Process simulation of modified dry grind ethanol plant with recycle of pretreated and enzymatically hydrolyzed distillers' grains

Inhibition of cellulase activity by liquid hydrolysates from hydrothermally pretreated soybean straw

The one-pot biomass conversion process is a promising strategy to minimize potential product loss and reduce processing costs. However, this strategy has technical limitations due to the inhibitory effects of biomass components like lignin as well as the generated inhibitors (e.g., furans, phenols) during biomass processing. In this study, the inhibitory effects of liquid hydrolysates formed by hydrothermal pretreatment of soybean straw with either sodium hydroxide (NaOH) or hydrogen peroxide (H2O2) on cellulolytic enzyme activity were investigated. Hydrothermal pretreatment of soybean straw (10% w/v) was carried out with either sodium hydroxide (1% v/v) or hydrogen peroxide (1% v/v) at 121°C for 60 min to evaluate the effect of water-soluble inhibitors released from soybean pretreatment on cellulolytic enzyme activity. The fraction of cellulose in pretreated solids (1% w/v glucan) was enzymatically hydrolyzed for 72 h with 45 IU/g glucan (corresponding to 25 mg enzyme protein/g glucan) in the presence of either buffer or liquid hydrolysate generated from the pretreatments. Hydrolysis of NaOH and H2O2 pretreated solids resulted in 57% and 39% of glucose yields in buffer, respectively. In the presence of the liquid hydrolysates, NaOH and H2O2 pretreated biomass showed 20% and 30% glucose yield, respectively, indicating the enzyme suppression by inhibitors in the liquid hydrolysates. Of the enzyme activities in hydrolysates tested, NaOH hydrolysate showed a higher inhibitory effect on enzyme activities (mainly β-glucosidase) compared to H2O2 liquid, where enzyme deactivation has a first-order correlation and the manner in which the vacuum-filtered inhibitors were generated from pretreated soybean straw.

Enhancing the Enzymatic Saccharification of Grain Stillage by Combining Microwave-Assisted Hydrothermal Irradiation and Fungal Pretreatment

Grain stillage from the liquor industry was pretreated by using microwave-assisted hydrothermal pretreatment, fungal pretreatments, and their combination to enable efficient enzymatic hydrolysis for sugar production. The microwave-assisted hydrothermal (MH) pretreatment was optimized by using a response surface methodology, and the respective maximum reducing sugar yield and saccharification efficiency of 17.59 g/100 g and 33.85%, respectively, were achieved under the pretreatment conditions of microwave power = 120 W, solid-to-liquid ratio = 1:15 (g·mL^-1), and time = 3.5 min. The fungal pretreatment with Phanerochaete chrysosporium digestion (PC) achieved the maximum ligninolytic enzyme activities in 6 days with 10% inoculum size at which the reducing sugar yield and saccharification efficiency reached 19.74 g/100 g and 36.29%, respectively. To further improve the pretreatment efficiency, MH and PC pretreatments were combined, but the sequence of MH and PC mattered on the saccharification efficiency. The MH + PC pretreatment (the MH prior to the PC) was better than PC + MH (the PC prior to the MH) in terms of saccharification efficiency. Overall, the MH + PC pretreatment achieved superior reducing sugar yield and saccharification efficiency (25.51 g/100 g and 66.28%, respectively) over all other studied pretreatment methods. The variations of chemical compositions and structure features of the raw and pretreated grain stillage were characterized by using scanning electron microscopy and Fourier transform infrared spectroscopy. The results reveal that both MH and PC pretreatments mainly functioned on delignification and decreasing cellulose crystallinity, thus enhancing the enzymatic saccharification of the pretreated grain stillage. The combined MH and PC pretreatment could be a promising method to enable cost-efficient grain stillage utilization for downstream applications such as biofuels.

