingly, despite the different inocula used, a similar microbial community was found by the end of operation of both BTFs, with KMBC-112, Reynarella and Chitinophaga as the dominant genera.

A systematic comparison of ectoine production from upgraded biogas using Methylomicrobium alcaliphilum and a mixed haloalkaliphilic consortium

Biogas is the byproduct of anaerobic digestion with the highest valorization potential, however its full exploitation is limited by the lack of tax incentives and the inherent presence of pollutants. The development of technologies for biogas conversion into added-value products is crucial in order to ensure the competitiveness of this bioresource. This study constitutes the first proof of concept of upgraded biogas bioconversion into the high profit margin product ectoine. Ectoine represents the most expensive product synthesized by microorganisms with a retail value of 1000 $ kg^-1 and a yearly increasing demand that currently entails a total market opportunity of 15000 M€. First, the production of ectoine from upgraded biogas was assessed in batch bioreactors. The presence of H₂S did not exert a negative effect on the growth of the haloalkaliphilic ectoine producers, and ectoine yields up to 49 mg g biomass^-1 were obtained. A second experiment conducted in continuous bubble column bioreactors confirmed the feasibility of the process under continuous mode (with ectoine yields of 109 mg g biomass^-1). Finally, this study revealed that the removal of toxic compounds (i.e. medium dilution rate of 0.5 day^-1) and process operation with a consortium composed of methylotrophic/non-methylotrophic ectoine producers enhanced upgraded biogas bioconversion. This research discloses the basis for the application of this innovative technology and could boost the economic performance of anaerobic digestion.

Methane biodegradation and enhanced methane solubilization by the filamentous fungi Fusarium solani

Methane is one of the most important greenhouse gases emitted from natural and human activities. It is scarcely soluble in water; thus, it has a low bioavailability for microorganisms able to degrade it. In this work, the capacity of the fungus Fusarium solani to improve the solubility of methane in water and to biodegrade methane was assayed. Experiments were performed in microcosms with vermiculite as solid support and mineral media, at temperatures between 20 and 35 °C and water activities between 0.9 and 0.95, using pure cultures of F. solani and a methanotrophic consortium (Methylomicrobium album and Methylocystis sp) as a control. Methane was the only carbon and energy source. Results indicate that using thermally inactivated biomass of F. solani, decreases the partition coefficient of methane in water up to two orders of magnitude. Moreover, F. solani can degrade methane, in fact at 35 °C and the highest water activity, the methane degradation rate attained by F. solani was 300 mg m^-3 h^-1, identical to the biodegradation rate achieved by the consortium of methanotrophic bacteria.

Novel haloalkaliphilic methanotrophic bacteria: An attempt for enhancing methane bio-refinery

Methane bioconversion into products with a high market value, such as ectoine or hydroxyectoine, can be optimized via isolation of more efficient novel methanotrophic bacteria. The research here presented focused on the enrichment of methanotrophic consortia able to co-produce different ectoines during CH₄ metabolism. Four different enrichments (Cow3, Slu3, Cow6 and Slu6) were carried out in basal media supplemented with 3 and 6% NaCl, and using methane as the sole carbon and energy source. The highest ectoine accumulation (∼20 mg ectoine g biomass^-1) was recorded in the two consortia enriched at 6% NaCl (Cow6 and Slu6). Moreover, hydroxyectoine was detected for the first time using methane as a feedstock in Cow6 and Slu6 (∼5 mg g biomass^-1). The majority of the haloalkaliphilic bacteria identified by 16S rRNA community profiling in both consortia have not been previously described as methanotrophs. From these enrichments, two novel strains (representing novel species) capable of using methane as the sole carbon and energy source were isolated: Alishewanella sp. strain RM1 and Halomonas sp. strain PGE1. Halomonas sp. strain PGE1 showed higher ectoine yields (70-92 mg ectoine g biomass^-1) than those previously described for other methanotrophs under continuous cultivation mode (∼37-70 mg ectoine g biomass^-1). The results here obtained highlight the potential of isolating novel methanotrophs in order to boost the competitiveness of industrial CH₄-based ectoine production.

