On energy consumption for size-reduction and yields from subsequent enzymatic saccharification of pretreated lodgepole pine

Impact of Mechanical Refining Conditions on the Energy Consumption, Enzymatic Digestibility, and Economics of Sugar Production from Corn Stover

Reducing the energy intensity of the mechanical refining-based pretreatment process for producing lignocellulosic-derived sugars without significantly affecting enzymatic hydrolysis sugar yields is challenging. This work investigated the impact of different refining conditions on energy consumption, enzymatic sugar yields, minimum sugar selling price, and environmental impacts for the conversion of corn stover to sugars. A positive proportionate correlation between specific energy consumption and enzymatic sugar yields was observed when changing the refiner plate gap was changed, which agrees with other reported works. However, the correlation between specific energy consumption and enzymatic sugar yields is not straightforward when the rotational speed and refiner plate design change. We observed that, for a corn stover material with low consistency disc refining, specific energy consumption decreased by >50% by decreasing the rotation speed without affecting enzymatic sugar yields. By changing refiner plate designs, a 45% reduction in specific energy consumption could be achieved without affecting the glucose yield, albeit still with a detrimental impact on the xylose yield. Our high-fidelity disc refining model was able to predict the energy consumption for different refiner plate geometry designs and operating conditions. Techno-economic and life-cycle analyses indicate that the plate design and operating conditions have a direct impact on overall process power consumption and sugar yields, with sugar yields strongly dictating the minimum sugar selling price, the life cycle greenhouse gas emissions, and fossil energy consumption. To minimize the environmental impact and maximize process economics, optimization of the mechanical refining process should target maintaining high sugar yields, while lowering refining energy consumption.

Comparison of Alkaline Sulfite Pretreatment and Acid Sulfite Pretreatment with Low Chemical Loading in Saccharification of Poplar

Sulfite pretreatment is a productive process for lignin dissolution in lignocelluloses and to reduce the hydrophobicity of lignin by sulfonation, thus promoting the hydrolyzability of the substrate. Previously, sulfite pretreatment needs high dosages of chemicals and thus results in the high cost of the pretreatment and the great pressure of environmental pollution. To overcome these problems, it was crucial to research whether alkaline sulfite pretreatment (ALS) and acid sulfite pretreatment (ACS) with low chemical loading could enhance the saccharification of poplar. In this work, the results indicated that with low loading of chemicals in sulfite pretreatment, ALS pretreatment (1.6% Na2SO3 and 0.5% NaOH) at 180 °C removed more lignin, resulted in lower hydrophobicity and higher cellulase adsorption capacity of poplar than ACS pretreatment (1.6% Na2SO3 and 0.5% H2SO4) at 180 °C. A satisfying glucose yield of 84.9% and a xylose yield of 76.0% were obtained from poplar after ALS pretreatment with 1.6% Na2SO3 and 0.5% NaOH at 180 °C for 1 h using 10 FPU cellulase/g dry matter, saving sodium sulfite by 60.0% compared to the loading of sulfite in traditional sulfite pretreatment. The strategy developed in this work reduced chemical loading and cellulase loading in alkali sulfite pretreatment for the saccharification of poplar.

Poly(3-hydroxybuyrate) production from industrial hemp waste pretreated with a chemical-free hydrothermal process

In this study, a mild two-stage hydrothermal pretreatment was employed to optimally valorize industrial hemp (Cannabis sativa sp.) fibrous waste into sugars for Poly(3-hydroxybuyrate) (PHB) production using recombinant Escherichia coli LSBJ. Biomass was pretreated using hot water at 160, 180, and 200°C for 5 and 10 minutes (15% solids), followed by disk refining. The sugar yields during enzymatic hydrolysis were found to improve with increasing temperature and the yields for hot water-disk refining pretreatment (HWDM) were higher compared to only hot water pretreatment at all conditions. The maximum glucose (56 g/L) and cellulose conversion (92%) were achieved for HWDM at 200°C for 10 minutes. The hydrolysate obtained was fermented at a sugar concentration of 20 g/L. The PHB inclusion and concentration of 48% and 1.8 g/L, respectively, were similar to those from pure sugars. A pH-controlled fermentation resulted in a near bi-fold increase in PHB yield (3.46 g/L).

Pretreatment of Wheat Straw Lignocelluloses by Deep Eutectic Solvent for Lignin Extraction

In order to increase the fractionation efficiency of the wheat straw, a deep eutectic solvent (DES) system consisting of chlorine/lactic acid was used in this study for wheat straw pretreatment. The outcomes exhibited that DES pretreatment significantly enhanced the capability to extract lignin, retain cellulose, and remove hemicellulose. The best condition for the pretreatment of wheat straw was 150 °C for 6 h. The process retained most cellulose in the pretreated biomass (49.94-73.60%), and the enzymatic digestibility of the pretreatment residue reached 89.98%. Further characterization of lignin showed that the high yield (81.54%) and the high purity (91.33%) resulted from the ether bond cleavage in lignin and the connection between hemicellulose and lignin. As for application, the enzymatic hydrolysis of the best condition reached 89.98%, and the lignin also had suitable stability. The investigation exhibited that DES pretreatment has the potential to realize an efficient fractionation of lignocellulosic biomass into high-applicability cellulose and lignin of high-quality.

