Comparison of SO2 and H2SO4 impregnation of softwood prior to steam pretreatment on ethanol production

Metabolic engineering of Saccharomyces cerevisiae for second-generation ethanol production from xylo-oligosaccharides and acetate

Simultaneous intracellular depolymerization of xylo-oligosaccharides (XOS) and acetate fermentation by engineered Saccharomyces cerevisiae offers significant potential for more cost-effective second-generation (2G) ethanol production. In the present work, the previously engineered S. cerevisiae strain, SR8A6S3, expressing enzymes for xylose assimilation along with an optimized route for acetate reduction, was used as the host for expressing two β-xylosidases, GH43-2 and GH43-7, and a xylodextrin transporter, CDT-2, from Neurospora crassa, yielding the engineered SR8A6S3-CDT-2-GH34-2/7 strain. Both β-xylosidases and the transporter were introduced by replacing two endogenous genes, GRE3 and SOR1, that encode aldose reductase and sorbitol (xylitol) dehydrogenase, respectively, and catalyse steps in xylitol production. The engineered strain, SR8A6S3-CDT-2-GH34-2/7 (sor1Δ gre3Δ), produced ethanol through simultaneous XOS, xylose, and acetate co-utilization. The mutant strain produced 60% more ethanol and 12% less xylitol than the control strain when a hemicellulosic hydrolysate was used as a mono- and oligosaccharide source. Similarly, the ethanol yield was 84% higher for the engineered strain using hydrolysed xylan, compared with the parental strain. Xylan, a common polysaccharide in lignocellulosic residues, enables recombinant strains to outcompete contaminants in fermentation tanks, as XOS transport and breakdown occur intracellularly. Furthermore, acetic acid is a ubiquitous toxic component in lignocellulosic hydrolysates, deriving from hemicellulose and lignin breakdown. Therefore, the consumption of XOS, xylose, and acetate expands the capabilities of S. cerevisiae for utilization of all of the carbohydrate in lignocellulose, potentially increasing the efficiency of 2G biofuel production.

Critical comparison of the properties of cellulose nanofibers produced from softwood and hardwood through enzymatic, chemical and mechanical processes

Current knowledge on the properties of different types of cellulose nanofibers (CNFs) is fragmented. Properties variation is very extensive, depending on raw materials, effectiveness of the treatments to extract the cellulose fraction from the lignocellulosic biomass, pretreatments to facilitate cellulose fibrillation and final mechanical process to separate the microfibrils. Literature offers multiple parameters to characterize the CNFs prepared by different routes. However, there is a lack of an extensive guide to compare the CNFs. In this study, we perform a critical comparison of rheological, compositional, and morphological features of CNFs, produced from the most representative types of woody plants, hardwood and softwood, using different types and intensities of pretreatments, including enzymatic, chemical and mechanical ones, and varying the severity of mechanical treatment focusing on the relationship between macroscopic and microscopic parameters. This structured information will be exceedingly useful to select the most appropriate CNF for a certain application based on the most relevant parameters in each case.

Effects of severe pretreatment conditions and lignocellulose-derived furan byproducts on anaerobic digestion of dairy manure

Dairy manure subjected to four pretreatments (acid, alkaline, sulfite (SPORL), alkaline hydrogen peroxide (AHP)) at high chemical dosages (termed severe conditions) were evaluated for enhancements in biogas production and inhibitory effects due to concomitant generation of furan byproducts. All four pretreatments enhanced solubilization of carbohydrates, but only alkaline and AHP resulted in higher methane yield (356 and 333 mL/g-VS, respectively) relative to moderate pretreatment conditions (311 and 261 mL/g-VS, respectively). Methane yield of severe-SPORL pretreatment (233 mL/g-VS) was greater than that of untreated manure (116 mL/g-VS), but lower than that of moderate-SPORL (353 mL/g-VS). Severe-acid pretreatment showed early termination in biogas production likely due to inhibitory effects of furfural and 5-hydroxymethyl furfural. Both experimental data and kinetic modeling indicated that severe-acid pretreatment led to degradation of carbohydrates to furfural, which reduced biogas production due to direct toxicity rather than competitive inhibitory effects. Pretreatment conditions (severity and byproduct levels) for dairy manure biomass may be optimized based on the current findings.

Acid Hydrotropic Fractionation of Lignocelluloses for Sustainable Biorefinery: Advantages, Opportunities, and Research Needs

This Minireview provides a comprehensive discussion on the potential of using acid hydrotropes for sustainably fractionating lignocelluloses for biorefinery applications. Acid hydrotropes are a class of acids that have hydrotrope properties toward lignin, which helps to solubilize lignin in aqueous systems. With the capability of cleaving ether and ester bonds and even lignin-carbohydrate complex (LCC) linkages, these acid hydrotropes can therefore isolate lignin embedded in the plant biomass cell wall and subsequently solubilize the isolated lignin in aqueous systems. Performances of two acid hydrotropes, that is, an aromatic sulfonic acid [p-toluenesulfonic acid (p-TsOH)] and a dicarboxylic acid [maleic acid (MA)], in terms of delignification and dissolution of hemicelluloses, and reducing lignin condensation, were evaluated and compared. The advantages of lignin esterification by MA for producing cellulosic sugars through enzymatic hydrolysis and lignin-containing cellulose nanofibrils (LCNFs) through mechanical fibrillation from the fractionated water insoluble solids (WIS), and for obtaining less condensed lignin with light color, were demonstrated. The excellent enzymatic digestibility of maleic acid hydrotropic fractionation WISs was also demonstrated by comparing with WISs from other fractionation processes. The recyclability and reusability of acid hydrotropes were also reviewed. Finally, perspectives on future research needs to address key technical issues for commercialization were also provided.

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.

