Toward high solids loading process for lignocellulosic biofuel production at a low cost

Application of Adaptive Laboratory Evolution in Lipid and Terpenoid Production in Yeast and Microalgae

Due to the complexity of metabolic and regulatory networks in microorganisms, it is difficult to obtain robust phenotypes through artificial rational design and genetic perturbation. Adaptive laboratory evolution (ALE) engineering plays an important role in the construction of stable microbial cell factories by simulating the natural evolution process and rapidly obtaining strains with stable traits through screening. This review summarizes the application of ALE technology in microbial breeding, describes the commonly used methods for ALE, and highlights the important applications of ALE technology in the production of lipids and terpenoids in yeast and microalgae. Overall, ALE technology provides a powerful tool for the construction of microbial cell factories, and it has been widely used in improving the level of target product synthesis, expanding the range of substrate utilization, and enhancing the tolerance of chassis cells. In addition, in order to improve the production of target compounds, ALE also employs environmental or nutritional stress strategies corresponding to the characteristics of different terpenoids, lipids, and strains.

Enhancing enzymatic hydrolysis efficiency of crop straws via tetrahydrofuran/water co-solvent pretreatment

Pretreatment and enzymatic hydrolysis are critical steps in bio-ethanol production from lignocellulose. The enhancement of enzymatic hydrolysis of several typical crop straws and the particle size adaptability of sorghum straw by tetrahydrofuran/water co-solvent pretreatment were studied. Efficient cellulose conversions (>83.2%) and adequate hemicellulose conversion (>40.7%) were obtained from pretreated rice straw, sorghum straw, wheat straw and corn stover in enzymatic hydrolysis, and the highest glucose yield and xylose yield were 274.0 and 26.3 mg/g dry solid, respectively. Glucose production of 140.4 mg/mL was obtained when the pretreated sorghum straw with mixed particle sizes was employed in enzymatic hydrolysis at 20% solid loading (8 FPU/g cellulose). When the enzyme loading reduced to 4 FPU/g cellulose, 221.7 mg/g dry solid glucose yield and 68.6% enzymatic hydrolysis efficiency could be still obtained with 15% solid loading, exhibiting high potential for bio-ethanol production.

Combined adaptive evolution and transcriptomic profiles reveal aromatic aldehydes tolerance mechanisms in Yarrowia lipolytica

Yarrowia lipolytica is an efficient oleaginous yeast, whereas its activity is typically reduced by inhibitors present in lignocellulosic hydrolysate. Understanding the response mechanism of Y. lipolytica to hydrolysate inhibitors and developing inhibitor tolerant strains are vital to lignocellulose valorization by this promising species. In this study, through adaptive laboratory evolution on three representative aromatic aldehyde inhibitors, evolved strains were obtained. Fermentation phenotype suggested that aromatic aldehydes conversion was one main reason for high tolerance of adapted strains. Transcriptome profiling analysis and reverse metabolic engineering confirmed that overexpressing the aldehyde ketone reductase gene YALI0_B07117g and aldehyde dehydrogenase gene YALI0_B01298g effectively converted aromatic aldehyde to corresponding alcohols and acids. The potential degradation pathways for aromatic aldehyde inhibitors in Y. lipolytica XYL+ were then discussed. This study provided insights to the aromatic aldehyde degradation in Y. lipolytica and a reliable basis for the development of aromatic aldehyde tolerant strains.

Enhanced conversion of biomass to furfurylamine with high productivity by tandem catalysis with sulfonated perlite and ω-transaminase whole-cell biocatalyst

Production of bio-based chemicals from renewable bioresource is a key driver for moving towards sustainable industry. Furfurylamine is known as an important furfural-upgrading product in organic synthesis, as well as monolithic synthetic pharmaceuticals, fibers, additives and polymers. In one-pot manner, biomass was tandemly catalyzed to furfurylamine with sulfonated Sn-PL catalyst and recombinant ω-transaminase biocatalyst. Sn-PL (2.4 wt%) catalyzed bamboo shoot shell, corncob and rice straw (75.0 g/L) to 76.5-113.0 mM furfural at 44.7-58.5 % yield in γ-valerolactone-water (2:8, v:v) at 170 ℃. The obtained biomass slurries containing furfural were biotransformed to furfurylamine at high yield (0.39-0.42 g furfurylamine/g xylan in biomass) with ω-transaminase biocatalyst using isopropylamine (3.0 mol isopropylamine/mol furfural) as amine donor at 35 ℃. Such a chemoenzymatic one-pot process combined the advantages of both solid acids and whole-cells catalysts, which provided an efficient and sustainable approach for preparing an important bio-based furan chemical furfurylamine.