Process intensification of the ionoSolv pretreatment: effects of biomass loading, particle size and scale-up from 10 mL to 1 L

The ionoSolv process is one of the most promising technologies for biomass pretreatment in a biorefinery context. In order to evaluate the transition of the ionoSolv pretreatment of biomass from bench-scale experiments to commercial scale, there is a need to get better insight in process intensification. In this work, the effects of biomass loading, particle size, pulp washing protocols and 100-fold scale up for the pretreatment of the grassy biomass Miscanthus giganteus with the IL triethylammonium hydrogen sulfate, [TEA][HSO4], are presented as a necessary step in that direction. At the bench scale, increasing biomass loading from 10 to 50 wt% reduced glucose yields from 68 to 23% due to re-precipitation of lignin onto the pulp surface. Omitting the pulp air-drying step maintained saccharification yields at 66% at 50 wt% loading due to reduced fiber hornification. 100-fold scale-up (from 10 mL to 1 L) improved the efficacy of ionoSolv pretreatment and increasing loadings from 10 to 20 wt% reduced lignin reprecipitation and led to higher glucose yields due to the improved heat and mass transfer caused by efficient slurry mixing in the reactor. Pretreatment of particle sizes of 1-3 mm was more effective than fine powders (0.18-0.85 mm) giving higher glucose yields due to reduced surface area available for lignin re-precipitation while reducing grinding energy needs. Stirred ionoSolv pretreatment showed great potential for industrialization and further process intensification after optimization of the pretreatment conditions (temperature, residence time, stirring speed), particle size and biomass loading. Pulp washing protocols need further improvement to reduce the incidence of lignin precipitation and the water requirements of lignin washing.

Pretreatment of pine lignocelluloses by recyclable deep eutectic solvent for elevated enzymatic saccharification and lignin nanoparticles extraction

This study investigated the process intensification strategies for the pretreatment of Radiata Pine with the green deep eutectic solvent (DES) system composed of benzyltrimethylammonium chloride/formic acid (BTMAC/FA). The results showed that DES pretreatment drastically improved the delignification and hemicelluloses-removal capacity. The conducted process acceptably remained most of the cellulose in pretreated biomass (88.3%-91.8%). Benefiting from the overcoming of recalcitrance, the enzymatic digestibility of pretreated residues reached 92.4%. The efficient conversion was mainly ascribed to the lignin and hemicelluloses co-extraction. Meanwhile, the lignin yield and enzymatic saccharification was still largely maintained after five reuses. Further structural characteristics of lignin nanoparticles revealed that the lignin possessed high purity (95.19-97.51%), medium molecular weight (9600 to 6495 g/mol), and low polydispersity (ca 2.0), which was attributed to cleavage of ether bonds in lignin as well as linkages between lignin and hemicelluloses. Overall, this study illustrated that DES pretreatment was promising to achieve an efficient fractionation of woody biomass into fermentable glucose and high-quality lignin.

Optimization of two-stage pretreatment for maximizing ethanol production in 1.5G technology

Two-stage pretreatment conditions were optimized to convert corn fiber, separated from whole stillage in a corn dry grind ethanol plant, to fermentable sugars via hydrolysis. Liquid hot water pretreatment (25% solids) at 180 °C for 10 min, followed by three cycles of disk milling, provided maximum glucose, xylose, and arabinose yields of 88.5%, 41.0%, and 30.4% respectively after hydrolysis with Cellulase I. The glucose, xylose, and arabinose yields with Cellulase II at optimum conditions were 94.9%, 74.2%, and 66.3%, respectively. SSF of corn fiber using engineered yeast, with both Cellulase I and II, provided maximum ethanol concentrations of 2.13% and 2.73% (v/v). The protein content in the residual solid after fermentation was 47.95% and 52.05% for Cellulase I and II, respectively. This technology provides additional ethanol in a dry grind plant by converting corn fiber into ethanol and increases the protein content of DDGS, thereby improving the quality.

High solids loading biorefinery for the production of cellulosic sugars from bioenergy sorghum

A novel process applying high solids loading in chemical-free pretreatment and enzymatic hydrolysis was developed to produce sugars from bioenergy sorghum. Hydrothermal pretreatment with 50% solids loading was performed in a pilot scale continuous reactor followed by disc refining. Sugars were extracted from the enzymatic hydrolysis at 10% to 50% solids content using fed-batch operations. Three surfactants (Tween 80, PEG 4000, and PEG 6000) were evaluated to increase sugar yields. Hydrolysis using 2% PEG 4000 had the highest sugar yields. Glucose concentrations of 105, 130, and 147 g/L were obtained from the reaction at 30%, 40%, and 50% solids content, respectively. The maximum sugar concentration of the hydrolysate, including glucose and xylose, obtained was 232 g/L. Additionally, the glucose recovery (73.14%) was increased compared to that of the batch reaction (52.74%) by using two-stage enzymatic hydrolysis combined with fed-batch operation at 50% w/v solids content.

Chemical Free Two-Step Hydrothermal Pretreatment to Improve Sugar Yields from Energy Cane

Energy cane is an attractive lignocellulosic feedstock for processing into biofuels and bioproducts. A low-severity two-step hydrothermal pretreatment was investigated on energy cane for the production of monomeric sugar. Pretreatment temperature and time, in addition to the effect of disk milling, were observed for the glucose and xylose yields during hydrolysis. At residence times above 5 min in case of pretreatment at 200 °C, all of the hemicellulose was observed to be solubilized. The pretreatment condition of 200 °C for 10 min with disk milling was observed to provide the highest glucose concentration of 5.4%, and 200 °C for 5 min with disk milling provided the highest xylose concentration of 2.15%. The effect of disk milling in improving the sugar concentrations during hydrolysis was significant, especially at lower pretreatment temperatures and times. Low xylose yields at higher temperatures were attributed to the formation of degradation products at increased severity.