Organosolv Fractionation of Softwood Biomass for Biofuel and Biorefinery Applications

Softwoods represent a significant fraction of the available lignocellulosic biomass for conversion into a variety of bio-based products. Its inherent recalcitrance, however, makes its successful utilization an ongoing challenge. In the current work the research efforts for the fractionation and utilization of softwood biomass with the organosolv process are reviewed. A short introduction into the specific challenges of softwood utilization, the development of the biorefinery concept, as well as the initial efforts for the development of organosolv as a pulping method is also provided for better understanding of the related research framework. The effect of organosolv pretreatment at various conditions, in the fractionation efficiency of wood components, enzymatic hydrolysis and bioethanol production yields is then discussed. Specific attention is given in the effect of the pretreated biomass properties such as residual lignin on enzymatic hydrolysis. Finally, the valorization of organosolv lignin via the production of biofuels, chemicals, and materials is also described.

Pilot-scale steam explosion pretreatment with 2-naphthol to overcome high softwood recalcitrance

BACKGROUND

Steam explosion pretreatment has been examined in many studies for enhancing the enzymatic digestibility of lignocellulosic biomass and is currently the most common pretreatment method in commercial biorefineries. It is however not effective for overcoming the extremely high recalcitrance of softwood to biochemical conversion. Recent fundamental research in small-scale liquid hot water pretreatment has shown, though, that the addition of a carbocation scavenger like 2-naphthol can prevent lignin repolymerization and thus enhance the enzymatic digestibility of softwood cellulose. This work studies the technical application potential of this approach in a larger steam explosion pilot plant for surmounting softwood recalcitrance.

RESULTS

The addition of 35.36 g 2-naphthol to the steam explosion pretreatment of 1.5 kg spruce wood chips allowed to considerably enhance the enzymatic cellulose digestibility. Different ways of adding the solid 2-naphthol to steam pretreatment were tested. Mixing with the biomass before pretreatment could enhance digestibility by up to 55% compared to control experiments. Impregnation of the biomass with 2-naphthol was yet more effective. Acetone and ethanol were tested to dissolve 2-naphthol and impregnate the biomass. The solvents were then removed again by evaporation before the pretreatment. The impregnation allowed to enhance digestibility by up to 179 and 192%, respectively. A comparison to prevalent acid-catalyzed steam explosion pretreatments for softwood revealed that the scavenger approach allows for obtaining exceptionally high yields in enzymatic hydrolysis. The biomass impregnation with 2-naphthol even renders a complete enzymatic cellulose conversion possible, which is remarkable for a softwood pretreatment not removing lignin. Steam pretreatment experiments without explosive decompression revealed that the enhancing effects of the explosion and the scavenger complement each other well. The explosion enhances the accessibility of the cellulose while the use of the scavenger reduces particularly the deactivation of enzymes.

CONCLUSIONS

This is the first study to show that a carbocation scavenger in steam pretreatment can enhance the enzymatic digestibility of lignocellulosic biomass. The approach opens up a novel possibility for overcoming the high softwood recalcitrance in a process that does not require an acid catalyst or the removal of lignin from the biomass.

A mild thermomechanical process for the enzymatic conversion of radiata pine into fermentable sugars and lignin

BACKGROUND

Conversion of softwoods into sustainable fuels and chemicals is important for parts of the world where softwoods are the dominant forest species. While they have high theoretical sugar yields, softwoods are amongst the most recalcitrant feedstocks for enzymatic processes, typically requiring both more severe pretreatment conditions and higher enzyme doses than needed for other lignocellulosic feedstocks. Although a number of processes have been proposed for converting softwoods into sugars suitable for fuel and chemical production, there is still a need for a high-yielding, industrially scalable and cost-effective conversion route.

RESULTS

We summarise work leading to the development of an efficient process for the enzymatic conversion of radiata pine (Pinus radiata) into wood sugars. The process involves initial pressurised steaming of wood chips under relatively mild conditions (173 °C for 3-72 min) without added acid catalyst. The steamed chips then pass through a compression screw to squeeze out a pressate rich in solubilised hemicelluloses. The pressed chips are disc-refined and wet ball-milled to produce a substrate which is rapidly saccharified using commercially available enzyme cocktails. Adding 0.1% polyethylene glycol during saccharification was found to be particularly effective with these substrates, reducing enzyme usage to acceptable levels, e.g. 5 FPU/g OD substrate. The pressate is separately hydrolysed using acid, providing additional hemicellulose-derived sugars, for an overall sugar yield of 535 kg/ODT chips (76% of theoretical). The total pretreatment energy input is comparable to other processes, with the additional energy for attrition being balanced by a lower thermal energy requirement. This pretreatment strategy produces substrates with low levels of fermentation inhibitors, so the glucose-rich mainline and pressate syrups can be fermented to ethanol without detoxification. The lignin from the process remains comparatively unmodified, as evident from the level of retained β-ether interunit linkages, providing an opportunity for conversion into saleable co-products.

CONCLUSIONS

This process is an efficient route for the enzymatic conversion of radiata pine, and potentially other softwoods, into a sugar syrup suitable for conversion into fuels and chemicals. Furthermore, the process uses standard equipment that is largely proven at commercial scale, de-risking process scale-up.

Combining the effects of pulping severity and alkali concentration to optimize the lignocellulose-based AlkaPolP biorefinery concept

Within the framework of the development of a novel lignocellulose biorefinery concept alkaline polyol pulping (AlkaPolP) of Pinus sylvestris was performed at different alkali concentrations. The obtained experimental data were used to develop simple mathematical models that allow the prediction of product yields and properties in dependence on a single parameter combining the effects of time, temperature and catalyst concentration. For this purpose the usual approach expressing the pulping severity R0 had to be complemented by the alkali concentration resulting in a modified severity factor R₀('). The found regression models in the form of functions f(R₀(')) can be used as a tool for the identification of those pulping conditions giving the desired product characteristics. Because the yields of the biorefinery products reach their maxima at different pulping conditions the optimization of the whole process turned out to be a multi-objective optimization problem.

