Influence of aeration on bioethanol production from ozonized wheat straw hydrolysates using Pichia stipitis

High-solid enzymatic hydrolysis of sugarcane bagasse and ethanol production in repeated batch process using column reactors

Alkaline sulfite pretreated sugarcane bagasse was enzymatically hydrolyzed in a packed-bed column reactor and a bubble column reactor was evaluated to produce ethanol from the hydrolysate. Initial solid loadings of 9-16% were used in column reactor in the hydrolysis step, and the use of lower value (9%) resulted in 41 g L^-1 of glucose in the hydrolysate, corresponding to 87% of cellulose hydrolysis yield. This yield was reduced to 65% for a solid loading of 16%, corresponding to a glucose concentration of 54 g L^-1. Subsequently, Saccharomyces cerevisiae and Scheffersomyces stipitis were used for ethanol production in medium based on hydrolysate previously obtained, using different aeration flowrates (0.3, 0.5 and 0.7 vvm). In simple batch fermentation using S. cerevisiae, higher ethanol yield (0.40 g.g^-1) and productivity (1.58 g.L^-1.h^-1) were achieved using 0.5 vvm. When S. stipitis was used in simple batch co-fermentations, the maximum ethanol productivities were obtained using 0.5 and 0.7 vvm (0.64 and 0.63 g.L^-1.h^-1, respectively). Successive repeated batches resulted in average ethanol concentration of 38 g.L^-1 and fermentation efficiency of 82%, when using S. cerevisiae. For S. stipitis, those values were, respectively, 36 g.L^-1 and 50%, with volumetric productivity increased along the cycles. Thus, the potential of the bioreactors as simple systems for use in the biological steps of biorefineries was demonstrated.

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s13205-021-02932-3.

The Improvement of Bioethanol Production by Pentose-Fermenting Yeasts Isolated from Herbal Preparations, the Gut of Dung Beetles, and Marula Wine

Efficient conversion of pentose sugars to ethanol is important for an economically viable lignocellulosic bioethanol process. Ten yeasts fermenting both D-xylose and L-arabinose were subjected to an adaptation process with L-arabinose as carbon source in a medium containing acetic acid. Four Meyerozyma caribbica-adapted strains were able to ferment L-arabinose to ethanol in the presence of 3 g/L acetic acid at 35°C. Meyerozyma caribbica Mu 2.2f fermented L-arabinose to produce 3.0 g/L ethanol compared to the parental strain with 1.0 g/L ethanol in the absence of acetic acid. The adapted M. caribbica Mu 2.2f strain produced 3.6 and 0.8 g/L ethanol on L-arabinose and D-xylose, respectively, in the presence of acetic acid while the parental strain failed to grow. In a bioreactor, the adapted M. caribbica Mu 2.2f strain produced 5.7 g/L ethanol in the presence of 3 g/L acetic acid with an ethanol yield and productivity of 0.338 g/g and 0.158 g/L/h, respectively, at a K _L a value of 3.3 h^-1. The adapted strain produced 26.7 g/L L-arabitol with a yield of 0.900 g/g at a K _L a value of 4.9 h^-1.

Metabolic fluxes-oriented control of bioreactors: a novel approach to tune micro-aeration and substrate feeding in fermentations

Background

Fine-tuning the aeration for cultivations when oxygen-limited conditions are demanded (such as the production of vaccines, isobutanol, 2–3 butanediol, acetone, and bioethanol) is still a challenge in the area of bioreactor automation and advanced control. In this work, an innovative control strategy based on metabolic fluxes was implemented and evaluated in a case study: micro-aerated ethanol fermentation.

Results

The experiments were carried out in fed-batch mode, using commercial Saccharomyces cerevisiae, defined medium, and glucose as carbon source. Simulations of a genome-scale metabolic model for Saccharomyces cerevisiae were used to identify the range of oxygen and substrate fluxes that would maximize ethanol fluxes. Oxygen supply and feed flow rate were manipulated to control oxygen and substrate fluxes, as well as the respiratory quotient (RQ). The performance of the controlled cultivation was compared to two other fermentation strategies: a conventional “Brazilian fuel-ethanol plant” fermentation and a strictly anaerobic fermentation (with ultra-pure nitrogen used as the inlet gas). The cultivation carried out under the proposed control strategy showed the best average volumetric ethanol productivity (7.0 g L⁻¹ h⁻¹), with a final ethanol concentration of 87 g L⁻¹ and yield of 0.46 g_ethanol g_substrate⁻¹. The other fermentation strategies showed lower yields (close to 0.40 g_ethanol g_substrate⁻¹) and ethanol productivity around 4.0 g L⁻¹ h⁻¹.