Lignocellulosic crop residue composting by cellulolytic nitrogen-fixing bacteria: A novel tool for environmental sustainability

Lignocellulosic crop residue (LCCR) composting is a cost-effective and sustainable approach for addressing environmental pollution associated with open biomass burning and application of chemical fertilizers in agriculture. The value-added bio-product of the composting process contributes to the improvement of the soil properties and plant growth in an environment-friendly way. However, the conventional process employed for composting LCCRs is slow and becomes an impediment for farmers who plant two or three crops a year. This concern has led to the development of different techniques for rapid composting of LCCRs. The use of cellulolytic nitrogen-fixing microorganisms for composting has emerged as a promising method for enhancing LCCR composting and quality of the compost. Therefore, this review addresses the recent progress on the potential use of cellulolytic nitrogen-fixing bacteria (CNFB) for LCCR composting and discusses various applications of nutrient-rich compost for sustainable agriculture to increase crop yields in a nature-friendly way. This knowledge of bacteria with both cellulose-degrading and nitrogen-fixing activities is significant with respect to rapid composting, soil fertility, plant growth and sustainable management of the lignocellulosic agricultural waste and it provides a means for the development of new technology for sustainability.

Sugar production from bioenergy sorghum by using pilot scale continuous hydrothermal pretreatment combined with disk refining

Chemical-free pretreatments are attracting increased interest because they generate less inhibitor in hydrolysates. In this study, pilot-scaled continuous hydrothermal (PCH) pretreatment followed by disk refining was evaluated and compared to laboratory-scale batch hot water (LHW) pretreatment. Bioenergy sorghum bagasse (BSB) was pretreated at 160-190 °C for 10 min with and without subsequent disk milling. Hydrothermal pretreatment and disk milling synergistically improved glucose and xylose release by 10-20% compared to hydrothermal pretreatment alone. Maximum yields of glucose and xylose of 82.55% and 70.78%, respectively were achieved, when BSB was pretreated at 190 °C and 180 °C followed by disk milling. LHW pretreated BSB had 5-15% higher sugar yields compared to PCH for all pretreatment conditions. The surface area improvement was also performed. PCH pretreatment combined with disk milling increased BSB surface area by 31.80-106.93%, which was greater than observed using LHW pretreatment.

Cellulose Nanomaterials-Binding Properties and Applications: A Review

Cellulose nanomaterials (CNs) are of increasing interest due to their appealing inherent properties such as bio-degradability, high surface area, light weight, chirality and the ability to form effective hydrogen bonds across the cellulose chains or within other polymeric matrices. Extending CN self-assembly into multiphase polymer structures has led to useful end-results in a wide spectrum of products and countless innovative applications, for example, as reinforcing agent, emulsion stabilizer, barrier membrane and binder. In the current contribution, after a brief description of salient nanocellulose chemical structure features, its types and production methods, we move to recent advances in CN utilization as an ecofriendly binder in several disparate areas, namely formaldehyde-free hybrid composites and wood-based panels, papermaking/coating processes, and energy storage devices, as well as their potential applications in biomedical fields as a cost-effective and tissue-friendly binder for cartilage regeneration, wound healing and dental repair. The prospects of a wide range of hybrid materials that may be produced via nanocellulose is introduced in light of the unique behavior of cellulose once in nano dimensions. Furthermore, we implement some principles of colloidal and interfacial science to discuss the critical role of cellulose binding in the aforesaid fields. Even though the CN facets covered in this study by no means encompass the great amount of literature available, they may be regarded as the basis for future developments in the binder applications of these highly desirable materials.

Bioethanol Production from Renewable Raw Materials and Its Separation and Purification: A Review

Production of biofuels from renewable feedstocks has captured considerable scientific attention since they could be used to supply energy and alternative fuels. Bioethanol is one of the most interesting biofuels due to its positive impact on the environment. Currently, it is mostly produced from sugar- and starch-containing raw materials. However, various available types of lignocellulosic biomass such as agricultural and forestry residues, and herbaceous energy crops could serve as feedstocks for the production of bioethanol, energy, heat and value-added chemicals. Lignocellulose is a complex mixture of carbohydrates that needs an efficient pretreatment to make accessible pathways to enzymes for the production of fermentable sugars, which after hydrolysis are fermented into ethanol. Despite technical and economic difficulties, renewable lignocellulosic raw materials represent low-cost feedstocks that do not compete with the food and feed chain, thereby stimulating the sustainability. Different bioprocess operational modes were developed for bioethanol production from renewable raw materials. Furthermore, alternative bioethanol separation and purification processes have also been intensively developed. This paper deals with recent trends in the bioethanol production as a fuel from different renewable raw materials as well as with its separation and purification processes.

Effects of Oligosaccharides Isolated From Pinewood Hot Water Pre-hydrolyzates on Recombinant Cellulases

Loblolly pine residues have enormous potential to be the raw material for advanced biofuel production due to extensive sources and high cellulose content. Hot water (HW) pretreatment, while being a relatively economical and clean technology for the deconstruction of lignocellulosic biomass, could also inhibit the ensuing enzymatic hydrolysis process because of the production of inhibitors. In this study, we investigated the effect of oligosaccharide fractions purified from HW pre-hydrolyzate of pinewood using centrifugal partition chromatography (CPC) on three recombinant cellulolytic enzymes (E1, CBHI and CBHII), which were expressed in the transgenic corn grain system. The efficiency of recombinant enzymes was measured using either a 4-methylumbelliferyl-β-D-cellobioside (MUC) or a cellulose-dinitrosalicylic acid (DNS) assay system. The results showed that HW pre-hydrolyzate CPC fractions contain phenolics, furans, and monomeric and oligomeric sugars. Among CPC fractions, oligomers composed of xylan, galactan, and mannan were inhibitory to the three recombinant enzymes and to the commercial cellulase cocktail, reducing the enzymatic efficiency to as low as 10%.