Fermentation of lignocellulosic hydrolyzate using a submerged membrane bioreactor at high dilution rates

A submerged membrane bioreactor (sMBR) was developed to ferment toxic lignocellulosic hydrolyzate to ethanol. The sMBR achieved high cell density of Saccharomyces cerevisiae during continuous cultivation of the hydrolyzate by completely retaining all yeast cells inside the sMBR. The performance of the sMBR was evaluated based on the ethanol yield and productivity at the dilution rates 0.2, 0.4, 0.6, and 0.8h(-1) with the increase of dilution rate. Results show that the yeast in the sMBR was able to ferment the wood hydrolyzate even at high dilution rates, attaining a maximum volumetric ethanol productivity of 7.94 ± 0.10 g L(-1)h(-1) at a dilution rate of 0.8h(-1). Ethanol yields were stable at 0.44 ± 0.02 g g(-1) during all the tested dilution rates, and the ethanol productivity increased from 2.16 ± 0.15 to 7.94 ± 0.10 g L(-1)h(-1). The developed sMBR systems running at high yeast density demonstrate a potential for a rapid and productive ethanol production from wood hydrolyzate.

Steam pretreatment of spruce forest residues: optimal conditions for biogas production and enzymatic hydrolysis

Steam refining of non-debarked spruce forest residues was investigated as pretreatment for enzymatic hydrolysis as well as for biogas production. Pretreatment conditions were varied in the range of 190-220 °C, 5-10 min and 0-3.7% SO₂ according to a statistical design. For both applications highest product yields were predicted at 220 °C and 2.4% SO₂, whereas the reaction time had only a minor influence. The conformity of the model results allows the conclusion that enzymatic hydrolysis is a suitable test method to evaluate the degradability of lignocellulosic biomass in the biogas process. In control experiments under optimal conditions the results of the model were verified. The yield of total monomeric carbohydrates after enzymatic hydrolysis was equivalent to 55% of all theoretically available polysaccharides. The corresponding biogas yield from the pretreated wood amounted to 304 mL/gODM. Furthermore, furans produced under optimal process conditions showed no inhibitory effect on biogas production. It can be concluded that steam refining opens the structure of wood, thus improving the enzymatic hydrolysis of the polysaccharides to fermentable monomeric sugars and subsequently enabling a higher and faster production of biogas. Anaerobic fermentation of pretreated wood is a serious alternative to alcoholic fermentation especially when low quality wood grades and residues are used. Anaerobic digestion should be further investigated in order to diversify the biorefinery options for lignocellulosic materials.

Pretreatment based on two-step steam explosion combined with an intermediate separation of fiber cells--optimization of fermentation of corn straw hydrolysates

Pretreatment is necessary for lignocellulose to achieve a highly efficient enzymatic hydrolysis and fermentation. However, coincident with pretreatment, compounds inhibiting microorganism growth are formed. Some tissues or cells, such as thin-walled cells that easily hydrolyze, will be excessively degraded because of the structural heterogeneity of lignocellulose, and some inhibitors will be generated under the same pretreatment conditions. Results showed, compared with one-step steam explosion (1.2 MPa/8 min), two-step steam explosion with an intermediate separation of fiber cells (ISFC) (1.1 Mpa/4 min-ISFC-1.2 MPa/4 min) can increase enzymatic hydrolyzation by 12.82%, reduce inhibitor conversion by 33%, and increase fermentation product (2,3-butanediol) conversion by 209%. Thus, the two-step steam explosion with ISFC process is proposed to optimize the hydrolysis process of lignocellulose by modifying the raw material from the origin. This novel process reduces the inhibitor content, promotes the biotransformation of lignocellulose, and simplifies the process of excluding the detoxification unit operation.

Efficient fractionation of spruce by SO(2)-ethanol-water treatment: closed mass balances for carbohydrates and sulfur

SO(2)-ethanol-water (SEW) lignocellulosic fractionation has the potential to overcome the present techno-economic barriers that hinder the commercial implementation of renewable transportation fuel production. In this study, SEW fractionation of spruce wood chips is examined for its ability to separate the main wood components, hemicelluloses, lignin, and cellulose, and the potential to recover SO(2) and ethanol from the spent fractionation liquid. Therefore, overall sulfur and carbohydrate mass balances are established. 95-97 % of the charged SO(2) remains in the liquid and can be fully recovered by distillation. During fractionation, hemicelluloses and lignin are effectively dissolved, whereas cellulose is preserved in the solid (fibre) phase. Hemicelluloses are hydrolysed, producing up to 50 % monomeric sugars, whereas dehydration and oxidation of carbohydrates are insignificant. The latter is proven by the closed carbohydrate material balances as well as by the near absence of corresponding by-products (furfural, hydroxymethylfurfural (HMF) and aldonic acids). In addition, acid methanolysis/GC and acid hydrolysis/high performance anion exchange chromatography (HPAEC) methods for the carbohydrate determination are compared.

Feedstock mixture effects on sugar monomer recovery following dilute acid pretreatment and enzymatic hydrolysis

This study seeks to investigate the effects of biomass mixtures on overall sugar recovery from the combined processes of dilute acid pretreatment and enzymatic hydrolysis. Aspen, a hardwood species well suited to biochemical processing, was chosen as the model species for this study. Balsam, a high-lignin softwood species, and switchgrass, an herbaceous energy crop with high ash content, were chosen as adjuncts. A matrix of three different dilute acid pretreatment severities and three different enzyme loading levels was used to characterize interactions between pretreatment and enzymatic hydrolysis. No synergism or antagonism was observed for any of the feedstock mixtures. Maximum glucose yield was 70% of theoretical for switchgrass and maximum xylose yield was 99.7% of theoretical for aspen. Supplemental β-glucosidase increased glucose yield from enzymatic hydrolysis by an average of 15%. Total sugar recoveries for mixtures could be predicted to within 4% by linear interpolation of the pure species results.

Evolutionary engineering strategies to enhance tolerance of xylose utilizing recombinant yeast to inhibitors derived from spruce biomass

BACKGROUND

One of the crucial factors for a sustainable and economical production of lignocellulosic based bioethanol is the availability of a robust fermenting microorganism with high tolerance to inhibitors generated during the pretreatment of lignocellulosic raw materials, since these inhibitors are known to severely hinder growth and fermentation.