Characterization of Orange Peel Waste and Valorization to Obtain Reducing Sugars

Annually, millions of tons of foods are generated with the purpose to feed the growing world population. One particular eatable is orange, the production of which in 2018 was 75.54 Mt. One way to valorize the orange residue is to produce bioethanol by fermenting the reducing sugars generated from orange peel. Hence, the objective of the present work was to determine the experimental conditions to obtain the maximum yield of reducing sugars from orange peel using a diluted acid hydrolysis process. A proximate and chemical analysis of the orange peel were conducted. For the hydrolysis, two factorial designs were prepared to measure the glucose and fructose concentration with the 3,5-DNS acid method and UV-Visible spectroscopy. The factors were acid concentration, temperature and hydrolysis time. After the hydrolysis, the orange peel samples were subjected to an elemental SEM-EDS analysis. The results for the orange peel were 73.530% of moisture, 99.261% of volatiles, 0.052% of ash, 0.687% of fixed carbon, 19.801% of lignin, 69.096% of cellulose and 9.015% of hemicellulose. The highest concentration of glucose and fructose were 24.585 and 9.709 g/L, respectively. The results highlight that sugar production is increased by decreasing the acid concentration.

Constraints and advances in high-solids enzymatic hydrolysis of lignocellulosic biomass: a critical review

The industrial production of sugar syrups from lignocellulosic materials requires the conduction of the enzymatic hydrolysis step at high-solids loadings (i.e., with over 15% solids [w/w] in the reaction mixture). Such conditions result in sugar syrups with increased concentrations and in improvements in both capital and operational costs, making the process more economically feasible. However, this approach still poses several technical hindrances that impact the process efficiency, known as the "high-solids effect" (i.e., the decrease in glucan conversion yields as solids load increases). The purpose of this review was to present the findings on the main limitations and advances in high-solids enzymatic hydrolysis in an updated and comprehensive manner. The causes for the rheological limitations at the onset of the high-solids operation as well as those influencing the "high-solids effect" will be discussed. The subject of water constraint, which results in a highly viscous system and impairs mixing, and by extension, mass and heat transfer, will be analyzed under the perspective of the limitations imposed to the action of the cellulolytic enzymes. The "high-solids effect" will be further discussed vis-à-vis enzymes end-product inhibition and the inhibitory effect of compounds formed during the biomass pretreatment as well as the enzymes' unproductive adsorption to lignin. This review also presents the scientific and technological advances being introduced to lessen high-solids hydrolysis hindrances, such as the development of more efficient enzyme formulations, biomass and enzyme feeding strategies, reactor and impeller designs as well as process strategies to alleviate the end-product inhibition. We surveyed the academic literature in the form of scientific papers as well as patents to showcase the efforts on technological development and industrial implementation of the use of lignocellulosic materials as renewable feedstocks. Using a critical approach, we expect that this review will aid in the identification of areas with higher demand for scientific and technological efforts.

Process integration for ethanol production from corn and corn stover as mixed substrates

This work investigated all possible process integration strategies for ethanol production from corn and dilute acid pretreated corn stover (CS) as mixed substrates. Three corn to pretreated CS ratios (20%:10%, 10%:20% and 5%:25%) were examined. When the ratio of corn to pretreated CS was 20%:10%, the process integration strategy that mixed corn with CS hydrolysate for liquefaction followed by SSF resulted in the highest ethanol titer of 99.3 g/L. Mixing liquefied corn with pretreated CS for hydrolysis/saccharification followed by fermentation was the best strategy for the other two ratios. The strategy of mixing liquefied corn with pretreated CS for 6 h hydrolysis followed by fermentation showed the highest productivity for all the tested ratios.