Integrated experimental and technoeconomic evaluation of two-stage Cu-catalyzed alkaline-oxidative pretreatment of hybrid poplar

BACKGROUND

When applied to recalcitrant lignocellulosic feedstocks, multi-stage pretreatments can provide more processing flexibility to optimize or balance process outcomes such as increasing delignification, preserving hemicellulose, and maximizing enzymatic hydrolysis yields. We previously reported that adding an alkaline pre-extraction step to a copper-catalyzed alkaline hydrogen peroxide (Cu-AHP) pretreatment process resulted in improved sugar yields, but the process still utilized relatively high chemical inputs (catalyst and H₂O₂) and enzyme loadings. We hypothesized that by increasing the temperature of the alkaline pre-extraction step in water or ethanol, we could reduce the inputs required during Cu-AHP pretreatment and enzymatic hydrolysis without significant loss in sugar yield. We also performed technoeconomic analysis to determine if ethanol or water was the more cost-effective solvent during alkaline pre-extraction and if the expense associated with increasing the temperature was economically justified.

RESULTS

After Cu-AHP pretreatment of 120 °C NaOH-H₂O pre-extracted and 120 °C NaOH-EtOH pre-extracted biomass, approximately 1.4-fold more total lignin was solubilized (78% and 74%, respectively) compared to the 30 °C NaOH-H₂O pre-extraction (55%) carried out in a previous study. Consequently, increasing the temperature of the alkaline pre-extraction step to 120 °C in both ethanol and water allowed us to decrease bipyridine and H₂O₂ during Cu-AHP and enzymes during hydrolysis with only a small reduction in sugar yields compared to 30 °C alkaline pre-extraction. Technoeconomic analysis indicated that 120 °C NaOH-H₂O pre-extraction has the lowest installed ($246 million) and raw material ($175 million) costs compared to the other process configurations.

CONCLUSIONS

We found that by increasing the temperature of the alkaline pre-extraction step, we could successfully lower the inputs for pretreatment and enzymatic hydrolysis. Based on sugar yields as well as capital, feedstock, and operating costs, 120 °C NaOH-H₂O pre-extraction was superior to both 120 °C NaOH-EtOH and 30 °C NaOH-H₂O pre-extraction.

Overcoming factors limiting high-solids fermentation of lignocellulosic biomass to ethanol

Simultaneous saccharification and fermentation (SSF) of solid biomass can reduce the complexity and improve the economics of lignocellulosic ethanol production by consolidating process steps and reducing end-product inhibition of enzymes compared with separate hydrolysis and fermentation (SHF). However, a long-standing limitation of SSF has been too low ethanol yields at the high-solids loading of biomass needed during fermentation to realize sufficiently high ethanol titers favorable for more economical ethanol recovery. Here, we illustrate how competing factors that limit ethanol yields during high-solids fermentations are overcome by integrating newly developed cosolvent-enhanced lignocellulosic fractionation (CELF) pretreatment with SSF. First, fed-batch glucose fermentations by Saccharomyces cerevisiae D₅A revealed that this strain, which has been favored for SSF, can produce ethanol at titers of up to 86 g⋅L^-1 Then, optimizing SSF of CELF-pretreated corn stover achieved unprecedented ethanol titers of 79.2, 81.3, and 85.6 g⋅L^-1 in batch shake flask, corresponding to ethanol yields of 90.5%, 86.1%, and 80.8% at solids loadings of 20.0 wt %, 21.5 wt %, and 23.0 wt %, respectively. Ethanol yields remained at over 90% despite reducing enzyme loading to only 10 mg protein⋅g glucan^-1 [∼6.5 filter paper units (FPU)], revealing that the enduring factors limiting further ethanol production were reduced cell viability and glucose uptake by D₅A and not loss of enzyme activity or mixing issues, thereby demonstrating an SSF-based process that was limited by a strain's metabolic capabilities and tolerance to ethanol.

Irradiation pretreatment facilitates the achievement of high total sugars concentration from lignocellulose biomass

This study evaluated the two hydrolysis strategies, involving one thermal and one dilute acid/enzymatic hydrolysis, to produce high xylose and glucose concentrations from lignocellulose assisted with irradiation pretreatment. Prior to hydrolysis, lignocellulose was pretreated by γ-irradiation at 800KGy. The merits of irradiation pretreatment on lignocellulose were contributed to size-reduced particle distributions and low shear rate of material, which allowed high biomass loadings up to 30-40%(w/v, equals to 23-29wt.%) for the consequent hydrolysis process. Results showed that hemicellulose fraction could achieve ∼84g/L of total sugars containing ∼55g/L xylose and ∼21g/L glucose through this two steps hydrolysis. Cellulose fraction would release ∼251g/L of total sugars consisting of ∼235g/L glucose and ∼16g/L xylose in the ultimate enzymatic hydrolysate. To the best of our knowledge, it was the first report of achieving 235g/L glucose in cellulose enzymatic hydrolysate derived from lignocellulose.

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.