RESULTS

A long-term adaptation in repetitive batch cultures in shake flasks using a cocktail of 12 different inhibitors and a long-term chemostat adaptation using spruce hydrolysate were used as evolutionary engineering strategies to improve the inhibitor tolerance in the metabolically engineered xylose utilizing Saccharomyces cerevisiae strain, TMB3400. The yeast was evolved for a period of 429 and 97 generations in repetitive batch cultures and chemostat cultivation, respectively. During the evolutionary engineering in repetitive batch cultures the maximum specific growth rate increased from 0.18 h-1 to 0.33 h-1 and the time of lag phase was decreased from 48 h to 24 h. In the chemostat adaptation, after 97 generations, the specific conversion rates of HMF and furfural were found to be 3.5 and 4 folds higher respectively, compared to rates after three generations. Two evolved strains (RK60-5, RKU90-3) and one evolved strain (KE1-17) were isolated from evolutionary engineering in repetitive batches and chemostat cultivation, respectively. The strains displayed significantly improved growth performance over TMB3400 when cultivated in spruce hydrolysate under anaerobic conditions, the evolved strains exhibited 25 to 38% increase in specific consumption rate of sugars and 32 to 50% increased specific ethanol productivity compared to TMB3400. The evolved strains RK60-5 and RKU90-3 were unable to consume xylose under anaerobic conditions, whereas, KE1-17 was found to consume xylose at similar rates as TMB3400.

CONCLUSION

Using evolutionary engineering strategies in batch and chemostat cultivations we have generated three evolved strains that show significantly better tolerance to inhibitors in spruce hydrolysate and displayed a shorter time for overall fermentation of sugars compared to the parental strain.

Ethanol production from Eucalyptus plantation thinnings

Conditions for optimal pretreatment of eucalypt (Eucalyptus dunnii) and spotted gum (Corymbia citriodora) forestry thinning residues for bioethanol production were empirically determined using a 3(3) factorial design. Up to 161mg/g xylose (93% theoretical) was achieved at moderate combined severity factors (CSF) of 1.0-1.6. At CSF>2.0, xylose levels declined, owing to degradation. Moreover at high CSF, depolymerisation of cellulose was evident and corresponded to glucose (155mg/g, ∼33% cellulose) recovery in prehydrolysate. Likewise, efficient saccharification with Cellic® CTec 2 cellulase correlated well with increasing process severity. The best condition yielded 74% of the theoretical conversion and was attained at the height of severity (CSF of 2.48). Saccharomyces cerevisiae efficiently fermented crude E. dunnii hydrolysate within 30h, yielding 18g/L ethanol, representing a glucose to ethanol conversion rate of 0.475g/g (92%). Based on our findings, eucalyptus forest thinnings represent a potential feedstock option for the emerging Australian biofuel industry.

The influence of ferrous sulfate utilization on the sugar yields from dilute-acid pretreatment of softwood for bioethanol production

By employing metal salts in dilute-acid pretreatment the severity can be reduced due to reduced activation energy. This study reports on a dilute-acid steam pretreatment of spruce chips by addition of a small amount of ferrous sulfate to the acid catalyst, i.e., either SO2, H2SO3 or H2SO4. The utilization of ferrous sulfate resulted in a slightly increased overall glucose yield (from 74% to 78% of the theoretical value) in pretreatment with SO2 and H2SO3. Impregnation with ferrous sulfate and sulfuric acid did not give any improvement compared with pretreatment based solely on H2SO4.

Improved one-step steam pretreatment of SO2-impregnated softwood with time-dependent temperature profile for ethanol production

In the production of ethanol from lignocellulosic material, pretreatment of the raw material before enzymatic hydrolysis and fermentation is essential to obtain high overall yields of sugar and ethanol. Two-step steam pretreatment results in higher ethanol yields from softwood than the standard one-step pretreatment process. However, the difficulty with separation and washing of the material at high pressure between the two pretreatment steps is a major drawback. In this study, a new one-step pretreatment procedure was investigated, in which the time-temperature profile was varied during pretreatment. The efficiency of pretreatment was assessed by performing simultaneous saccharification and fermentation on the pretreated slurries. Pretreatment of SO(2)-impregnated softwood performed by varying the temperature (190-226 degrees C), the residence time (5-10 min), and the mode of temperature increase (linear or stepwise), resulted in recovery of about 90% of the mannose and glucose present in the raw material. The highest ethanol yield, 75% of theoretical based on the glucan and mannan content of the raw material, was obtained at pretreatment conditions of 190 degrees C for 12 min. Similar ethanol yields were achieved when running the pretreatment as one-step (190-200 degrees C), two levels of temperature, at shorter residence time (7 min), which results in lower capital costs for the process.

Techno-economic evaluation of stillage treatment with anaerobic digestion in a softwood-to-ethanol process

BACKGROUND

Replacing the energy-intensive evaporation of stillage by anaerobic digestion is one way of decreasing the energy demand of the lignocellulosic biomass to the ethanol process. The biogas can be upgraded and sold as transportation fuel, injected directly into the gas grid or be incinerated on-site for combined heat and power generation. A techno-economic evaluation of the spruce-to-ethanol process, based on SO2-catalysed steam pretreatment followed by simultaneous saccharification and fermentation, has been performed using the commercial flow-sheeting program Aspen Plus™. Various process configurations of anaerobic digestion of the stillage, with different combinations of co-products, have been evaluated in terms of energy efficiency and ethanol production cost versus the reference case of evaporation.

RESULTS

Anaerobic digestion of the stillage showed a significantly higher overall energy efficiency (87-92%), based on the lower heating values, than the reference case (81%). Although the amount of ethanol produced was the same in all scenarios, the production cost varied between 4.00 and 5.27 Swedish kronor per litre (0.38-0.50 euro/L), including the reference case.

CONCLUSIONS

Higher energy efficiency options did not necessarily result in lower ethanol production costs. Anaerobic digestion of the stillage with biogas upgrading was demonstrated to be a favourable option for both energy efficiency and ethanol production cost. The difference in the production cost of ethanol between using the whole stillage or only the liquid fraction in anaerobic digestion was negligible for the combination of co-products including upgraded biogas, electricity and district heat.