Development of Robust Yeast Strains for Lignocellulosic Biorefineries Based on Genome-Wide Studies

Lignocellulosic biomass has been widely studied as the renewable feedstock for the production of biofuels and biochemicals. Budding yeast Saccharomyces cerevisiae is commonly used as a cell factory for bioconversion of lignocellulosic biomass. However, economic bioproduction using fermentable sugars released from lignocellulosic feedstocks is still challenging. Due to impaired cell viability and fermentation performance by various inhibitors that are present in the cellulosic hydrolysates, robust yeast strains resistant to various stress environments are highly desired. Here, we summarize recent progress on yeast strain development for the production of biofuels and biochemical using lignocellulosic biomass. Genome-wide studies which have contributed to the elucidation of mechanisms of yeast stress tolerance are reviewed. Key gene targets recently identified based on multiomics analysis such as transcriptomic, proteomic, and metabolomics studies are summarized. Physiological genomic studies based on zinc sulfate supplementation are highlighted, and novel zinc-responsive genes involved in yeast stress tolerance are focused. The dependence of host genetic background of yeast stress tolerance and roles of histones and their modifications are emphasized. The development of robust yeast strains based on multiomics analysis benefits economic bioconversion of lignocellulosic biomass.

In-Situ Vacuum Assisted Gas Stripping Recovery System for Ethanol Removal from a Column Bioreactor

A three-step process consisting of biomass hydrolysis, fermentation and in-situ gas stripping by a vacuum assisted recovery system, was optimized to increase the ethanol production from sugar beet pulp. The process combines the advantages of stripping and vacuum separation and enhances the fermentation productivity through in-situ ethanol removal. Using the design of experiment and response surface methodology, the effect of major factors in the process, such as pressure, recycling ratio and solids concentration, was tested to efficiently remove ethanol after the combined hydrolysis and fermentation step. Statistical analysis indicates that a decreased pressure rate and an increased liquid phase recycling ratio enhance the productivity and the yield of the strip-vacuum fermentation process. The results also highlight further possibilities of this process to improve integrated bioethanol production processes. According to the statistical analysis, ethanol production is strongly influenced by recycling ratio and vacuum ratio. Mathematical models that were established for description of investigated processes can be used for the optimization of the ethanol production.

Enhancement of sugar recovery and ethanol production from wheat straw through alkaline pre-extraction followed by steam pretreatment

To improve sugar recovery and ethanol production from wheat straw, a sequential two-stage pretreatment process combining alkaline pre-extraction and acid catalyzed steam treatment was investigated. The results showed that alkaline pre-extraction using 8% (w/w) sodium hydroxide at 80 °C for 90 min followed by steam pretreatment with 3% (w/w) sulfur dioxide at 151 °C for 16 min was sufficient to prepare a substrate that could be efficiently hydrolyzed at high solid loadings. Moreover, alkaline pre-extraction reduced the process severity of steam pretreatment and decreased the generation of inhibitory compounds. During enzymatic hydrolysis, increasing solid loading decreased the yield of monomeric sugars. Enzymatic hydrolysis at 25% (w/v) solid loading, the yields of approximately 80% of glucose and 65% of xylose could be reached with an enzyme dosage of 25 mg protein/g glucan. Following fermentation of hydrolysate with sugar concentration of approximately 120 g/L, an ethanol concentration of 54.5 g/L was achieved.

Ethanol production from mixtures of sugarcane bagasse and Dioscorea composita extracted residue with high solid loading

Various mixing ratios of alkali pretreated sugarcane bagasse and starch-rich waste Dioscorea composita hemls extracted residue (DER) were evaluated via simultaneous saccharification and fermentation (SSF) with 12% (w/w) solid loading, and the mixture ratio of 1:1 achieved the highest ethanol concentration and yield. When the solid loading was increased from 12% to 32%, the ethanol concentration was increased to 72.04 g/L, whereas the ethanol yield was reduced from 84.40% to 73.71%. With batch feeding and the addition of 0.1% (w/v) Tween 80, the final ethanol concentration and yield of SSF at 34% loading were 82.83 g/L and 77.22%, respectively. Due to the integration with existing starch-based ethanol industry, the co-fermentation is expected to be a competitive alternative form for cellulosic ethanol production.

Endogenous lycopene improves ethanol production under acetic acid stress in Saccharomyces cerevisiae

BACKGROUND

Acetic acid, generated from the pretreatment of lignocellulosic biomass, is a significant obstacle for lignocellulosic ethanol production. Reactive oxidative species (ROS)-mediated cell damage is one of important issues caused by acetic acid. It has been reported that decreasing ROS level can improve the acetic acid tolerance of Saccharomyces cerevisiae.