Development and applications of transparent conductive nanocellulose paper

Increasing attention has been paid to the next generation of 'green' electronic devices based on renewable nanocellulose, owing to its low roughness, good thermal stability and excellent optical properties. Various proof-of-concept transparent nanopaper-based electronic devices have been fabricated; these devices exhibit excellent flexibility, bendability and even foldability. In this review, we summarize the recent progress of transparent nanopaper that uses different types of nanocellulose, including pure nanocellulose paper and composite nanocellulose paper. The latest development of transparent and flexible nanopaper electronic devices are illustrated, such as electrochromic devices, touch sensors, solar cells and transistors. Finally, we discuss the advantages of transparent nanopaper compared to conventional flexible plastic substrate and the existing challenges to be tackled in order to realize this promising potential.

Improvement of sugar yields from corn stover using sequential hot water pretreatment and disk milling

Efficient pretreatment is essential for economic conversion of lignocellulosic feedstocks into monosaccharides for biofuel production. To realize high sugar yields with low inhibitor concentrations, hot water or dilute acid pretreatment followed by disk milling is proposed. Corn stover at 20% solids was pretreated with hot water at 160-200°C for 4-8min with and without subsequent milling. Hot water pretreatment and disk milling acted synergistically to improve glucose and xylose yields by 89% and 134%, respectively, compared to hot water pretreatment alone. Hot water pretreated (180°C for 4min) and milled samples had the highest glucose and xylose yields among all hot water pretreated and milled samples, which were comparable to samples pretreated with 0.55% dilute acid at 160°C for 4min. However, samples pretreated with 1% dilute acid at 150°C for 4min and disk milled had the highest observed glucose (87.3%) and xylose yields (83.4%).

Micromorphological changes and mechanism associated with wet ball milling of Pinus radiata substrate and consequences for saccharification at low enzyme loading

In this work, substrates prepared from thermo-mechanical treatment of Pinus radiata chips were vibratory ball milled for different times. In subsequent enzymatic hydrolysis, percent glucan conversion passed through a maximum value at a milling time of around 120min and then declined. Scanning electron microscopy revealed breakage of fibers to porous fragments in which lamellae and fibrils were exposed during ball milling. Over-milling caused compression of the porous fragments to compact globular particles with a granular texture, decreasing accessibility to enzymes. Carbon-13 NMR spectroscopy showed partial loss of interior cellulose in crystallites, leveling off once fiber breakage was complete. A mathematical model based on observed micromorphological changes supports ball milling mechanism. At a low enzyme loading of 2FPU/g of substrate and milling time of 120min gave a total monomeric sugar yield of 306g/kg of pulp which is higher than conventional pretreatment method such as steam exploded wood.

Physico-Chemical Alternatives in Lignocellulosic Materials in Relation to the Kind of Component for Fermenting Purposes

The complete bioconversion of the carbohydrate fraction is of great importance for a lignocellulosic-based biorefinery. However, due to the structure of the lignocellulosic materials, and depending basically on the main parameters within the pretreatment steps, numerous byproducts are generated and they act as inhibitors in the fermentation operations. In this sense, the impact of inhibitory compounds derived from lignocellulosic materials is one of the major challenges for a sustainable biomass-to-biofuel and -bioproduct industry. In order to minimise the negative effects of these compounds, numerous methodologies have been tested including physical, chemical, and biological processes. The main physical and chemical treatments have been studied in this work in relation to the lignocellulosic material and the inhibitor in order to point out the best mechanisms for fermenting purposes. In addition, special attention has been made in the case of lignocellulosic hydrolysates obtained by chemical processes with SO₂, due to the complex matrix of these materials and the increase in these methodologies in future biorefinery markets. Recommendations of different detoxification methods have been given.

Post-treatment mechanical refining as a method to improve overall sugar recovery of steam pretreated hybrid poplar

This study investigates the effect of mechanical refining to improve the sugar yield from biomass processed under a wide range of steam pretreatment conditions. Hybrid poplar chips were steam pretreated using six different conditions with or without SO2. The resulting water insoluble fractions were subjected to mechanical refining. After refining, poplar pretreated at 205°C for 10min without SO2 obtained a 32% improvement in enzymatic hydrolysis and achieved similar overall monomeric sugar recovery (539kg/tonne) to samples pretreated with SO2. Refining did not improve hydrolyzability of samples pretreated at more severe conditions, nor did it improve the overall sugar recovery. By maximizing overall sugar recovery, refining could partially decouple the pretreatment from other unit operations, and enable the use of low temperature, non-sulfur pretreatment conditions. The study demonstrates the possibility of using post-treatment refining to accommodate potential pretreatment process upsets without sacrificing sugar yields.

Use of mechanical refining to improve the production of low-cost sugars from lignocellulosic biomass

Mechanical refining is widely used in the pulp and paper industry to enhance the end-use properties of products by creating external fibrillation and internal delamination. This technology can be directly applied to biochemical conversion processes. By implementing mechanical refining technology, biomass recalcitrance to enzyme hydrolysis can be overcome and carbohydrate conversion can be enhanced with commercially attractive levels of enzymes. In addition, chemical and thermal pretreatment severity can be reduced to achieve the same level of carbohydrate conversion, which reduces pretreatment cost and results in lower concentrations of inhibitors. Refining is versatile and a commercially proven technology that can be operated at process flows of ∼ 1500 dry tons per day of biomass. This paper reviews the utilization of mechanical refining in the pulp and paper industry and summarizes the recent development in applications for biochemical conversion, which potentially make an overall biorefinery process more economically viable.