Effects of enzyme feeding strategy on ethanol yield in fed-batch simultaneous saccharification and fermentation of spruce at high dry matter

BACKGROUND

To make lignocellulosic fuel ethanol economically competitive with fossil fuels, it is necessary to reduce the production cost. One way to achieve this is by increasing the substrate concentration in the production process, and thus reduce the energy demand in the final distillation of the fermentation broth. However, increased substrate concentration in simultaneous saccharification and fermentation (SSF) processes has been shown to result in reduced ethanol yields and severe stirring problems. Because the SSF medium is being continuously hydrolyzed, running the process in fed-batch mode could potentially reduce the stirring problems and lead to increased ethanol yields in high-solids SSF. Different enzyme feeding strategies, with the enzymes either present in the reactor from start-up or fed into the reactor together with the substrate, have been studied, along with the influence of the enzyme feeding strategy on the final ethanol yield and productivity.

RESULTS

In the present study, SSF was run successfully with 10% and 14% water-insoluble solids (WIS) in batch and fed-batch mode. The mixing of the material in the reactor was significantly better in fed-batch than batch mode, and similarly high or higher ethanol yields were achieved in fed-batch mode compared with batch SSF in some cases. No general trend in the dependence of ethanol yield on enzyme feeding strategy was found.

CONCLUSIONS

The optimum enzyme feeding strategy appears to depend on the conditions during SSF, such as the WIS concentration and the concentration of inhibitory compounds in the SSF medium.

Impact of impregnation time and chip size on sugar yield in pretreatment of softwood for ethanol production

Efficient pretreatment is necessary to make the wood-to-ethanol process more feasible. In this study, chips of different sizes were impregnated with SO(2) and steam-pretreated. Dilute-acid pretreatment together with subsequent enzymatic hydrolysis resulted in solubilization of between 69% and 73% of the fermentable sugars (glucose and mannose) in the raw material for the combinations of impregnation times and chip sizes investigated. Shorter impregnation times resulted in slightly lower mannose yields for the larger chips, probably due to poor diffusion of the catalyst. Small differences in glucose yield after enzymatic hydrolysis showed that the overall glucose yield was slightly higher for the smaller chips, however, whether the increased energy demand and cost of size reduction is compensated for by the higher yield, requires techno-economical evaluations.

Acid hydrolysis of hemicellulose in green liquor pre-pulping extract of mixed northern hardwoods

Forest biomass is a promising resource for future biofuels and bioproducts. Pre-pulping extraction of hemicellulose by alkaline (Green Liquor) pretreatment produces a neutral-pH extract containing hemicellulose-derived oligomers. A near-term option for use of this extract is to hydrolyze the oligomers to fermentable monomer sugars. Chips of mixed northern hardwoods were cooked in a rocking digester at 160 degrees C for 110 min in Green Liquor at a concentration of 3% Na2O equivalent salts on dry wood. The mass of wood extracted into the Green Liquor extract was approximately 11.4% of the debarked wood mass, which resulted in a dilute solution of oligomeric hemicelluloses sugars. The concentration of the extract was increased through partial evaporation prior to hydrolysis. Dilute sulfuric acid hydrolysis was applied at conditions ranging from 100 to 160 degrees C, 2% to 6% (w/v) H2SO4, and 2- to 258-min residence time. The maximum fermentable sugar concentration achieved from evaporated extract was 10.7 g/L, representing 90.7% of the maximum possible yield. Application of the biomass pretreatment severity function to the hydrolysis results proved to offer a relatively poor prediction of temperature and reaction time interaction. The combined severity function, which incorporates reaction time, temperature, and acid concentration, did prove to provide a useful means of trading off the combined effects of these three variables on total sugar yields.

The influence of solid/liquid separation techniques on the sugar yield in two-step dilute acid hydrolysis of softwood followed by enzymatic hydrolysis

BACKGROUND

Two-step dilute acid hydrolysis of softwood, either as a stand-alone process or as pretreatment before enzymatic hydrolysis, is considered to result in higher sugar yields than one-step acid hydrolysis. However, this requires removal of the liquid between the two steps. In an industrial process, filtration and washing of the material between the two steps is difficult, as it should be performed at high pressure to reduce energy demand. Moreover, the application of pressure leads to more compact solids, which may affect subsequent processing steps. This study was carried out to investigate the influence of pressing the biomass, in combination with the effects of not washing the material, on the sugar yield obtained from two-step dilute acid hydrolysis, with and without subsequent enzymatic digestion of the solids.

RESULTS

Washing the material between the two acid hydrolysis steps, followed by enzymatic digestion, resulted in recovery of 96% of the mannose and 81% of the glucose (% of the theoretical) in the liquid fraction, regardless of the choice of dewatering method (pressing or vacuum filtration). Not washing the solids between the two acid hydrolysis steps led to elevated acidity of the remaining solids during the second hydrolysis step, which resulted in lower yields of mannose, 85% and 74% of the theoretical, for the pressed and vacuum-filtered slurry, respectively, due to sugar degradation. However, this increase in acidity resulted in a higher glucose yield (94.2%) from pressed slurry than from filtered slurry (77.6%).

CONCLUSION

Pressing the washed material between the two acid hydrolysis steps had no significant negative effect on the sugar yields of the second acid hydrolysis step or on enzymatic hydrolysis. Not washing the material resulted in a harsher second acid hydrolysis step, which caused greater degradation of the sugars during subsequent acid hydrolysis of the solids, particularly in case of the vacuum-filtered solids. However, pressing in combination with not washing the material between the two steps enhanced the sugar yield of the enzymatic digestion step. Hence, it is suggested that the unwashed slurry be pressed to as high a dry matter content as possible between the two acid hydrolysis stages in order to achieve high final sugar yields.

Pretreatments to enhance the digestibility of lignocellulosic biomass

Lignocellulosic biomass represents a rather unused source for biogas and ethanol production. Many factors, like lignin content, crystallinity of cellulose, and particle size, limit the digestibility of the hemicellulose and cellulose present in the lignocellulosic biomass. Pretreatments have as a goal to improve the digestibility of the lignocellulosic biomass. Each pretreatment has its own effect(s) on the cellulose, hemicellulose and lignin; the three main components of lignocellulosic biomass. This paper reviews the different effect(s) of several pretreatments on the three main parts of the lignocellulosic biomass to improve its digestibility. Steam pretreatment, lime pretreatment, liquid hot water pretreatments and ammonia based pretreatments are concluded to be pretreatments with high potentials. The main effects are dissolving hemicellulose and alteration of lignin structure, providing an improved accessibility of the cellulose for hydrolytic enzymes.