RESULTS

Lycopene is known as an antioxidant. In the study, we investigated effects of endogenous lycopene on cell growth and ethanol production of S. cerevisiae in acetic acid media. By accumulating endogenous lycopene during the aerobic fermentation of the seed stage, the intracellular ROS level of strain decreased to 1.4% of that of the control strain during ethanol fermentation. In the ethanol fermentation system containing 100 g/L glucose and 5.5 g/L acetic acid, the lag phase of strain was 24 h shorter than that of control strain. Glucose consumption rate and ethanol titer of yPS002 got to 2.08 g/L/h and 44.25 g/L, respectively, which were 2.6- and 1.3-fold of the control strain. Transcriptional changes of INO1 gene and CTT1 gene confirmed that endogenous lycopene can decrease oxidative stress and improve intracellular environment.

CONCLUSIONS

Biosynthesis of endogenous lycopene is first associated with enhancing tolerance to acetic acid in S. cerevisiae. We demonstrate that endogenous lycopene can decrease intracellular ROS level caused by acetic acid, thus increasing cell growth and ethanol production. This work innovatively   puts forward a new strategy for second generation bioethanol production during lignocellulosic fermentation.

Simultaneous saccharification and aerobic fermentation of high titer cellulosic citric acid by filamentous fungus Aspergillus niger

Simultaneous saccharification and fermentation (SSF) is the most efficient operation in biorefining conversion, but aerobic SSF under high solids loading significantly faces the serious oxygen transfer limitation. This study took the first insight into an aerobic SSF by high oxygen demanding filamentous fungi in highly viscous lignocellulose hydrolysate. The results show that oxygen requirement in the aerobic SSF by Aspergillus niger was well satisfied for production of cellulosic citric acid. The record high citric acid titer of 136.3 g/L and the overall conversion yield of 74.9% of cellulose were obtained by the aerobic SSF. The advantage of SSF to the separate hydrolysis and fermentation (SHF) on citric acid fermentation was compared based on the rigorous Aspen Plus modeling. The techno-economic analysis indicates that the minimum citric acid selling price (MCSP) of $0.603 per kilogram by SSF was highly competitive with the commercial citric acid from starch feedstock.

The effect of switchgrass loadings on feedstock solubilization and biofuel production by Clostridium thermocellum

BACKGROUND

Efficient deconstruction and bioconversion of solids at high mass loadings is necessary to produce industrially relevant titers of biofuels from lignocellulosic biomass. To date, only a few studies have investigated the effect of solids loadings on microorganisms of interest for consolidated bioprocessing. Here, the effects that various switchgrass loadings have on Clostridium thermocellum solubilization and bioconversion are investigated.

RESULTS

Clostridium thermocellum was grown for 10 days on 10, 25, or 50 g/L switchgrass or Avicel at equivalent glucan loadings. Avicel was completely consumed at all loadings, but total cellulose solubilization decreased from 63 to 37% as switchgrass loadings increased from 10 to 50 g/L. Washed, spent switchgrass could be additionally hydrolyzed and fermented in second-round fermentations suggesting that access to fermentable substrates was not the limiting factor at higher feedstock loadings. Results from fermentations on Avicel or cellobiose using culture medium supplemented with 50% spent fermentation broth demonstrated that compounds present in the supernatants from the 25 or 50 g/L switchgrass loadings were the most inhibitory to continued fermentation.

CONCLUSIONS

Recalcitrance alone cannot fully account for differences in solubilization and end-product formation between switchgrass and Avicel at increased substrate loadings. Experiments aimed at separating metabolic inhibition from inhibition of hydrolysis suggest that C. thermocellum's hydrolytic machinery is more vulnerable to inhibition from switchgrass-derived compounds than its fermentative metabolism.

Effect of solids loading on ethanol production: Experimental, economic and environmental analysis

This study explores the effect of high-solids loading for a fed batch enzymatic hydrolysis and fermentation. The solids loading considered was 19%, 30% and 45% using wheat straw and corn stover as a feedstock. Based on the experimental results, techno-economic analysis and life cycle assessments were performed. The experimental results showed that 205±25.8g/L glucose could be obtained from corn stover at 45% solids loading after 96h which when fermented yielded 115.9±6.37g/L ethanol after 60h of fermentation. Techno-economic analysis showed that corn stover at 45% loading yielded the highest ROI at 8% with a payback period less than 12years. Similarly, the global warming potential was lowest for corn stover at 45% loading at -37.8gCO₂ eq./MJ ethanol produced.