Pilot-scale study on the acid-catalyzed steam explosion of rice straw using a continuous pretreatment system

Pretreatments of lignocellulosic and algal biomasses for sustainable biohydrogen production: Recent progress, carbon neutrality, and circular economy

Lignocellulosic and algal biomasses are known to be vital feedstocks to establish a green hydrogen supply chain toward achieving a carbon-neutral society. However, one of the most pressing issues to be addressed is the low digestibility of these biomasses in biorefinery processes, such as dark fermentation, to produce green hydrogen. To date, various pretreatment approaches, such as physical, chemical, and biological methods, have been examined to enhance feedstock digestibility. However, neither systematic reviews of pretreatment to promote biohydrogen production in dark fermentation nor economic feasibility analyses have been conducted. Thus, this study offers a comprehensive review of current biomass pretreatment methods to promote biohydrogen production in dark fermentation. In addition, this review has provided comparative analyses of the technological and economic feasibility of existing pretreatment techniques and discussed the prospects of the pretreatments from the standpoint of carbon neutrality and circular economy.

Advances in physicochemical pretreatment strategies for lignocellulose biomass and their effectiveness in bioconversion for biofuel production

The inherent recalcitrance of lignocellulosic biomass is a significant barrier to efficient lignocellulosic biorefinery owing to its complex structure and the presence of inhibitory components, primarily lignin. Efficient biomass pretreatment strategies are crucial for fragmentation of lignocellulosic biocomponents, increasing the surface area and solubility of cellulose fibers, and removing or extracting lignin. Conventional pretreatment methods have several disadvantages, such as high operational costs, equipment corrosion, and the generation of toxic byproducts and effluents. In recent years, many emerging single-step, multi-step, and/or combined physicochemical pretreatment regimes have been developed, which are simpler in operation, more economical, and environmentally friendly. Furthermore, many of these combined physicochemical methods improve biomass bioaccessibility and effectively fractionate ∼96 % of lignocellulosic biocomponents into cellulose, hemicellulose, and lignin, thereby allowing for highly efficient lignocellulose bioconversion. This review critically discusses the emerging physicochemical pretreatment methods for efficient lignocellulose bioconversion for biofuel production to address the global energy crisis.

Recent Advances in the Bioconversion of Waste Straw Biomass with Steam Explosion Technique: A Comprehensive Review

Waste straw biomass is an abundant renewable bioresource raw material on Earth. Its stubborn wooden cellulose structure limits straw lignocellulose bioconversion into value-added products (e.g., biofuel, chemicals, and agricultural products). Compared to physicochemical and other preprocessing techniques, the steam explosion method, as a kind of hydrothermal method, was considered as a practical, eco-friendly, and cost-effective method to overcome the above-mentioned barriers during straw lignocellulose bioconversion. Steam explosion pretreatment of straw lignocellulose can effectively improve the conversion efficiency of producing biofuels and value-added chemicals and is expected to replace fossil fuels and partially replace traditional chemical fertilizers. Although the principles of steam explosion destruction of lignocellulosic structures for bioconversion to liquid fuels and producing solid biofuel were well known, applications of steam explosion in productions of value-added chemicals, organic fertilizers, biogas, etc. were less identified. Therefore, this review provides insights into advanced methods of utilizing steam explosion for straw biomass conversion as well as their corresponding processes and mechanisms. Finally, the current limitations and prospects of straw biomass conversion with steam explosion technology were elucidated.

Hydrodynamic cavitation for lignocellulosic biomass pretreatment: a review of recent developments and future perspectives

The hydrodynamic cavitation comes out as a promising route to lignocellulosic biomass pretreatment releasing huge amounts of energy and inducing physical and chemical transformations, which favor lignin-carbohydrate matrix disruption. The hydrodynamic cavitation process combined with other pretreatment processes has shown an attractive alternative with high pretreatment efficiency, low energy consumption, and easy setup for large-scale applications compared to conventional pretreatment methods. This present review includes an overview of this promising technology and a detailed discussion on the process of parameters that affect the phenomena and future perspectives of development of this area.