Pretreatment of lignocellulosic wastes to improve ethanol and biogas production: a review

Lignocelluloses are often a major or sometimes the sole components of different waste streams from various industries, forestry, agriculture and municipalities. Hydrolysis of these materials is the first step for either digestion to biogas (methane) or fermentation to ethanol. However, enzymatic hydrolysis of lignocelluloses with no pretreatment is usually not so effective because of high stability of the materials to enzymatic or bacterial attacks. The present work is dedicated to reviewing the methods that have been studied for pretreatment of lignocellulosic wastes for conversion to ethanol or biogas. Effective parameters in pretreatment of lignocelluloses, such as crystallinity, accessible surface area, and protection by lignin and hemicellulose are described first. Then, several pretreatment methods are discussed and their effects on improvement in ethanol and/or biogas production are described. They include milling, irradiation, microwave, steam explosion, ammonia fiber explosion (AFEX), supercritical CO(2) and its explosion, alkaline hydrolysis, liquid hot-water pretreatment, organosolv processes, wet oxidation, ozonolysis, dilute-and concentrated-acid hydrolyses, and biological pretreatments.

Lantana camara for fuel ethanol production using thermotolerant yeast

AIM

Evaluation of Lantana camara's use as feedstock for fuel ethanol production.

METHODS AND RESULTS

Lantana camara plant material was hydrolysed with 1% sulfuric acid for 18 h at room temperature, followed by heat treatment of 121 degrees C for 20 min. Hemicellulosic hydrolyzate was separated and used for detoxification by ethyl acetate and overliming. Cellulosic fraction was hydrolysed with Aspergillus niger crude cellulase enzyme for 18 h at 55 degrees C. Using 15% (dw/v) substrate 73 g l(-1) total reducing sugars were obtained to give 78.7% hydrolysis of carbohydrate content. Acid and enzyme hydrolyzates were mixed equally and used for fermentation with thermotolerant Saccharomyces cerevisiae (VS(3)). Yeast fermented L. camara hydrolyzate well with a fermentation efficiency of 83.7% to give an ethanol yield of 0.431 +/- 0.018 g ethanol pre g sugar and productivity of 0.5 +/- 0.021 g l(-1) h(-1).

CONCLUSIONS

Even though inhibitors were present in L. camara hydrolyzate, maximum sugars were utilized by thermotolerant yeast.

SIGNIFICANCE AND IMPACT OF THE STUDY

Use of L. camara for fuel ethanol production with improved strains and detoxification can be recommended.

Substrate pretreatment: the key to effective enzymatic hydrolysis of lignocellulosics?

Although the structure and function of cellulase systems continue to be the subject of intense research, it is widely acknowledged that the rate and extent of the cellulolytic hydrolysis of lignocellulosic substrates is influenced not only by the effectiveness of the enzymes but also by the chemical, physical and morphological characteristics of the heterogeneous lignocellulosic substrates. Although strategies such as site-directed mutagenesis or directed evolution have been successfully employed to improve cellulase properties such as binding affinity, catalytic activity and thermostability, complementary goals that we and other groups have studied have been the determination of which substrate characteristics are responsible for limiting hydrolysis and the development of pretreatment methods that maximize substrate accessibility to the cellulase complex. Over the last few years we have looked at the various lignocellulosic substrate characteristics at the fiber, fibril and microfibril level that have been modified during pretreatment and subsequent hydrolysis. The initial characteristics of the woody biomass and the effect of subsequent pretreatment play a significant role on the development of substrate properties, which in turn govern the efficacy of enzymatic hydrolysis. Focusing particularly on steam pretreatment, this review examines the influence that pretreatment conditions have on substrate characteristics such as lignin and hemicellulose content, crystallinity, degree of polymerization and specific surface, and the resulting implications for effective hydrolysis by cellulases.

Liquefaction of lignocellulose at high-solids concentrations

To improve process economics of the lignocellulose to ethanol process a reactor system for enzymatic liquefaction and saccharification at high-solids concentrations was developed. The technology is based on free fall mixing employing a horizontally placed drum with a horizontal rotating shaft mounted with paddlers for mixing. Enzymatic liquefaction and saccharification of pretreated wheat straw was tested with up to 40% (w/w) initial DM. In less than 10 h, the structure of the material was changed from intact straw particles (length 1-5 cm) into a paste/liquid that could be pumped. Tests revealed no significant effect of mixing speed in the range 3.3-11.5 rpm on the glucose conversion after 24 h and ethanol yield after subsequent fermentation for 48 h. Low-power inputs for mixing are therefore possible. Liquefaction and saccharification for 96 h using an enzyme loading of 7 FPU/g.DM and 40% DM resulted in a glucose concentration of 86 g/kg. Experiments conducted at 2%-40% (w/w) initial DM revealed that cellulose and hemicellulose conversion decreased almost linearly with increasing DM. Performing the experiments as simultaneous saccharification and fermentation also revealed a decrease in ethanol yield at increasing initial DM. Saccharomyces cerevisiae was capable of fermenting hydrolysates up to 40% DM. The highest ethanol concentration, 48 g/kg, was obtained using 35% (w/w) DM. Liquefaction of biomass with this reactor system unlocks the possibility of 10% (w/w) ethanol in the fermentation broth in future lignocellulose to ethanol plants.