Promise of combined hydrothermal/chemical and mechanical refining for pretreatment of woody and herbaceous biomass

Production of advanced biofuels from woody and herbaceous feedstocks is moving into commercialization. Biomass needs to be pretreated to overcome the physicochemical properties of biomass that hinder enzyme accessibility, impeding the conversion of the plant cell walls to fermentable sugars. Pretreatment also remains one of the most costly unit operations in the process and among the most critical because it is the source of chemicals that inhibit enzymes and microorganisms and largely determines enzyme loading and sugar yields. Pretreatments are categorized into hydrothermal (aqueous)/chemical, physical, and biological pretreatments, and the mechanistic details of which are briefly outlined in this review. To leverage the synergistic effects of different pretreatment methods, conducting two or more pretreatments consecutively has gained attention. Especially, combining hydrothermal/chemical pretreatment and mechanical refining, a type of physical pretreatment, has the potential to be applied to an industrial plant. Here, the effects of the combined pretreatment (combined hydrothermal/chemical pretreatment and mechanical refining) on energy consumption, physical structure, sugar yields, and enzyme dosage are summarized.

Effective alkaline metal-catalyzed oxidative delignification of hybrid poplar

BACKGROUND

Strategies to improve copper-catalyzed alkaline hydrogen peroxide (Cu-AHP) pretreatment of hybrid poplar were investigated. These improvements included a combination of increasing hydrolysis yields, while simultaneously decreasing process inputs through (i) more efficient utilization of H2O2 and (ii) the addition of an alkaline extraction step prior to the metal-catalyzed AHP pretreatment. We hypothesized that utilizing this improved process could substantially lower the chemical inputs needed during pretreatment.

RESULTS

Hybrid poplar was pretreated utilizing a modified process in which an alkaline extraction step was incorporated prior to the Cu-AHP treatment step and H2O2 was added batch-wise over the course of 10 h. Our results revealed that the alkaline pre-extraction step improved both lignin and xylan solubilization, which ultimately led to improved glucose (86 %) and xylose (95 %) yields following enzymatic hydrolysis. An increase in the lignin solubilization was also observed with fed-batch H2O2 addition relative to batch-only addition, which again resulted in increased glucose and xylose yields (77 and 93 % versus 63 and 74 %, respectively). Importantly, combining these strategies led to significantly improved sugar yields (96 % glucose and 94 % xylose) following enzymatic hydrolysis. In addition, we found that we could substantially lower the chemical inputs (enzyme, H2O2, and catalyst), while still maintaining high product yields utilizing the improved Cu-AHP process. This pretreatment also provided a relatively pure lignin stream consisting of ≥90 % Klason lignin and only 3 % xylan and 2 % ash following precipitation. Two-dimensional heteronuclear single-quantum coherence (2D HSQC) NMR and size-exclusion chromatography demonstrated that the solubilized lignin was high molecular weight (Mw ≈ 22,000 Da) and only slightly oxidized relative to lignin from untreated poplar.

CONCLUSIONS

This study demonstrated that the fed-batch, two-stage Cu-AHP pretreatment process was effective in pretreating hybrid poplar for its conversion into fermentable sugars. Results showed sugar yields near the theoretical maximum were achieved from enzymatically hydrolyzed hybrid poplar by incorporating an alkaline extraction step prior to pretreatment and by efficiently utilizing H2O2 during the Cu-AHP process. Significantly, this study reports high sugar yields from woody biomass treated with an AHP pretreatment under mild reaction conditions.

Enhancement in the enzymatic digestibility of hybrid poplar with poor residual hemicelluloses after Na2SO3 pretreatment

The aim of this work was to illustrate the contributions of delignification and the introduced sulfonic groups on the enzymatic digestibility of the Na2SO3-pretreated hybrid poplar with poor residual hemicelluloses (HPPRH). The higher the content of the introduced sulfonic group in the pretreated HPPRH was, the higher its enzymatic digestibility could be achieved. Delignification was favorable to increasing the content of sulfonic group in the pretreated HPPRH. The introduced sulfonic group contributed much more to the total glucose yield at low level of residual lignin. The introduced sulfonic groups could contribute 17.30% of total glucose yield (92.70%) and delignification could do 38.43% of it. Meanwhile, the delignification rate and the sulfonic group content in the pretreated HPRH were 59.88% and 283.51mmolkg(-1) lignin, respectively. Therefore, the sulfonic group introduced on the pretreated lignocellulosics could improve the enzymatic digestibility and make the sulfite process effective.

How chip size impacts steam pretreatment effectiveness for biological conversion of poplar wood into fermentable sugars

BACKGROUND

Woody biomass is highly recalcitrant to enzymatic sugar release and often requires significant size reduction and severe pretreatments to achieve economically viable sugar yields in biological production of sustainable fuels and chemicals. However, because mechanical size reduction of woody biomass can consume significant amounts of energy, it is desirable to minimize size reduction and instead pretreat larger wood chips prior to biological conversion. To date, however, most laboratory research has been performed on materials that are significantly smaller than applicable in a commercial setting. As a result, there is a limited understanding of the effects that larger biomass particle size has on the effectiveness of steam explosion pretreatment and subsequent enzymatic hydrolysis of wood chips.