Engineering aspects of hydrothermal pretreatment: From batch to continuous operation, scale-up and pilot reactor under biorefinery concept

Different pretreatments strategies have been developed over the years mainly to enhance enzymatic cellulose degradation. In the new biorefinery era, a more holistic view on pretreatment is required to secure optimal use of the whole biomass. Hydrothermal pretreatment technology is regarded as very promising for lignocellulose biomass fractionation biorefinery and to be implemented at the industrial scale for biorefineries of second generation and circular bioeconomy, since it does not require no chemical inputs other than liquid water or steam and heat. This review focuses on the fundamentals of hydrothermal pretreatment, structure changes of biomass during this pretreatment, multiproduct strategies in terms of biorefinery, reactor technology and engineering aspects from batch to continuous operation. The treatise includes a case study of hydrothermal biomass pretreatment at pilot plant scale and integrated process design.

The effect of continuous tubular reactor technologies on the pretreatment of lignocellulosic biomass at pilot-scale for bioethanol production

A pilot-scale continuous tubular reactor increases enzymatic digestibility of four different feedstocks by removing xylan and effectively achieving economically viable ethanol concentrations.

Pretreatment of sugarcane bagasse using hydrodynamic cavitation technology: Semi-continuous and continuous process

Development of new technologies for pretreatment of lignocellulosic biomass is a current research challenge. In this way, hydrodynamic cavitation (HC) was used to assist alkaline hydrogen peroxide pretreatment of sugarcane bagasse (SCB) in sequential batches (SB-HC), semi-continuous (SC-HC) and continuous (C-HC) processes. Pretreatment resulted in compositional modifications in the material, mainly regarding the cellulose and lignin contents. The released sugars after enzymatic hydrolysis resulted, on average, in 42 g and 32-35 g of glucose per 100 g of SCB for samples treated in B-HC (10 min of process) and SC-HC process (7.5 min residence time), respectively. In C-HC process, with an average residence time of 7.5 min and 3.75 min, 38-46 g and 32-38 g of glucose per 100 g of SCB were obtained respectively in enzymatic hydrolysis step. HC technology was shown as a promising alternative for pretreatment of lignocellulosic biomass in all evaluated configurations aiming to produce high value bioproducts.

Evaluation and characterization of novel sources of sustainable lignocellulosic residues for bioethanol production using ultrasound-assisted alkaline pre-treatment

In recent years, research is focused on finding a sustainable and eco-friendly lignocellulosic biomass for the effective production of bioethanol to meet the world's energy demand. The present study investigates the bioethanol production potential of four different lignocellulosic biomass residues viz., Saccharum arundinaceum (hardy sugar cane), Arundo donax (giant reed), Typha angustifolia (narrow-leaved cattail), and Ipomoea carnea (pink morning glory). The maximum reducing sugar release showed 185.00 ± 1.57, 213.73 ± 3.47, 187.57 ± 2.14, 294.08 ± 3.98 mg/g and fermentation efficiency of 72.60 ± 8.17%, 82.59 ± 7.42%, 77.45 ± 7.35%, and 85.04 ± 8.37% which was analyzed by estimating the percentage of bioethanol yield were achieved for Saccharum arundinaceum, Arundo donax, Typha angustifolia, and Ipomoea carnea, respectively. The chemical composition of biomass was characterized using National Renewable Energy Limited (NREL) protocol. The effect of ultrasound (US)-assisted alkaline pre-treatment on the four biomasses was characterized by different techniques. The cavitation phenomena of US-assisted alkaline pre-treatment was evident from the decreased value of lignin percentage, increased surface porosity and area, changes in crystallinity index (CrI) values and in the functional groups of biomass. The results revealed that all the four lignocellulosic biomass residues could be utilized as an effective and sustainable source for the production of bioethanol using US-assisted sodium hydroxide as a pre-treatment tool.