Conclusion

The control system based on fluxes was successfully implemented. The proposed approach could also be adapted to control several bioprocesses that require restrict aeration.

Two-Stage Aeration Fermentation Strategy to Improve Bioethanol Production by Scheffersomyces stipitis

Hardwood spent sulfite liquor (HSSL) is a by-product from pulp industry with a high concentration of pentose sugars, besides some hexoses suitable for bioethanol production by Scheffersomyces stipitis. The establishment of optimal aeration process conditions that results in specific microaerophilic conditions required by S. stipitis is the main challenge for ethanol production. The present study aimed to improve the ethanol production from HSSL by S. stipitis through a two-stage aeration fermentation. Experiments with controlled dissolved oxygen tension (DOT) in the first stage and oxygen restriction in the second stage were carried out. The best results were obtained with DOT control at 50% in the first stage, where the increase of oxygen availability provided faster growth and higher biomass yield, and no oxygen supply with an agitation rate of 250 rpm, in the second stage allowed a successful induction of ethanol production. Fermentation using 60% of HSSL (v/v) as substrate for S. stipitis provided a maximum specific growth rate of 0.07 h−1, an ethanol productivity of 0.04 g L h−1 and an ethanol yield of 0.39 g g−1, respectively. This work showed a successful two-stage aeration strategy as a promising aeration alternative for bioethanol production from HSSL by S. stipitis.

Enhanced ethanol production at commercial scale from molasses using high gravity technology by mutant S. cerevisiae

Very high gravity (VHG) technology was employed on industrial scale to produce ethanol from molasses (fermented) as well as by-products formation estimation. The effect of different Brix° (32, 36 and 40) air-flow rates (0.00, 0.20, 0.40, and 0.60 vvm) was studied on ethanol production. The maximum ethanol production was recorded to be 12.2% (v/v) at 40 Brix° with 0.2 vvm air-flow rate. At optimum level aeration and 40 Brix° VHG, the residual sugar level was recorded in the range of 12.5–18.5 g/L, whereas the viable cell count remained constant up to 50 h of fermentation and dry matter production increased with fermentation time. Both water and steam consumption reduced significantly under optimum conditions of Brix° and aeration rate with compromising the ethanol production. Results revealed VHG with continuous air flow is viable technique to reduce the ethanol production cost form molasses at commercial scale.

Enhanced fuel ethanol production from rice straw hydrolysate by an inhibitor-tolerant mutant strain of Scheffersomyces stipitis

A novel process for bioethanol production from lignocellulosic biomass using an inhibitor-tolerant mutant strain of Scheffersomyces stipitis and cell-recycling continuous fermentation.

Effect of ozonolysis parameters on the inhibitory compound generation and on the production of ethanol by Pichia stipitis and acetone-butanol-ethanol by Clostridium from ozonated and water washed sugarcane bagasse

Sugarcane bagasse (SCB) was ozone pretreated and detoxified by water washing, applying a L9(3)(4) orthogonal array (OA) design of experiments to study the effect of pretreatment parameters (moisture content, ozone concentration, ozone/oxygen flow and particle size) on the generation of inhibitory compounds and on the composition of hydrolysates of ozonated-washed samples. Ozone concentration resulted the highest influence process parameter on delignification and sugar release after washing; while, for inhibitory compound formation, moisture content also had an important role. Ozone expended in pretreatment related directly with sugar release and inhibitory compound formation. Washing detoxification was effective, providing non-inhibitory hydrolysates. Maximum glucose and xylose release yields obtained were 84% and 67%, respectively, for ozonated-washed SCB. Sugar concentration resulted in the decisive factor for biofuels yields. Ethanol production achieved an 88% yield by Pichia stipitis, whereas Clostridium acetobutylicum produced 0.072gBUTANOL/gSUGAR and 0.188gABE/gSUGAR, and, Clostridium beijerinckii 0.165gBUTANOL/gSUGAR and 0.257gABE/gSUGAR.