RESULTS

To address these concerns, novel downscaled analysis and high throughput pretreatment and hydrolysis (HTPH) were applied to examine whether differences exist in the composition and digestibility within a single pretreated wood chip due to heterogeneous pretreatment across its thickness. Heat transfer modeling, Simons' stain testing, magnetic resonance imaging (MRI), and scanning electron microscopy (SEM) were applied to probe the effects of pretreatment within and between pretreated wood samples to shed light on potential causes of variation, pointing to enzyme accessibility (i.e., pore size) distribution being a key factor dictating enzyme digestibility in these samples. Application of these techniques demonstrated that the effectiveness of pretreatment of Populus tremuloides can vary substantially over the chip thickness at short pretreatment times, resulting in spatial digestibility effects and overall lower sugar yields in subsequent enzymatic hydrolysis.

CONCLUSIONS

These results indicate that rapid decompression pretreatments (e.g., steam explosion) that specifically alter accessibility at lower temperature conditions are well suited for larger wood chips due to the non-uniformity in temperature and digestibility profiles that can result from high temperature and short pretreatment times. Furthermore, this study also demonstrated that wood chips were hydrated primarily through the natural pore structure during pretreatment, suggesting that preserving the natural grain and transport systems in wood during storage and chipping processes could likely promote pretreatment efficacy and uniformity.

Reactors for High Solid Loading Pretreatment of Lignocellulosic Biomass

The review summarized the types, the geometry, and the design principle of pretreatment reactors at high solid loading of lignocellulose material. Among the reactors used, the explosion reactors and the helical stirring reactors are to be considered as the practical form for high solids loading pretreatment operation; the comminution reactors and the extruder reactors are difficult to be used as an independent unit, but possible to be used in the combined form with other types of reactors. The principles of the pretreatment reactor design at high solid loading were discussed and several basic principles for the design were proposed. This review provided useful information for choosing the reactor types and designing the geometry of pretreatment operation at the high solids loading.

Revisiting size-exclusion chromatography for measuring structural changes in raw and pretreated mixed hardwoods and switchgrass

The study of the biomass porous structure and its role in defining the accessibility of cell-wall-degrading enzymes (CWDEs) to the substrate is very important for understanding the cellulase-cellulose reaction system. Specific pore volume and specific surface area are two important measures of accessibility and a variety of methods have been used to make these measurements. For this study a size exclusion chromatography system was developed to measure specific pore volume and specific surface areas for raw and pretreated mixed-hardwood and switchgrass. Polyethylene glycol (PEG) probes of known molecular diameter (1.8-13 nm) were allowed to diffuse into the pore structure of the various biomass substrate packed in the column and subsequently eluted to generate high resolution concentration measurements with excellent reproducibility. Replicate measurements of probe concentrations from this system consistently yielded coefficient of variance of less than 1.5%. Our results showed that particle size reduction had a smaller influence on the specific pore volume distribution of raw mixed-hardwoods, whereas for switchgrass the larger particles yielded a significantly lower estimate for the pore volume distribution compared to the smaller particles. Our results also clearly showed that our bi-phasic pretreatment yielded the largest increase in pore volume accessibility for mixed-hardwoods relative to switchgrass. From these results a pore size change mechanism was proposed that could explain the influence of size reduction and pretreatment on pore volume measurements.

Comparison of lab, pilot, and industrial scale low consistency mechanical refining for improvements in enzymatic digestibility of pretreated hardwood

Mechanical refining has been shown to improve biomass enzymatic digestibility. In this study industrial high-yield sodium carbonate hardwood pulp was subjected to lab, pilot and industrial refining to determine if the mechanical refining improves the enzymatic hydrolysis sugar conversion efficiency differently at different refining scales. Lab, pilot and industrial refining increased the biomass digestibility for lignocellulosic biomass relative to the unrefined material. The sugar conversion was increased from 36% to 65% at 5 FPU/g of biomass with industrial refining at 67.0 kWh/t, which was more energy efficient than lab and pilot scale refining. There is a maximum in the sugar conversion with respect to the amount of refining energy. Water retention value is a good predictor of improvements in sugar conversion for a given fiber source and composition. Improvements in biomass digestibility with refining due to lab, pilot plant and industrial refining were similar with respect to water retention value.

Ethanol production from non-detoxified whole slurry of sulfite-pretreated empty fruit bunches at a low cellulase loading

Sulfite pretreatment to overcome the recalcitrance of lignocelluloses (SPORL) was applied to an empty fruit bunches (EFB) for ethanol production. SPORL facilitated delignification through lignin sulfonation and dissolution of xylan to result in a highly digestible substrate. The pretreated whole slurry was enzymatically saccharified at a solids loading of 18% using a relatively low cellulase loading of 15 FPU/g glucan and simultaneously fermented without detoxification using Saccharomyces cerevisiae of YRH400. An ethanol yield of 217 L/tonne EFB was achieved at titer of 32 g/L. Compared with literature studies, SPORL produced high ethanol yield and titer with much lower cellulase loading without detoxification.

Combined deacetylation and PFI refining pretreatment of corn cob for the improvement of a two-stage enzymatic hydrolysis

A combined deacetylation and PFI refining pretreatment was applied to corn cob for the improvement of a two-stage enzymatic hydrolysis. In stage 1, the pretreated corn cob was first hydrolyzed by xylanase to produce xylo-oligosaccharides (XOS). In stage 2, the solid residue isolated from stage 1 was further hydrolyzed by cellulase and β-glucosidase. NaOH, Na2CO3, and Ca(OH)2 were tested to remove acetyl groups in the process of deacetylation, and it was found that Ca(OH)2 could be the most suitable alkali for deacetylation in this work. After deacetylation using 0.8 mmol of Ca(OH)2/g of substrate and PFI refining, 50.5% xylan in the raw material could be hydrolyzed into XOS. The corresponding xylan yield of stage 1, the glucan yield of stage 2, and the total sugar yield (all sugars released in the hydrolyzate) after the two-stage enzymatic hydrolysis were 0.306, 0.305, and 0.661 g/g of corn cob, respectively.