Cellulose conversion of corn pericarp without pretreatment

We report enzyme hydrolysis of cellulose in unpretreated pericarp at a cellulase loading of 0.25FPU/g pericarp solids using a phenol tolerant Aspergillus niger pectinase preparation. The overall protein added was 5mg/g and gave 98% cellulose conversion in 72h. However, for double the amount of enzyme from Trichoderma reesei, which is significantly less tolerant to phenols, conversion was only 16%. The key to achieving high conversion without pretreatment is combining phenol inhibition-resistant enzymes (such as from A. niger) with unground pericarp from which release of phenols is minimal. Size reduction of the pericarp, which is typically carried out in a corn-to-ethanol process, where corn is first ground to a fine powder, causes release of highly inhibitory phenols that interfere with cellulase enzyme activity. This work demonstrates hydrolysis without pretreatment of large particulate pericarp is a viable pathway for directly producing cellulose ethanol in corn ethanol plants.

Enhanced fermentability of poplar by combination of alkaline peroxide pretreatment and semi-simultaneous saccharification and fermentation

To improve ethanol productivity with few inhibitors generated, a novel process of combined alkaline peroxide (AP) pretreatment and semi-simultaneous saccharification and fermentation (SSSF) was developed in this work. Pretreatment with 10% (g H2O2/g wood) H2O2 at 160°C for 2h followed by SSSF was found to be the optimal combination with remarkably increased ethanol yield. The proposed process resulted in 63.1% of ethanol yield, which was about five times more than that of the untreated sample that was processed using conventional simultaneous saccharification and fermentation (SSF). The efficient conversion was ascribed to the high delignification efficiency (64.9%) of AP pretreatment, which led to incompact structure and generation of fewer inhibitors during SSSF (c. 6g/L of lactic acid) than SSF (c. 10 g/L of lactic acid). This combined approach was proved to be an effective method for the promotion of the bioconversion of lignocellulosic materials.

Utilization of dry distiller's grain and solubles as nutrient supplement in the simultaneous saccharification and ethanol fermentation at high solids loading of corn stover

Dry distiller's grain and solubles (DDGS) is a major by-product of corn-based ethanol production and is usually used as animal feed. Here, it was added to the simultaneous saccharification and ethanol fermentation (SSF) carried out at high solids loading of steam explosion pretreated corn stover using a mutant strain Saccharomyces cerevisiae DQ1. The performance of SSF process with DDGS was comparable to those using the expensive yeast extract supplementation. With 30% (w/w) solids plus the addition of cellulase and 1g DDGS l(-1), the final ethanol reached 55 g l(-1) (7% v/v). The results indicated that the expensive supplement of yeast extract could be replaced by DDGS.

Economic Analysis of the Production of Amylases and Other Hydrolases by Aspergillus awamori in Solid-State Fermentation of Babassu Cake

Amylases are one of the most important industrial enzymes produced worldwide, with their major application being in ethanol manufacturing. This work investigated the production of amylases by solid-state fermentation of babassu cake, using the filamentous fungus Aspergillus awamori IOC-3914. Lab-scale experiments were carried out to generate input data for simulations of an industrial plant for amylase production. Additionally to the target enzymes, other hydrolases (cellulases, xylanases, and proteases) were also produced, enriching the final product. The most suitable fermentation time was 144 hours, when exoamylase and endoamylase activities of 40.5 and 42.7 U g⁻¹ were achieved, respectively. A first evaluation showed a large impact of the inoculum propagation medium on production costs. Therefore, five propagation media were compared, and PDA medium presented the best cost-benefit ratio. The credits obtained from sales of fermented cake as a coproduct enabled a significant decrease in the production cost of the enzyme product, down to 10.40 USD kg⁻¹.