Acid-catalyzed steam pretreatment of lodgepole pine and subsequent enzymatic hydrolysis and fermentation to ethanol

Utilization of ethanol produced from biomass has the potential to offset the use of gasoline and reduce CO(2) emissions. This could reduce the effects of global warming, one of which is the current outbreak of epidemic proportions of the mountain pine beetle (MPB) in British Columbia (BC), Canada. The result of this is increasing volumes of dead lodgepole pine with increasingly limited commercial uses. Bioconversion of lodgepole pine to ethanol using SO(2)-catalyzed steam explosion was investigated. The optimum pretreatment condition for this feedstock was determined to be 200 degrees C, 5 min, and 4% SO(2) (w/w). Simultaneous saccharification and fermentation (SSF) of this material provided an overall ethanol yield of 77% of the theoretical yield from raw material based on starting glucan, mannan, and galactan, which corresponds to 244 g ethanol/kg raw material within 30 h. Three conditions representing low (L), medium (M), and high (H) severity were also applied to healthy lodgepole pine. Although the M severity conditions of 200 degrees C, 5 min, and 4% SO(2) were sufficiently robust to pretreat healthy wood, the substrate produced from beetle-killed (BK) wood provided consistently higher ethanol yields after SSF than the other substrates tested. BK lodgepole pine appears to be an excellent candidate for efficient and productive bioconversion to ethanol.

Pretreatment of lignocellulosic materials for efficient bioethanol production

Second-generation bioethanol produced from various lignocellulosic materials, such as wood, agricultural or forest residues, has the potential to be a valuable substitute for, or a complement to, gasoline. One of the crucial steps in the ethanol production is the hydrolysis of the hemicellulose and cellulose to monomer sugars. The most promising method for hydrolysis of cellulose to glucose is by use of enzymes, i.e. cellulases. However, in order to make the raw material accessible to the enzymes some kind of pretreatment is necessary. During the last few years a large number of pretreatment methods have been developed, comprising methods working at low pH, i.e. acid based, medium pH (without addition of catalysts), and high pH, i.e. with a base as catalyst. Many methods have been shown to result in high sugar yields, above 90% of theoretical for agricultural residues, especially for corn stover. For more recalcitrant materials, e.g. softwood, acid hydrolysis and steam pretreatment with acid catalyst seem to be the methods that can be used to obtain high sugar and ethanol yields. However, for more accurate comparison of different pretreatment methods it is necessary to improve the assessment methods under real process conditions. The whole process must be considered when a performance evaluation is to be made, as the various pretreatment methods give different types of materials. (Hemicellulose sugars can be obtained either in the liquid as monomer or oligomer sugars, or in the solid material to various extents; lignin can be either in the liquid or remain in the solid part; the composition and amount/concentration of possible inhibitory compounds also vary.) This will affect how the enzymatic hydrolysis should be performed (e.g. with or without hemicellulases), how the lignin is recovered and also the use of the lignin co-product.

Preliminary results on optimization of pilot scale pretreatment of wheat straw used in coproduction of bioethanol and electricity

The overall objective in this European Union-project is to develop cost and energy effective production systems for coproduction of bioethanol and electricity based on integrated biomass utilization. A pilot plan reactor for hydrothermal pretreatment (including weak acid hydrolysis, wet oxidation, and steam pretreatment) with a capacity of 100 kg/h was constructed and tested for pretreatment of wheat straw for ethanol production. Highest hemicellulose (C5 sugar) recovery and extraction of hemicellulose sugars was obtained at 190 degrees C whereas highest C6 sugar yield was obtained at 200 degrees C. Lowest toxicity of hydrolysates was observed at 190 degrees C; however, addition of H2O2 improved the fermentability and sugar recoveries at the higher temperatures. The estimated total ethanol production was 223 kg/t straw assuming utilisation of both C6 and C5 during fermentation, and 0.5 g ethanol/g sugar.

Effect of initial moisture content and chip size on the bioconversion efficiency of softwood lignocellulosics

Previous optimization strategies for the bioconversion of lignocellulosics by steam explosion technologies have focused on the effects of temperature, pH, and treatment time, but have not accounted for changes in severity brought about by properties inherent in the starting feedstock. Consequently, this study evaluated the effects of chip properties, feedstock size (40-mesh, 1.5 x 1.5 cm, 5 x 5 cm), and moisture content (12% and 30%) on the overall bioconversion process, and more specifically on the efficacy of removal of recalcitrant lignin from the lignocellulosic substrates following steam explosion. Increasing chip size resulted in an improvement in the solids recovery, with concurrent increases in the water soluble, hemicellulose-derived sugar recovery (7.5%). This increased recovery is a result of a decrease in the "relative severity" of the pretreatment as chip size increases. Additionally, the decreased relative severity minimized the condensation of the recalcitrant residual lignin and therefore increased the efficacy of peroxide fractionation, where a 60% improvement in lignin removal was possible with chips of larger initial size. Similarly, increased initial moisture content reduced the relative severity of the pretreatment, generating improved solids and hemicellulose-derived carbohydrate recovery. Both increased chip size and higher initial moisture content results in a substrate that performs better during peroxide delignification, and consequently enzymatic hydrolysis. Furthermore, a post steam-explosion refining step increased hemicellulose-derived sugar recovery and was most effectively delignified (to as low as 6.5%). The refined substrate could be enzymatically hydrolyzed to very high levels (98%) and relatively fast rates (1.23 g/L/h).

Carbonic acid enhancement of hydrolysis in aqueous pretreatment of corn stover

Carbonic acid and liquid hot water pretreatments were applied to corn stover. Temperatures ranged from 180 to 220 degrees C; reaction times varied between 2 and 32 min and prereaction carbon dioxide pressure was either 0 or 800 psig. Over the range of reaction conditions tested, it was found that the presence of carbonic acid had an effect of increasing the concentrations of xylose and furan compounds in the hydrolysate that was significant at above the 99% confidence level. Thus there appears to be an increase in the severity of the pretreatment conditions with the presence of carbonic acid. These results are contrary to previously reported results on aspen wood, where the presence of carbonic acid was not found to have an effect on either the xylose or furan concentrations. Although pretreatment conditions were more severe with the addition of carbonic acid, the presence of carbonic acid resulted in a hydrolysate with a higher final pH. Thus it appears that the higher severity conditions reduce the accumulation of organic acids in the hydrolysate. This result was consistent with previously reported work on carbonic acid pretreatment of aspen wood.