Multi-production of high added market value metabolites from diluted methane emissions via methanotrophic extremophiles

This study constitutes the first-proof-of-concept of a methane biorefinery based on the multi-production of high profit margin substances (ectoine, hydroxyectoine, polyhydroxyalkanoates (PHAs) and exopolysaccharides (EPS)) using methane as the sole carbon and energy source. Two bubble column bioreactors were operated under different magnesium concentrations (0.2, 0.02 and 0.002 g L^-1) to validate and optimize this innovative strategy for valorization of CH₄ emissions. High Mg²⁺ concentrations promoted the accumulation of ectoine (79.7-94.2 mg g biomass^-1), together with high hydroxyectoine yields (up to 13 mg g biomass^-1) and EPS concentrations (up to 2.6 g L culture broth^-1). Unfortunately, PHA synthesis was almost negligible (14.3 mg L^-1) and only found at the lowest Mg²⁺ concentration tested. Halomonas, Marinobacter, Methylophaga and Methylomicrobium, previously described as ectoine producers, were dominant in both bioreactors, Methylomicrobium being the only described methanotroph. This study encourages further research on CH₄ biorefineries capable of creating value out of GHG mitigation.

Technologies for the bioconversion of methane into more valuable products

Methane, with a global warming potential twenty five times higher than that of CO₂ is the second most important greenhouse gas emitted nowadays. Its bioconversion into microbial molecules with a high retail value in the industry offers a potential cost-efficient and environmentally friendly solution for mitigating anthropogenic diluted CH₄-laden streams. Methane bio-refinery for the production of different compounds such as ectoine, feed proteins, biofuels, bioplastics and polysaccharides, apart from new bioproducts characteristic of methanotrophic bacteria, has been recently tested in discontinuous and continuous bioreactors with promising results. This review constitutes a critical discussion about the state-of-the-art of the potential and research niches of biotechnologies applied in a CH₄ biorefinery approach.

o-Xylene removal using one- and two-phase partitioning biotrickling filters: steady/transient-state performance and microbial community

In this study, one- and two-phase partitioning biotrickling filters (1P-BTF and 2P-BTF, respectively) inoculated with a pre-acclimated mixed culture were examined for the removal of hydrophobic and refractory o-xylene. A small fraction of silicone oil (5% v/v) was added as a non-aqueous phase. Due to the presence of silicone oil, the 2P-BTF exhibited superior performance and stability for o-xylene biodegradation at steady and transient operations. Higher macro-kinetic constants for o-xylene removal by the Michaelis-Menten model were obtained for the 2P-BTF with a saturation constant of 0.396 g m^-3 and a maximum elimination capacity of 105.7 g m^-3 h^-1. The enhancement of removal performance for the 2P-BTF was supported by dominant specialized microorganisms with o-xylene biodegradability. The diversity of microbial community was influenced by the presence of silicone oil. This study demonstrated that a BTF with 5% of silicone oil could be applied for the treatment of hydrophobic and refractory volatile organic compounds. It also provided valuable information for better understanding the relationship between microbial community and removal performance using two-phase partitioning bioreactors.

Nitrous Oxide Abatement Coupled with Biopolymer Production As a Model GHG Biorefinery for Cost-Effective Climate Change Mitigation

N₂O represents ∼6% of the global greenhouse gas emission inventory and the most important O₃-depleting substance emitted in this 21st century. Despite its environmental relevance, little attention has been given to cost-effective and environmentally friendly N₂O abatement methods. Here we examined, the potential of a bubble column (BCR) and an internal loop airlift (ALR) bioreactors of 2.3 L for the abatement of N₂O from a nitric acid plant emission. The process was based on the biological reduction of N₂O by Paracoccus denitrificans using methanol as a carbon/electron source. Two nitrogen limiting strategies were also tested for the coproduction of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) coupled with N₂O reduction. High N₂O removal efficiencies (REs) (≈87%) together with a low PHBV cell accumulation were observed in both bioreactors in excess of nitrogen. However, PHBV contents of 38-64% were recorded under N limiting conditions along with N₂O-REs of ≈57% and ≈84% in the ALR and BCR, respectively. Fluorescence in situ hybridization analyses showed that P. denitrificans was dominant (>50%) after 6 months of experimentation. The successful abatement of N₂O concomitant with PHBV accumulation confirmed the potential of integrating biorefinery concepts into biological gas treatment for a cost-effective GHG mitigation.