Ethanol production from corn stover hemicellulosic hydrolysate using immobilized recombinant yeast cells

An overview on fermentation strategies to overcome lignocellulosic inhibitors in second-generation ethanol production using cell immobilization

The development of technologies to ferment carbohydrates (mainly glucose and xylose) obtained from the hydrolysis of lignocellulosic biomass for the production of second-generation ethanol (2G ethanol) has many economic and environmental advantages. The pretreatment step of this biomass is industrially performed mainly by steam explosion with diluted sulfuric acid and generates hydrolysates that contain inhibitory compounds for the metabolism of microorganisms, harming the next step of ethanol production. The main inhibitors are: organic acids, furan, and phenolics. Several strategies can be applied to decrease the action of these compounds in microorganisms, such as cell immobilization. Based on data published in the literature, this overview will address the relevant aspects of cell immobilization for the production of 2G ethanol, aiming to evaluate this method as a strategy for protecting microorganisms against inhibitors in different modes of operation for fermentation. This is the first overview to date that shows the relation between inhibitors, cells immobilization, and fermentation operation modes for 2G ethanol. In this sense, the state of the art regarding the main inhibitors in 2G ethanol and the most applied techniques for cell immobilization, besides batch, repeated batch and continuous fermentation using immobilized cells, in addition to co-culture immobilization and co-immobilization of enzymes, are presented in this work.

Current status of metabolic engineering of microorganisms for bioethanol production by effective utilization of pentose sugars of lignocellulosic biomass

Lignocellulosic biomass, consisting of homo- and heteropolymeric sugars, acts as a substrate for the generation of valuable biochemicals and biomaterials. The readily available hexoses are easily utilized by microbes due to the presence of transporters and native metabolic pathways. But, utilization of pentose sugar viz., xylose and arabinose are still challenging due to several reasons including (i) the absence of the particular native pathways and transporters, (ii) the presence of inhibitors, and (iii) lower uptake of pentose sugars. These challenges can be overcome by manipulating metabolic pathways/glycosidic enzymes cascade by using genetic engineering tools involving inverse-metabolic engineering, ex-vivo isomerization, Adaptive Laboratory Evolution, Directed Metabolic Engineering, etc. Metabolic engineering of bacteria and fungi for the utilization of pentose sugars for bioethanol production is the focus area of research in the current decade. This review outlines current approaches to biofuel development and strategies involved in the metabolic engineering of different microbes that can uptake pentose for bioethanol production.

Enhanced enzymatic saccharification and ethanol production of corn stover via pretreatment with urea and steam explosion

Enhancing the degradation of lignocellulosic structure is essential for the efficient use of corn stover. This study investigated the effects of using urea combined with steam explosion on the enzymatic hydrolysis and ethanol production of corn stover. The results demonstrated that 4.87% urea addition and 1.22 MPa steam pressure were optimal for ethanol production. The highest reducing sugar yield (350.12 mg/g) was increased by 116.42% (p < 0.05), and the corresponding degradation rates of cellulose, hemicellulose, and lignin in pretreated corn stover were increased by 40.26%, 45.89% and 53.71% compared with the untreated corn stover (p < 0.05). Moreover, the maximal sugar alcohol conversion rate was approximately 48.3%, and the ethanol yield reached 66.5%. In addition, the key functional groups in corn stover lignin under combined pretreatment were identified. These findings offer new insights into corn stover pretreatment and can help develop feasible technologies to enhance ethanol production.

Bread waste - A potential feedstock for sustainable circular biorefineries

The management of staggering volume of food waste generated (∼1.3 billion tons) is a serious challenge. The readily available untapped food waste can be promising feedstock for setting up biorefineries and one good example is bread waste (BW). The current review emphasis on capability of BW as feedstock for sustainable production of platform and commercially important chemicals. It describes the availability of BW (>100 million tons) to serve as a feedstock for sustainable biorefineries followed by examples of platform chemicals which have been produced using BW including ethanol, lactic acid, succinic acid and 2,3-butanediol through biological route. The BW-based production of these metabolites is compared against 1G and 2G (lignocellulosic biomass) feedstocks. The review also discusses logistic and supply chain challenges associated with use of BW as feedstock. Towards the end, it is concluded with a discussion on life cycle analysis of BW-based production and comparison with other feedstocks.