Mechanical pretreatments of lignocellulosic biomass: towards facile and environmentally sound technologies for biofuels production

The transformation of lignocellulosic biomass into biofuels represents an interesting and sustainable alternative to fossil fuel for the near future.

Comparison of different mechanical refining technologies on the enzymatic digestibility of low severity acid pretreated corn stover

The effect of mechanical refining on the enzymatic digestibility of pretreated corn stover (PCS) was investigated. Low severity, dilute sulfuric acid PCS was subjected to mechanical refining using a bench-scale food processor blender, a PFI mill, a 12-inch laboratory disk refiner, and a 25 mm co-rotating twin-screw extruder. Glucose yields from enzymatic hydrolysis were improved by 10-15% after blending and disk refining, while PFI refining and twin-screw extrusion showed a glucose yield improvement of 16-20%. A pilot scale refining test using a Szego mill was performed and showed approximately 10% improvements in biomass digestibility. This suggests the possibility to scale up a mechanical refining technique to obtain similar enzymatic digestibility glucose yield enhancement as achieved by PFI milling and extrusion technologies. Proposed mechanisms of each mechanical refining technology are presented and reasons for improvements in biomass digestibility are discussed in this paper.

Enhancement in enzymatic hydrolysis by mechanical refining for pretreated hardwood lignocellulosics

This study investigated the effectiveness of mechanical refining to overcome the biomass recalcitrance barrier. Laboratory scale refining was conducted via PFI mill and valley beater refiners using green liquor and Kraft hardwood pulps. A strong positive correlation was determined between sugar recovery and water retention value. Refining produced significant improvements in enzymatic hydrolysis yield relative to unrefined substrates (e.g., sugar recovery increase from 67% to 90%, for 15% lignin Kraft pulp). A maximum absolute enzymatic hydrolysis improvement with refining was observed at enzymatic hydrolysis conditions that produced intermediate conversion levels. For a 91% target sugar conversion, PFI refining at 4000 revolutions allowed for a 32% reduction in enzyme charge for 15% lignin content hardwood Kraft pulp and 96 h hydrolysis time, compared to the unrefined material.

Dry fractionation process as an important step in current and future lignocellulose biorefineries: a review

The use of lignocellulosic biomass is promising for biofuels and materials and new technologies for the conversion need to be developed. However, the inherent properties of native lignocellulosic materials make them resistant to enzymatic and chemical degradation. Lignocellulosic biomass requires being pretreated to change the physical and chemical properties of lignocellulosic matrix in order to increase cell wall polymers accessibility and bioavailability. Mechanical size reduction may be chemical free intensive operation thanks to decreasing particles size and cellulose crystallinity, and increasing accessible surface area. Changes in these parameters improve the digestibility and the bioconversion of lignocellulosic biomass. However, mechanical size reduction requires cost-effective approaches from an energy input point of view. Therefore, the energy consumption in relation to physicochemical properties of lignocellulosic biomass was discussed. Even more, chemical treatments combined with physicochemical size reduction approaches are proposed to reduce energy consumption in this review.

Evaluation energy efficiency of bioconversion knot rejects to ethanol in comparison to other thermochemically pretreated biomass

Rejects from sulfite pulp mill that otherwise would be disposed of by incineration were converted to ethanol by a combined physical-biological process that was comprised of physical refining and simultaneous saccharification and fermentation (SSF). The energy efficiency was evaluated with comparison to thermochemically pretreated biomass, such as those pretreated by dilute acid (DA) and sulfite pretreatment to overcome recalcitrance of lignocelluloses (SPORL). It was observed that the structure deconstruction of rejects by physical refining was indispensable to effective bioconversion but more energy intensive than that of thermochemically pretreated biomass. Fortunately, the energy consumption was compensated by the reduced enzyme dosage and the elevated ethanol yield. Furthermore, adjustment of disk-plates gap led to reduction in energy consumption with negligible influence on ethanol yield. In this context, energy efficiency up to 717.7% was achieved for rejects, much higher than that of SPORL sample (283.7%) and DA sample (152.8%).

Sulfite (SPORL) pretreatment of switchgrass for enzymatic saccharification

SPORL (Sulfite Pretreatment to Overcome Recalcitrance of Lignocellulose) pretreatment was applied to switchgrass and optimized through an experimental design using Response Surface Methodology within the range of temperature (163-197 °C), time (3-37 min), sulfuric acid dosage (0.8-4.2% on switchgrass), and sodium sulfite dosage (0.6-7.4% on switchgrass). Performance of SPORL was compared with that of dilute acid (DA) and alkali (AL) in switchgrass pretreatment. Results indicated that SPORL pretreatment improved the digestibility of switchgrass through sufficiently removing hemicellulose, partially dissolving lignin, and reducing hydrophobicity of lignin by sulfonation. The removal of hemicellulose was more critical to substrate digestibility than the removal of lignin during SPORL pretreatment. SPORL pretreated switchgrass had better enzymatic digestibility than DA and AL pretreated ones. The SPORL pretreated switchgrass could be hydrolyzed by 83% within 48 h with 15 FPU (filter paper unit) cellulase and 30 CBU (cellobiose unit) β-glucosidase/g cellulose.