Production of optically pure L(+)-lactic acid from waste plywood chips using an isolated thermotolerant Enterococcus faecalis SI at a pilot scale

Utilization of renewable and low-cost lignocellulosic wastes has received major focus in industrial lactic acid production. The use of high solid loadings in biomass pretreatment potentially offers advantages over low solid loadings including higher lactic acid concentration with decreased production and capital costs. In this study, an isolated Enterococcus faecalis SI with optimal temperature 42 °C was used to produce optically pure L-lactic acid (> 99%) from enzyme-saccharified hydrolysates of acid-impregnated steam explosion (AISE)-treated plywood chips. The L-lactic acid production increased by 10% at 5 L scale compared to the similar fermentation scheme reported by Wee et al. The fermentation with a high solid loading of 20% and 35% (w/v) AISE-pretreated plywood chips had been successfully scaled up to process development unit scale (100 L) and pilot scale (9 m³), respectively. This is the first report of pilot-scale lignocellulosic lactic acid fermentation by E. faecalis with high lactic acid titer (nearly 92 g L^-1) and yield (0.97 kg kg^-1). Therefore, large-scale L-lactic acid production by E. faecalis SI shows the potential application for industries.

Minimizing cellulase inhibition of whole slurry biomass hydrolysis through the addition of carbocation scavengers during acid-catalyzed pretreatment

The aim of this work was to study how to minimize cellulase inhibition of whole slurry biomass hydrolysis through addition of carbocation scavengers during acid-catalyzed pretreatment. Various potential carbocation scavengers were compared and their inhibition mitigating effects towards the hydrolytic performance of cellulase enzymes was assessed. The results indicated that the addition of carbocation scavengers during the pretreatment process could not only alleviate the inhibitory effect of the phenolics on the enzymatic hydrolysis but also increase the accessibility of cellulases to the pretreated substrates. It appeared that lignin-derived compounds such as 4-hydroxybenzoic acid, vanillic acid, syringic acid could all serve as efficient scavengers to alleviate the inhibitory effect of phenolics on cellulose hydrolysis where the syringic acid showed the best mitigating effect. By combining the carbocation scavengers in the pretreatment process, an improved cellulose hydrolysis of the pretreated whole slurry could be achieved without any post detoxification step.

A comparative analysis of pretreatment strategies on the properties and hydrolysis of brewers' spent grain

In this study, brewer's spent grain (BSG) was subjected to a range pretreatments to study the effect on reducing sugar yield. Glucose and xylose were found to be the predominant sugars in BSG. Brewers spent grain was high in cellulose (19.21g/100g of BSG) and lignin content (30.84g/100g of BSG). Microwave assisted alkali (MAA) pretreatment was found to be the most effective pretreatment for BSG, where the pretreatment was conducted at 400W for 60s. A maximum reducing yield was observed with high biomass loading (1g/10ml), cellulase (158.76μl/10ml), hemicellulase (153.3μl/10ml), pH (5.4) and an incubation time (120h). Upon enzymatic hydrolysis, MAA pretreated BSG yielded 228.25mg of reducing sugar/g of BSG which was 2.86-fold higher compared to native BSG (79.67mg/g of BSG); simultaneously BSG was de-lignified significantly. The changes in functional groups, crystallinity and thermal behaviour was studies by means of FTIR, XRD and DSC, respectively.

Understanding the structural and chemical changes of plant biomass following steam explosion pretreatment

BACKGROUND

Biorefining of lignocellulosic biomass has become one of the most valuable alternatives for the production of multi-products such as biofuels. Pretreatment is a prerequisite to increase the enzymatic conversion of the recalcitrant lignocellulose. However, there is still considerable debate regarding the key features of biomass impacting the cellulase accessibility. In this study, we evaluate the structural and chemical features of three different representative biomasses (Miscanthus × giganteus, poplar and wheat straw), before and after steam explosion pretreatment at increasing severities, by monitoring chemical analysis, SEM, FTIR and 2D NMR.

RESULTS

Regardless the biomass type, combined steam explosion pretreatment with dilute sulfuric acid impregnation resulted in significant improvement of the cellulose conversion. Chemical analyses revealed that the pretreatment selectively degraded the hemicellulosic fraction and associated cross-linking ferulic acids. As a result, the pretreated residues contained mostly cellulosic glucose and lignin. In addition, the pretreatment directly affected the cellulose crystallinity but these variations were dependent upon the biomass type. Important chemical modifications also occurred in lignin since the β-O-4' aryl-ether linkages were found to be homolytically cleaved, followed by some recoupling/recondensation to β-β' and β-5' linkages, regardless the biomass type. Finally, 2D NMR analysis of the whole biomass showed that the pretreatment preferentially degraded the syringyl-type lignin fractions in miscanthus and wheat straw while it was not affected in the pretreated poplar samples.