Hemicellulosic Bioethanol Production from Fast-Growing Paulownia Biomass

In order to exploit a fast-growing Paulownia hardwood as an energy crop, a xylose-enriched hydrolysate was obtained in this work to increase the ethanol concentration using the hemicellulosic fraction, besides the already widely studied cellulosic fraction. For that, Paulownia elongata x fortunei was submitted to autohydrolysis treatment (210 °C or S0 of 4.08) for the xylan solubilization, mainly as xylooligosaccharides. Afterwards, sequential stages of acid hydrolysis, concentration, and detoxification were evaluated to obtain fermentable sugars. Thus, detoxified and non-detoxified hydrolysates (diluted or not) were fermented for ethanol production using a natural xylose-consuming yeast, Scheffersomyces stipitis CECT 1922, and an industrial Saccharomyces cerevisiae MEC1133 strain, metabolic engineered strain with the xylose reductase/xylitol dehydrogenase pathway. Results from fermentation assays showed that the engineered S. cerevisiae strain produced up to 14.2 g/L of ethanol (corresponding to 0.33 g/g of ethanol yield) using the non-detoxified hydrolysate. Nevertheless, the yeast S. stipitis reached similar values of ethanol, but only in the detoxified hydrolysate. Hence, the fermentation data prove the suitability and robustness of the engineered strain to ferment non-detoxified liquor, and the appropriateness of detoxification of liquor for the use of less robust yeast. In addition, the success of hemicellulose-to-ethanol production obtained in this work shows the Paulownia biomass as a suitable renewable source for ethanol production following a suitable fractionation process within a biorefinery approach.

Encapsulation enhances protoplast fusant stability

A barrier to cost‐efficient biomanufacturing is the instability of engineered genetic elements, such as plasmids. Instability can also manifest at the whole‐genome level, when fungal dikaryons revert to parental species due to nuclear segregation during cell division. Here, we show that by encapsulating Saccharomyces cerevisiae‐Pichia stipitis dikaryons in an alginate matrix, we can limit cell division and preserve their expanded metabolic capabilities. As a proxy to cellulosic ethanol production, we tested the capacity of such cells to carry out ethanologenic fermentation of glucose and xylose, examining substrate use, ploidy, and cell viability in relation to planktonic fusants, as well as in relation to planktonic and encapsulated cell cultures consisting of mixtures of these species. Glucose and xylose consumption and ethanol production by encapsulated dikaryons were greater than planktonic controls. Simultaneous co‐fermentation did not occur; rather the order and kinetics of glucose and xylose catabolism by encapsulated dikaryons were similar to cultures where the two species were encapsulated together. Over repeated cycles of fed‐batch culture, encapsulated S. cerevisiae‐P. stipitis fusants exhibited a dramatic increase in genomic stability, relative to planktonic fusants. Encapsulation also increased the stability of antibiotic‐resistance plasmids used to mark each species and preserved a fixed ratio of S. cerevisiae to P. stipitis cells in mixed cultures. Our data demonstrate how encapsulating cells in an extracellular matrix restricts cell division and, thereby, preserves the stability and biological activity of entities ranging from genomes to plasmids to mixed populations, each of which can be essential to cost‐efficient biomanufacturing.

Alkaline Active Hemicellulases

Xylan and mannan are the two most abundant hemicelluloses, and enzymes that modify these polysaccharides are prominent hemicellulases with immense biotechnological importance. Among these enzymes, xylanases and mannanases which play the vital role in the hydrolysis of xylan and mannan, respectively, attracted a great deal of interest. These hemicellulases have got applications in food, feed, bioethanol, pulp and paper, chemical, and beverage producing industries as well as in biorefineries and environmental biotechnology. The great majority of the enzymes used in these applications are optimally active in mildly acidic to neutral range. However, in recent years, alkaline active enzymes have also become increasingly important. This is mainly due to some benefits of utilizing alkaline active hemicellulases over that of neutral or acid active enzymes. One of the advantages is that the alkaline active enzymes are most suitable to applications that require high pH such as Kraft pulp delignification, detergent formulation, and cotton bioscouring. The other benefit is related to the better solubility of hemicelluloses at high pH. Since the efficiency of enzymatic hydrolysis is often positively correlated to substrate solubility, the hydrolysis of hemicelluloses can be more efficient if performed at high pH. High pH hydrolysis requires the use of alkaline active enzymes. Moreover, alkaline extraction is the most common hemicellulose extraction method, and direct hydrolysis of the alkali-extracted hemicellulose could be of great interest in the valorization of hemicellulose. Direct hydrolysis avoids the time-consuming extensive washing, and neutralization processes required if non-alkaline active enzymes are opted to be used. Furthermore, most alkaline active enzymes are relatively active in a wide range of pH, and at least some of them are significantly or even optimally active in slightly acidic to neutral pH range. Such enzymes can be eligible for non-alkaline applications such as in feed, food, and beverage industries.This chapter largely focuses on the most important alkaline active hemicellulases, endo-β-1,4-xylanases and β-mannanases. It summarizes the relevant catalytic properties, structural features, as well as the real and potential applications of these remarkable hemicellulases in textile, paper and pulp, detergent, feed, food, and prebiotic producing industries. In addition, the chapter depicts the role of these extremozymes in valorization of hemicelluloses to platform chemicals and alike in biorefineries. It also reviews hemicelluloses and discusses their biotechnological importance.