Characterization of degradation products from alkaline wet oxidation of wheat straw

Alkaline wet oxidation pre-treatment (water, sodium carbonate, oxygen, high temperature and pressure) of wheat straw was performed as a 2(4-1) fractional factorial design with the process parameters: temperature, reaction time, sodium carbonate and oxygen. Alkaline wet oxidation was an efficient pre-treatment of wheat straw that resulted in solid fractions with high cellulose recovery (96%) and high enzymatic convertibility to glucose (67%). Carbonate and temperature were the most important factors for fractionation of wheat straw by wet oxidation. Optimal conditions were 10 min at 195 degrees C with addition of 12 bar oxygen and 6.5 g l(-1) Na2CO3. At these conditions the hemicellulose fraction from 100 g straw consisted of soluble hemicellulose (16 g), low molecular weight carboxylic acids (11 g), monomeric phenols (0.48 g) and 2-furoic acid (0.01 g). Formic acid and acetic acid constituted the majority of degradation products (8.5 g). The main phenol monomers were 4-hydroxybenzaldehyde, vanillin, syringaldehyde. acetosyringone (4-hydroxy-3,5-dimethoxy-acetophenone), vanillic acid and syringic acid, occurring in 0.04-0.12 g per 100 g straw concentrations. High lignin removal from the solid fraction (62%) did not provide a corresponding increase in the phenol monomer content but was correlated to high carboxylic acid concentrations. The degradation products in the hemicellulose fractions co-varied with the pre-treatment conditions in the principal component analysis according to their chemical structure, e.g. diacids (oxalic and succinic acids), furan aldehydes, phenol aldehydes, phenol ketones and phenol acids. Aromatic aldehyde formation was correlated to severe conditions with high temperatures and low pH. Apart from CO2 and water, carboxylic acids were the main degradation products from hemicellulose and lignin.

Metabolic engineering of Saccharomyces cerevisiae for xylose utilization

Metabolic engineering of Saccharomyces cerevisiae for ethanolic fermentation of xylose is summarized with emphasis on progress made during the last decade. Advances in xylose transport, initial xylose metabolism, selection of host strains, transformation and classical breeding techniques applied to industrial polyploid strains as well as modeling of xylose metabolism are discussed. The production and composition of the substrates--lignocellulosic hydrolysates--is briefly summarized. In a future outlook iterative strategies involving the techniques of classical breeding, quantitative physiology, proteomics, DNA micro arrays, and genetic engineering are proposed for the development of efficient xylose-fermenting recombinant strains of S. cerevisiae.

Reduced inhibition of enzymatic hydrolysis of steam-pretreated softwood

Softwood constitutes the main source of lignocellulosic material in Sweden which can be used for ethanol production from renewable resources. To make the biomass-to-ethanol process more economically feasible, it is preferable to include the sugar-rich prehydrolysate, i.e. the liquid obtained after the pretreatment step, in the enzymatic hydrolysis of the solid fraction. This study shows that the prehydrolysate inhibits cellulose conversion in the enzymatic hydrolysis step. When the prehydrolysate was included in the enzymatic hydrolysis, the cellulose conversion was reduced by up to 36%. However, this inhibition can be overcome by fermentation of the prehydrolysate prior to enzymatic hydrolysis.

On-line control of fed-batch fermentation of dilute-acid hydrolyzates

Dilute-acid hydrolyzates from lignocellulose are, to a varying degree, inhibitory to yeast. In the present work, dilute-acid hydrolyzates from spruce, birch, and forest residue, as well as synthetic model media, were fermented by Saccharomyces cerevisiae in fed-batch cultures. A control strategy based on on-line measurement of carbon dioxide evolution (CER) was used to control the substrate feed rate in a lab scale bioreactor. The control strategy was based solely on the ratio between the relative increase in CER and the relative increase in feed rate. Severely inhibiting hydrolyzates could be fermented without detoxification and the time required for fermentation of moderately inhibiting hydrolyzates was also reduced. The feed rate approached a limiting value for inhibiting media, with a corresponding pseudo steady-state value for CER. However, a slow decrease of CER with time was found for media containing high amounts of 5-hydroxymethyl furfural (HMF). The success of the control strategy is explained by the conversion of furfural and HMF by the yeast during fed-batch operation. The hydrolyzates contained between 1.4 and 5 g/l of furfural and between 2.4 and 6.5 g/l of HMF. A high conversion of furfural was obtained (between 65-95%) at the end of the feeding phase, but the conversion of HMF was considerably lower (between 12-40%).

Effect of substrate and cellulase concentration on simultaneous saccharification and fermentation of steam-pretreated softwood for ethanol production

Economic optimization of the production of ethanol by simultaneous saccharification and fermentation (SSF) requires knowledge about the influence of substrate and enzyme concentration on yield and productivity. Although SSF has been investigated extensively, the optimal conditions for SSF of softwoods have yet not been determined. In this study, SO2-impregnated and steam-pretreated spruce was used as substrate for the production of ethanol by SSF. Commercial enzymes were used in combination with the yeast Saccharomyces cerevisiae. The effects of the concentration of substrate (2% to 10% w/w) and of cellulases (5 to 32 FPU/g cellulose) were investigated. SSF was found to be sensitive to contamination because lactic acid was produced. The ethanol yield increased with increasing cellulase loading. The highest ethanol yield, 68% of the theoretical based on the glucose and mannose present in the original wood, was obtained at 5% substrate concentration. This yield corresponds to 82% of the theoretical based on the cellulose and soluble glucose and mannose present at the start of SSF. A higher substrate concentration caused inefficient fermentation, whereas a lower substrate concentration, 2%, resulted in increased formation of lactic acid, which lowered the yield. Compared with separate hydrolysis and fermentation, SSF gave a higher yield and doubled the productivity.

Ethanol production from renewable resources

Vast amounts of renewable biomass are available for conversion to liquid fuel, ethanol. In order to convert biomass to ethanol, the efficient utilization of both cellulose-derived and hemicellulose-derived carbohydrates is essential. Six-carbon sugars are readily utilized for this purpose. Pentoses, on the other hand, are more difficult to convert. Several metabolic factors limit the efficient utilization of pentoses (xylose and arabinose). Recent developments in the improvement of microbial cultures provide the versatility of conversion of both hexoses and pentoses to ethanol more efficiently. In addition, novel bioprocess technologies offer a promising prospective for the efficient conversion of biomass and recovery of ethanol.