Dilute-acid pretreatment of distillers' grains and corn fiber

Distillers' grains and corn fiber are the coproducts of the dry grind and wet corn milling industries, respectively. Availability of distillers' grains and corn fiber at the ethanol plant and their high levels of lignocellulosic material make them attractive feedstock for conversion to ethanol. In this study, dilute sulfuric acid hydrolysis for the conversion of distillers' grains and corn fiber to monomeric sugars and the formation of furfural were investigated. The extent of solubilization of biomass beyond monomeric sugars was also monitored. Biomass loadings in the range of 5-20 wt.% at 5% intervals, acid concentrations in the range of 0.5-1.5 vol.% at 0.5% intervals, and temperatures of 120 and 140 degrees C were studied. The highest yields of monomeric sugars were observed when the least amount of biomass loading was pretreated with the highest concentration of sulfuric acid and when the temperature was 140 degrees C. For the majority of the cases under consideration, the most effective period of hydrolysis appeared to be during the initial 20-30 min of the reaction. Formation of furfural during the course of hydrolysis was significantly lower at 120 degrees C and also lower for the distillers' grains samples compared with the corn fiber samples. The total amount of the solubilized matter during the hydrolysis was significantly higher than the amount of the monomeric sugars. Analyses according to standard procedure were performed to quantify moisture, oil, carbohydrates, and ash in distillers' grains and corn fiber samples. The total carbohydrate content of distillers' grains and corn fiber were 57.7+/-2.0 and 77.0+/-1.0 wt.%, respectively. The presented results will provide a foundation for the suitability of the pretreated distillers' grains and corn fiber for enzymatic hydrolysis step.

Integrating alkaline extraction of proteins with enzymatic hydrolysis of cellulose from wet distiller's grains and solubles

Fractionation of distiller's grains into value added products may serve to improve the economic viability of dry grind corn ethanol facilities in the wake of variable corn and ethanol prices. This research is aimed at creating a high protein, high lysine product from the grain using alkaline protein extractions in conjunction with hydrolysis of the remaining fiber to sugars which are then fermented to ethanol. Alkaline extractions improved the lysine content in protein products, although protein solubility did not exceed 45% of the total protein. In addition, oligomeric carbohydrates, starch, and other water solubles were also extracted, leading to a low purity protein product. Resulting sugar yields following ammonia fiber expansion (AFEX) pretreatment were also lower for extracted distiller's grains. From these experiments, it does not appear likely that alkaline extraction is a useful tool for fractionation of distiller's grains. However, pretreatment and hydrolysis can be an effective tool for further fractionation of protein.

Enzyme characterization for hydrolysis of AFEX and liquid hot-water pretreated distillers' grains and their conversion to ethanol

Dried distillers' grains with solubles (DDGS), a co-product of corn ethanol production, was investigated as a feedstock for additional ethanol production. DDGS was pretreated with liquid hot-water (LHW) and ammonia fiber explosion (AFEX) processes. Cellulose was readily converted to glucose from both LHW and AFEX treated DDGS using a mixture of commercial cellulase and beta-glucosidase; however, these enzymes were ineffective at saccharifying the xylan present in the pretreated DDGS. Several commercial enzyme preparations were evaluated in combination with cellulase to saccharify pretreated DDGS xylan and it was found that adding commercial grade (e.g. impure) pectinase and feruloyl esterase (FAE) preparations were effective at releasing arabinose and xylose. The response of sugar yields for pretreated AFEX and LHW DDGS (6wt%/solids) were determined for different enzyme loadings of FAE and pectinase and modeled as a response surfaces. Arabinose and xylose yields rose with increasing FAE and pectinase enzyme dosages for both pretreated materials. When hydrolyzed at 20wt%/solids with the same blend of commercial enzymes, the yields were 278 and 261g sugars (i.e. total of arabinose, xylose, and glucose) per kg of DDGS (dry basis, db) for AFEX and LHW pretreated DDGS, respectively. The pretreated DDGS's were also evaluated for fermentation using Saccharomyces cerevisiae at 15wt%/solids. Pretreated DDGS were readily fermented and were converted to ethanol at 89-90% efficiency based upon total glucans; S. cerevisiae does not ferment arabinose or xylose.