CONCLUSIONS

Our findings provide an enhanced understanding of parameters impacting biomass recalcitrance, which can be easily generalized to both woody and non-woody biomass species. Results indeed suggest that the hemicellulose removal accompanied by the significant reduction in the cross-linking phenolic acids and the redistribution of lignin are strongly correlated with the enzymatic saccharification, by loosening the cell wall structure thus allowing easier cellulase accessibility. By contrast, we have shown that the changes in the syringyl/guaiacyl ratio and the cellulose crystallinity do not seem to be relevant factors in assessing the enzymatic digestibility. Some biomass type-dependent and easily measurable FTIR factors are highly correlated to saccharification.

Effect of pretreatment severity in continuous steam explosion on enzymatic conversion of wheat straw: Evidence from kinetic analysis of hydrolysis time courses

Focusing on continuous steam explosion, the influence of pretreatment severity due to varied acid loading on hydrolysis of wheat straw by Trichoderma reesei cellulases was investigated based on kinetic evaluation of the saccharification of each pretreated substrate. Using semi-empirical descriptors of the hydrolysis time course, key characteristics of saccharification efficiency were captured in a quantifiable fashion. Not only hydrolysis rates per se, but also the transition point of their bi-phasic decline was crucial for high saccharification degree. After 48h the highest saccharification was achieved for substrate pretreated at relatively low severity (1.2% acid). Higher severity increased enzyme binding to wheat straw, but reduced the specific hydrolysis rates. Higher affinity of the lignocellulosic material for cellulases does not necessarily result in increased saccharification, probably because of lignin modifications occurring at high pretreatment severities. At comparable severity, continuous pretreatment produced a substrate more susceptible to enzymatic hydrolysis than the batch process.

Pretreatment optimization of Sorghum pioneer biomass for bioethanol production and its scale-up

Based on one parameter at a time, saccharification of delignified sorghum biomass by 4% and 70% v/v sulfuric acid resulted in maximum 30.8 and 33.8 g% sugar production from biomass respectively. The Box Behnken Design was applied for further optimization of acid hydrolysis. As a result of the designed experiment 36.3g% sugar production was achieved when 3% v/v H2SO4 treatment given for 60 min at 180°C. The process was scaled-up to treat 2 kg of biomass. During the screening of yeast cultures, isolate C, MK-I and N were found to be potent ethanol producers from sorghum hydrolyzate. Culture MK-I was the best so used for scale up of ethanol production up to 25 L capacity, which gave a yield of 0.49 g ethanol/g sugar from hydrolyzate obtained from 2 kg of sorghum biomass.

Production of optically pure L-lactic acid from lignocellulosic hydrolysate by using a newly isolated and D-lactate dehydrogenase gene-deficient Lactobacillus paracasei strain

The use of lignocellulosic feedstock for lactic acid production with a difficulty is that the release of inhibitory compounds during the pretreatment process which inhibit the growth of microorganism. Thus we report a novel lactic acid bacterium, Lactobacillus paracasei 7 BL, that has a high tolerance to inhibitors and produced optically pure l-lactic acid after the interruption of ldhD gene. The strain 7 BL fermented glucose efficiently and showed high titer of l-lactic acid (215 g/l) by fed-batch strategy. In addition, 99 g/l of l-lactic acid with high yield (0.96 g/g) and productivity (2.25-3.23 g/l/h) was obtained by using non-detoxified wood hydrolysate. Rice straw hydrolysate without detoxification was also tested and yielded a productivity rate as high as 5.27 g/l/h. Therefore, L. paracasei 7 BL represents a potential method of l-lactic acid production from lignocellulosic biomass and has attractive application for industries.

Improvement of lignin yield and purity from corncob in the presence of steam explosion and liquid hot pressured alcohol

Non-food biomass such as corncob is a very abundant and promising feedstock for sustainable energy production in China.