Ozonolysis: An advantageous pretreatment for lignocellulosic biomass revisited

Ozonolysis, as a lignocellulosic biomass pretreatment, goes back to 80s; however, in the last years it is becoming widespread again owing to its efficiency and mild operation conditions. Ozone reacts preferably with lignin than carbohydrates, promoting biomass destructuration and delignification, and so the sugar release by enzymatic hydrolysis. The hydrolysate from pretreated biomass has being used as sugars source for second-generation fuels production, mainly ethanol, methane and hydrogen. Short-chain carboxylic acids are the main inhibitory compounds generated, being properly removed by water washing. The most common inhibitory compounds reported for other pretreatments, furfural and HMF (5-hydroxymethylfurfural), are not found in ozone-pretreated hydrolysates. Composition of pretreated biomass and ozone consumption depends on several process parameters: reactor design, moisture content, particle size, pH, reaction time, ozone/air flow and ozone concentration. Additional studies are necessary to clarify process parameters effect and to optimize the process to achieve high yields with economic feasibility.

Efficient ethanol production from potato and corn processing industry waste using E. coli engineered to express Vitreoscilla haemoglobin

Engineering of ethanologenic E. coli to express the haemoglobin (VHb) from the bacterium Vitreoscilla has been shown to enhance ethanol production by fermentation of pure sugars, sugars from hydrolysis of lignocellulose, components of whey, and sugars from wastewater produced during potato processing. Here, these studies were extended to see whether the same effect could be seen when a mixture of waste materials from processing of potatoes and corn into potato and corn chips were used as sugar sources. Consistent increases in ethanol production coincident with VHb expression were seen in shake flasks at both low aeration and high aeration conditions. The ethanol increases were due almost entirely to increases in the amount of ethanol produced per unit of cell mass. The VHb strategy for increasing fermentation to ethanol (and perhaps other valuable fermentation products) may be of general use, particularly regarding conversion of otherwise discarded materials into valuable commodities.

Acetone-butanol-ethanol (ABE) production by Clostridium beijerinckii from wheat straw hydrolysates: efficient use of penta and hexa carbohydrates

ABE fermentation by Clostridium beijerinckii of steam-exploded and ozonated wheat straw hydrolysates was investigated. In steam-exploded hydrolysates, highest yields of 0.40 g/g ABE yield and 127.71 g ABE/kg wheat straw were achieved when the whole slurry from the pretreatment was used. In ozonated hydrolysates, 0.32 g/g ABE yield and 79.65 g ABE/kg wheat straw were obtained from washed ozonated wheat straw. Diverse effects were observed in steam explosion and ozonolysis of wheat straw which resulted in hemicellulose removal and acid insoluble lignin solubilization, respectively. SEM analysis showed structural differences in untreated and pretreated biomass. Depending on the operational strategy, after pretreatment and enzymatic hydrolysis, the glucose recovery ranged between 65.73-66.49% and 63.22-65.23% and the xylose recovery ranged between 45.19-61.00% and 34.54-40.91% in steam-exploded and ozonated hydrolysates, respectively. The effect of the main inhibitory compounds found in hydrolysates (oxalic acid, acetic acid, 5-hydroxymethylfurfural and furfural) was studied through ABE fermentation in model media.

Ethanol production from sunflower meal biomass by simultaneous saccharification and fermentation (SSF) with Kluyveromyces marxianus ATCC 36907

The lignocellulosic materials are considered promising renewable resources for ethanol production, but improvements in the processes should be studied to reduce operating costs. Thus, the appropriate enzyme loading for cellulose saccharification is critical for process economics. This study aimed at evaluating the concentration of cellulase and β-glucosidase in the production of bioethanol by simultaneous saccharification and fermentation (SSF) of sunflower meal biomass. The sunflower biomass was pretreated with 6% H2SO4 (w/v), at 121 °C, for 20 min, for hemicellulose removal and delignificated with 1% NaOH. SSF was performed with Kluyveromyces marxianus ATCC 36907, at 38 °C, 150 rpm, for 72 h, with different enzyme concentrations (Cellulase Complex NS22086-10, 15 and 20 FPU/gsubstrate and β-Glucosidase NS22118, with a cellulase to β-glucosidase ratio of 1.5:1; 2:1 and 3:1). The best condition for ethanol production was cellulase 20 FPU/gsubstrate and β-glucosidase 13.3 CBU/gsubstrate, resulting in 27.88 g/L ethanol, yield of 0.47 g/g and productivity of 0.38 g/L h. Under this condition the highest enzymatic conversion of cellulose to glucose was attained (87.06%).