Water solubilization of DDGS via derivatization with phosphite esters

Ethanol production from corn starch in the corn dry milling process leaves Distillers' Dry Grains and Solubles (DDGS) as a major by-product from which additional ethanol may be economically obtained from its glucan content. A challenge in processing the cellulose content of this material lies in its extensive inter-cellulose chain hydrogen bonding, which inhibits access of enzymes capable of cleaving glycosidic bonds, a transformation required for providing fermentable sugars. The phosphitylation of cellulosic OH groups using a reactive bicyclic phosphite ester is utilized to disrupt cellulosic hydrogen bonds, thus providing access to cellulose chains for further processing. We describe a method of pretreating DDGS with commercially available trimethylolpropane phosphite [P(OCH2)3CEt] in the presence of a slight molar excess of water to afford greater than 90% DDGS solubility in the reaction mixture in methanol and in water. Preliminary results using a model compound [D-(+)-permethylated cellobiose] indicate that glycosidic bonds are cleaved as a consequence of this pretreatment.

Life cycle assessment of fuel ethanol derived from corn grain via dry milling

Life cycle analysis enables to investigate environmental performance of fuel ethanol used in an E10 fueled compact passenger vehicle. Ethanol is derived from corn grain via dry milling. This type of analysis is an important component for identifying practices that will help to ensure that a renewable fuel, such as ethanol, may be produced in a sustainable manner. Based on data from eight counties in seven Corn Belt states as corn farming sites, we show ethanol derived from corn grain as E10 fuel would reduce nonrenewable energy and greenhouse gas emissions, but would increase acidification, eutrophication and photochemical smog, compared to using gasoline as liquid fuel. The ethanol fuel systems considered in this study offer economic benefits, namely more money returned to society than the investment for producing ethanol. The environmental performance of ethanol fuel system varies significantly with corn farming sites because of different crop management practices, soil properties, and climatic conditions. The dominant factor determining most environmental impacts considered here (i.e., greenhouse gas emissions, acidification, eutrophication, and photochemical smog formation) is soil related nitrogen losses (e.g., N2O, NOx, and NO3-). The sources of soil nitrogen include nitrogen fertilizer, crop residues, and air deposition. Nitrogen fertilizer is probably the primary source. Simulations using an agro-ecosystem model predict that planting winter cover crops would reduce soil nitrogen losses and increase soil organic carbon levels, thereby greatly improving the environmental performance of the ethanol fuel system.

Cellulose conversion in dry grind ethanol plants

The expansion of the dry grind ethanol industry provides a unique opportunity to introduce cellulose conversion technology to existing grain to ethanol plants, while enhancing ethanol yields by up to 14%, and decreasing the volume while increasing protein content of distiller's grains. The technologies required are cellulose pretreatment, enzyme hydrolysis, fermentation, and drying. Laboratory data combined with compositional analysis and process simulations are used to present a comparative analysis of a dry grind process to a process with pretreatment and hydrolysis of cellulose in distiller's grains. The additional processing steps are projected to give a 32% increase in net present value if process modifications are made to a 100 million gallon/year plant.

Enzyme hydrolysis and ethanol fermentation of liquid hot water and AFEX pretreated distillers' grains at high-solids loadings