Pilot scale study on steam explosion and mass balance for higher sugar recovery from rice straw

Pretreatment of rice straw on pilot scale steam explosion has been attempted to achieve maximum sugar recovery. Three different reaction media viz. water, sulfuric acid and phosphoric acid (0.5%, w/w) were explored for pretreatment by varying operating temperature (160, 180 and 200°C) and reaction time (5 and 10min). Using water and 0.5% SA showed almost similar sugar recovery (∼87%) at 200 and 180°C respectively. However, detailed studies showed that the former caused higher production of oligomeric sugars (13.56g/L) than the later (3.34g/L). Monomeric sugar, followed the reverse trend (7.83 and 11.62g/L respectively). Higher oligomers have a pronounced effect in reducing enzymatic sugar yield as observed in case of water. Mass balance studies for water and SA assisted SE gave total saccharification yield as 81.8% and 77.1% respectively. However, techno-economical viability will have a trade-off between these advantages and disadvantages offered by the pretreatment medium.

Effects of acid impregnated steam explosion process on xylose recovery and enzymatic conversion of cellulose in corncob

Corncob residue is a cellulose-rich byproduct obtained from industrial xylose production via dilute acid hydrolysis processes. Enzymatic hydrolysis of cellulose in acid hydrolysis residue of corncob (AHRC) is often less efficient without further pretreatment. In this work, the process characteristics of acid impregnated steam explosion were studied in conjunction with a dilute acid process, and their effects on physiochemical changes and enzymatic saccharification of corncob residue were compared. With the acid impregnated steam explosion process, both higher xylose recovery and higher cellulose conversion were obtained. The maximum conversion of cellulose in acid impregnated steam explosion residue of corncob (ASERC) reached 85.3%, which was 1.6 times higher than that of AHRC. Biomass compositional analysis showed similar cellulose and lignin content in ASERC and AHRC. XRD analysis demonstrated comparable crystallinity of ASERC and AHRC. The improved enzymatic hydrolysis efficiency was attributed to higher porosity in ASERC, measured by mercury porosimetry.

Characterization of pilot-scale dilute acid pretreatment performance using deacetylated corn stover

BACKGROUND

Dilute acid pretreatment is a promising process technology for the deconstruction of low-lignin lignocellulosic biomass, capable of producing high yields of hemicellulosic sugars and enhancing enzymatic yields of glucose as part of a biomass-to-biofuels process. However, while it has been extensively studied, most work has historically been conducted at relatively high acid concentrations of 1 - 4% (weight/weight). Reducing the effective acid loading in pretreatment has the potential to reduce chemical costs both for pretreatment and subsequent neutralization. Additionally, if acid loadings are sufficiently low, capital requirements associated with reactor construction may be significantly reduced due to the relaxation of requirements for exotic alloys. Despite these benefits, past efforts have had difficulty obtaining high process yields at low acid loadings without supplementation of additional unit operations, such as mechanical refining.

RESULTS

Recently, we optimized the dilute acid pretreatment of deacetylated corn stover at low acid loadings in a 1-ton per day horizontal pretreatment reactor. This effort included more than 25 pilot-scale pretreatment experiments executed at reactor temperatures ranging from 150 - 170°C, residence times of 10 - 20 minutes and hydrolyzer sulfuric acid concentrations between 0.15 - 0.30% (weight/weight). In addition to characterizing the process yields achieved across the reaction space, the optimization identified a pretreatment reaction condition that achieved total xylose yields from pretreatment of 73.5% ± 1.5% with greater than 97% xylan component balance closure across a series of five runs at the same condition. Feedstock reactivity at this reaction condition after bench-scale high solids enzymatic hydrolysis was 77%, prior to the inclusion of any additional conversion that may occur during subsequent fermentation.

CONCLUSIONS

This study effectively characterized a range of pretreatment reaction conditions using deacetylated corn stover at low acid loadings and identified an optimum reaction condition was selected and used in a series of integrated pilot scale cellulosic ethanol production campaigns. Additionally, several issues exist to be considered in future pretreatment experiments in continuous reactor systems, including the formation of char within the reactor, as well as practical issues with feeding herbaceous feedstock into pressurized systems.