Ethanol production from glucose and xylose obtained from steam exploded water-extracted olive tree pruning using phosphoric acid as catalyst

In this work, the effect of phosphoric acid (1% w/w) in steam explosion pretreatment of water extracted olive tree pruning at 175°C and 195°C was evaluated. The objective is to produce ethanol from all sugars (mainly glucose and xylose) contained in the pretreated material. The water insoluble fraction obtained after pretreatment was used as substrate in a simultaneous saccharification and fermentation (SSF) process by a commercial strain of Saccharomyces cerevisiae. The liquid fraction, containing mainly xylose, was detoxified by alkali and ion-exchange resin and then fermented by the xylose fermenting yeast Scheffersomyces stipitis. Ethanol yields reached in a SSF process were close to 80% when using 15% (w/w) substrate consistency and about 70% of theoretical when using prehydrolysates detoxified by ion-exchange resins. Considering sugars recovery and ethanol yields about 160g of ethanol from kg of water extracted olive tree pruning could be obtained.

Potential of bioethanol production from olive mill solid wastes

The main objective of this study was to screen endogenous microorganisms grown on olive mill solid wastes (OMSW) with the potential to ferment pentoses and produce ethanol. Two yeasts were isolated and identified as Issatchenkia orientalis, and Pichia galeiformis/manshurica. The adaptation of the strains displayed a positive impact on the fermentation process. In terms of xylose utilization and ethanol production, all strains were able to utilize xylose and produce xylitol but no ethanol was detected. Separate hydrolysis and fermentation process on hydrolysate undergo detoxification, strain I. orientalis showed the best efficiency in producing of ethanol when supplemented with glucose. Using simultaneous saccharification and fermentation process following pretreatment of OMSW, the average ethanol yield was 3 g/100 g dry OMSW. Bioethanol production from OMSW is not economic despite the raw material is cheap.

Hydrolysis of ozone pretreated energy grasses for optimal fermentable sugar production

Ozonated energy grass varieties were enzymatically hydrolyzed to establish process parameters for maximum fermentable sugar production. Conditions for ozonolysis were selected on the basis of maximum delignification and glucan retention after pretreatment. To study the effect of lignin degradation products generated during ozonolysis on cellulolytic enzymes, hydrolysis was carried out for washed and unwashed pretreated solids. Washing the solids significantly (p<0.05) enhanced glucan conversion from 34.3% to 100% while delivering glucose yields of 146.2-431.9 mg/g biomass. Highest fermentable sugars were produced when grasses were ozonated for maximum delignification and washed solids were hydrolyzed using 0.1g/g Cellic® CTec2. In a comparative study on alkaline pretreatment with 1% NaOH for 60 min, Saccharum arundinaceum exhibited the highest glucan conversion with maximum sugar production of 467.9 mg/g. Although ozonolysis is an effective and environmentally friendly technique for cellulosic sugar production, process optimization is needed to ascertain economic feasibility of the process.

Potential of ozonolysis as a pretreatment for energy grasses

This study investigated the effect of ozonolysis on Miscanthus × giganteus, Miscanthus sinensis 'Gracillimus', Saccharum arundinaceum and Saccharum ravennae, collectively referred to as 'energy grasses'. Studies were conducted at three different ozone concentrations (40, 50 and 58 mg/l) using two ozone flow configurations - uni-directional and reversed flow. Pretreatment conditions for each variety were optimized based on lignin content and glucan recovery in ozonated solids. Results showed that ozonolysis was effective in removing up to 59.9% lignin without cellulose degradation. However, subsequent hydrolysis of pretreated solids with Cellic® CTec2 at 0.06 g/g raw biomass provided glucan conversion lower than untreated samples suggesting enzyme inhibition by lignin degradation products formed during ozonolysis. Future studies investigating hydrolysis efficiency of washed pretreated solids with higher enzyme loadings are therefore warranted to optimize the hydrolysis process and make it functionally feasible.

Experimental study and neural network modeling of sugarcane bagasse pretreatment with H2SO4 and O3 for cellulosic material conversion to sugar

In this study, pretreatment of sugarcane bagasse and subsequent enzymatic hydrolysis is investigated using two categories of pretreatment methods: dilute acid (DA) pretreatment and combined DA-ozonolysis (DAO) method. Both methods are accomplished at different solid ratios, sulfuric acid concentrations, autoclave residence times, bagasse moisture content, and ozonolysis time. The results show that the DAO pretreatment can significantly increase the production of glucose compared to DA method. Applying k-fold cross validation method, two optimal artificial neural networks (ANNs) are trained for estimations of glucose concentrations for DA and DAO pretreatment methods. Comparing the modeling results with experimental data indicates that the proposed ANNs have good estimation abilities.