Critical factors affecting ethanol production by immobilized Pichia stipitis using corn cob hemicellulosic hydrolysate

Fermentation of xylose from hydrolysate of acid-treated corn cob by Pichia stipitis is inhibited by acetic acid and lignin derivatives. In the present study, we have designed and implemented an immobilized cell culture for xylose to ethanol conversion from acid-treated corn cob hydrolysate without the removal of fermentation inhibitors. In this study, cultivations of suspended and immobilized Pichia were compared in terms of ethanol yield and productivity to investigate whether the cell immobilization could improve resistance to inhibitors. Cell immobilization clearly favored the fermentative metabolism in nondetoxified corn cob hydrolysate leading to an improvement of twofold ethanol productivity as compared to that achieved with suspension culture. Calcium alginate as an immobilization matrix was selected to immobilize Pichia cells. Concentrations of sodium alginate, calcium chloride, and fermentor agitation speed were optimized for ethanol production using statistical method. Statistical analysis showed that agitation speed had maximum influence on ethanol production by immobilized Pichia cells. In comparison to suspension culture, immobilization had a positive impact on the fermentative metabolism of Pichia, improving the ethanol yield from 0.40 to 0.43 g/g and productivity from 0.31 to 0.51 g/L/h for acid-treated corn cob hydrolysate.

Recent trends in bioethanol production from food processing byproducts

The widespread use of corn starch and sugarcane as sources of sugar for the production of ethanol via fermentation may negatively impact the use of farmland for production of food. Thus, alternative sources of fermentable sugars, particularly from lignocellulosic sources, have been extensively investigated. Another source of fermentable sugars with substantial potential for ethanol production is the waste from the food growing and processing industry. Reviewed here is the use of waste from potato processing, molasses from processing of sugar beets into sugar, whey from cheese production, byproducts of rice and coffee bean processing, and other food processing wastes as sugar sources for fermentation to ethanol. Specific topics discussed include the organisms used for fermentation, strategies, such as co-culturing and cell immobilization, used to improve the fermentation process, and the use of genetic engineering to improve the performance of ethanol producing fermenters.

Xylose Fermentation by Saccharomyces cerevisiae: Challenges and Prospects

Many years have passed since the first genetically modified Saccharomyces cerevisiae strains capable of fermenting xylose were obtained with the promise of an environmentally sustainable solution for the conversion of the abundant lignocellulosic biomass to ethanol. Several challenges emerged from these first experiences, most of them related to solving redox imbalances, discovering new pathways for xylose utilization, modulation of the expression of genes of the non-oxidative pentose phosphate pathway, and reduction of xylitol formation. Strategies on evolutionary engineering were used to improve fermentation kinetics, but the resulting strains were still far from industrial application. Lignocellulosic hydrolysates proved to have different inhibitors derived from lignin and sugar degradation, along with significant amounts of acetic acid, intrinsically related with biomass deconstruction. This, associated with pH, temperature, high ethanol, and other stress fluctuations presented on large scale fermentations led the search for yeasts with more robust backgrounds, like industrial strains, as engineering targets. Some promising yeasts were obtained both from studies of stress tolerance genes and adaptation on hydrolysates. Since fermentation times on mixed-substrate hydrolysates were still not cost-effective, the more selective search for new or engineered sugar transporters for xylose are still the focus of many recent studies. These challenges, as well as under-appreciated process strategies, will be discussed in this review.

Optimization of Bioethanol Production Using Whole Plant of Water Hyacinth as Substrate in Simultaneous Saccharification and Fermentation Process

Water hyacinth was used as substrate for bioethanol production in the present study. Combination of acid pretreatment and enzymatic hydrolysis was the most effective process for sugar production that resulted in the production of 402.93 mg reducing sugar at optimal condition. A regression model was built to optimize the fermentation factors according to response surface method in saccharification and fermentation (SSF) process. The optimized condition for ethanol production by SSF process was fermented at 38.87°C in 81.87 h when inoculated with 6.11 ml yeast, where 1.291 g/L bioethanol was produced. Meanwhile, 1.289 g/L ethanol was produced during experimentation, which showed reliability of presented regression model in this research. The optimization method discussed in the present study leading to relatively high bioethanol production could provide a promising way for Alien Invasive Species with high cellulose content.