The dry milling ethanol industry produces distiller's grains as major co-products, which are composed of unhydrolyzed and unfermented polymeric sugars. Utilization of the distiller's grains as an additional source of fermentable sugars has the potential to increase overall ethanol yields in current dry grind processes. In this study, controlled pH liquid hot water pretreatment (LHW) and ammonia fiber expansion (AFEX) treatment have been applied to enhance enzymatic digestibility of the distiller's grains. Both pretreatment methods significantly increased the hydrolysis rate of distiller's dried grains with solubles (DDGS) over unpretreated material, resulting in 90% cellulose conversion to glucose within 24h of hydrolysis at an enzyme loading of 15FPU cellulase and 40 IU beta-glucosidase per gram of glucan and a solids loading of 5% DDGS. Hydrolysis of the pretreated wet distiller's grains at 13-15% (wt of dry distiller's grains per wt of total mixture) solids loading at the same enzyme reduced cellulose conversion to 70% and increased conversion time to 72h for both LHW and AFEX pretreatments. However, when the cellulase was supplemented with xylanase and feruloyl esterase, the pretreated wet distiller's grains at 15% or 20% solids (w/w) gave 80% glucose and 50% xylose yields. The rationale for supplementation of cellulases with non-cellulolytic enzymes is given by Dien et al., later in this journal volume. Fermentation of the hydrolyzed wet distiller's grains by glucose fermenting Saccharomyces cerevisiae ATCC 4124 strain resulted in 100% theoretical ethanol yields for both LHW and AFEX pretreated wet distiller's grains. The solids remaining after fermentation had significantly higher protein content and are representative of a protein-enhanced wet DG that would result in enhanced DDGS. Enhanced DDGS refers to the solid product of a modified dry grind process in which the distiller's grains are recycled and processed further to extract the unutilized polymeric sugars. Compositional changes of the laboratory generated enhanced DDGS are also presented and discussed.

Fermentation of dried distillers' grains and solubles (DDGS) hydrolysates to solvents and value-added products by solventogenic clostridia

Pretreatment and hydrolysis of lignocellulosic biomass using either dilute acid, liquid hot water (LHW), or ammonium fiber expansion (AFEX) results in a complex mixture of sugars such as hexoses (glucose, galactose, mannose), and pentoses (xylose, arabinose). A detailed description of the utilization of representative mixed sugar streams (pentoses and hexoses) and their sugar preferences by the solventogenic clostridia (Clostridium beijerinckii BA101, C. acetobutylicum 260, C. acetobutylicum 824, Clostridium saccharobutylicum 262, and C. butylicum 592) is presented. In these experiments, all the sugars were utilized concurrently throughout the fermentation, although the rate of sugar utilization was sugar specific. For all clostridia tested, the rate of glucose utilization was higher than for the other sugars in the mixture. In addition, the availability of excess fermentable sugars in the bioreactor is necessary for both the onset and the maintenance of solvent production otherwise the fermentation will become acidogenic leading to premature termination of the fermentation process. During an investigation on the effect of some of the known lignocellulosic hydrolysate inhibitors on the growth and ABE production by clostridia, ferulic and p-coumaric acids were found to be potent inhibitors of growth and ABE production. Interestingly, furfural and HMF were not inhibitory to the solventogenic clostridia; rather they had a stimulatory effect on growth and ABE production at concentrations up to 2.0g/L.

Economic analysis of a modified dry grind ethanol process with recycle of pretreated and enzymatically hydrolyzed distillers' grains

A modification of the conventional dry grind process for producing ethanol from yellow dent corn is considered with respect to its economic value. Process modifications include recycling distillers' grains, after being pretreated and hydrolyzed, with the ground corn and water to go through fermentation again and increase ethanol yields from the corn starch. A dry grind financial model, which has been validated against other financial models in the industry, is utilized to determine the financial impact of the process changes. The hypothesis was that the enhanced process would yield higher revenues through additional ethanol sales, and higher valued dried distillers' grains (DDGS), due to its higher protein content, to mitigate the drop in DDGS yields. A 32% increase in net present value (NPV) for the overall operation is expected when applying the process modifications to a 100million gallon ethanol plant, and an enzyme cost of $0.20 for each additional gallon of ethanol produced. However, there may be no value added to the enhanced dried distillers' grains (eDDGS), even in light of its higher protein levels, as current pricing is expected to be more sensitive to the amino acid profile than the total protein level, and the eDDGS has lower lysine levels, a key amino acid. Thus, there is a decrease in revenue from eDDGS due to the combination of no price change and loss of DDGS yield to ethanol. The financial improvements are a result of the increased revenue from higher ethanol yields outpacing the sum of all added costs, which include higher capital costs, larger loan payments, increased operating costs, and decreased revenues from dried distillers' grains.