Hemicellulosic ethanol production by immobilized cells of Scheffersomyces stipitis: effect of cell concentration and stirring

Bioconversion of hemicellulosic hydrolysate into ethanol plays a pivotal role in the overall success of biorefineries. For the efficient fermentative conversion of hemicellulosic hydrolysates into ethanol, the use of immobilized cells system could provide the enhanced ethanol productivities with significant time savings. Here, we investigated the effect of 2 important factors (e.g., cell concentration and stirring) on ethanol production from sugarcane bagasse hydrolysate using the yeast Scheffersomyces stipitis immobilized in calcium alginate matrix. A 2(2) full factorial design of experiment was performed considering the process variables- immobilized cell concentration (3.0, 6.5 and 10.0 g/L) and stirring (100, 200 and 300 rpm). Statistical analysis showed that stirring has the major influence on ethanol production. Maximum ethanol production (8.90 g/l) with ethanol yield (Yp/s) of 0.33 g/g and ethanol productivity (Qp) of 0.185 g/l/h was obtained under the optimized process conditions (10.0 g/L of cells and 100 rpm).

Pilot-scale production of fuel ethanol from concentrated food waste hydrolysates using Saccharomyces cerevisiae H058

The aim of this study was to develop a bioprocess to produce ethanol from food waste at laboratory, semipilot and pilot scales. Laboratory tests demonstrated that ethanol fermentation with reducing sugar concentration of 200 g/L, inoculum size of 2 % (Initial cell number was 2 × 10⁶ CFU/mL) and addition of YEP (3 g/L of yeast extract and 5 g/L of peptone) was the best choice. The maximum ethanol concentration in laboratory scale (93.86 ± 1.15 g/L) was in satisfactory with semipilot scale (93.79 ± 1.11 g/L), but lower than that (96.46 ± 1.12 g/L) of pilot-scale. Similar ethanol yield and volumetric ethanol productivity of 0.47 ± 0.02 g/g, 1.56 ± 0.03 g/L/h and 0.47 ± 0.03 g/g, 1.56 ± 0.03 g/L/h after 60 h of fermentation in laboratory and semipilot fermentors, respectively, however, both were lower than that (0.48 ± 0.02 g/g, 1.79 ± 0.03 g/L/h) of pilot reactor. In addition, simple models were developed to predict the fermentation kinetics during the scale-up process and they were successfully applied to simulate experimental results.

Immobilization of Saccharomyces cerevisiae on to modified carboxymethylcellulose for production of ethanol

In this work, modified carboxymethylcellulose (CMC) was used as a new support material for production of ethanol. Crosslinked graft copolymers of CMC with N-vinyl-2-pyrrolidone (N-VP) were prepared in different grafting yields. The beads material was characterized by means of fourier transform infrared spectroscopy (FT-IR), differential scanning calorimetry (DSC), scanning electron microscope (SEM) and swelling experiment. Saccharomyces cerevisiae was immobilized using entrapment method in the graft copolymers of carboxymethylcellulose-g-poly(N-vinyl-2-pyrrolidone) (CMC-g-PVP) for ethanol fermentation. The effects of grafting yield, initial glucose concentration and crosslinker concentration on the yield of ethanol process were investigated. Reusability of the immobilized yeasts was investigated and found that the materials can be used four times without losing their activity. Ethanol production increased to 59.3 g/L from 46.4 g/L when percentage of N-VP in the graft copolymer was increased. The highest ethanol productivity was found to be 1.75-2.25 g/L h. Fermentation time decreased with the decreasing of crosslinker concentration. The results suggest that the proposed method for immobilization of Saccharomyces cerevisiae has potential in industrial applications for ethanol process.

Fuels and chemicals from hemicellulose sugars

Industrial processes of lignocellulosic material have made use of only the hexose component of the cellulose fraction. Pentoses and some minor hexoses present in the hemicellulose fraction, which may represent as much as 40% of lignocellulosic biomass, have in most cases been wasted. The lack of good methods for utilization of hemicellulose sugars is a key obstacle hindering the development of lignocellulose-based ethanol and other biofuels. In this chapter, we focus on the utilization of hemicellulose sugars, the structure of hemicellulose and its hydrolysis, and the biochemistry and process technology involved in their conversion to valuable fuels and chemicals.