Use of Empty Fruit Bunches from the oil palm for bioethanol production: a thorough comparison between dilute acid and dilute alkali pretreatment

The potential of imidazole as a new solvent in the pretreatment of agro-industrial lignocellulosic biomass

Lignocellulosic biomass is a renewable material of great abundance. However, its recalcitrant characteristic requires the application of pretreatments. Sugarcane bagasse (SB), soybean hulls (SH), cocoa pod husks (CPH) and oil palm empty fruit bunches (OPEFB) were subjected to imidazole pretreatment in order to evaluate chemical composition variations and influence over enzymatic hydrolysis efficiency. Non-treated SH, SB and OPEFB have higher content of holocellulose, while CPH is rich in lignin polymers (31.2%). After imidazole-pretreatment, all biomasses presented structural disorganization of lignocellulosic fibres and enrichment in the percentage of cellulose. Levels of up to 72% delignification were obtained, which allowed an enzymatic conversion greater than 95% for SB, SH and OPEFB, while only 83% was reached for CPH. Imidazole is then emerging as a potential catalyst for the pretreatment of agro-industrial by-products, allowing the valorisation of these residues and their reinsertion into the production chain under a biorefinery concept.

Process design, simulation, and techno-economic analysis of integrated production of furfural and glucose derived from palm oil empty fruit bunches

This study aims to propose a new process design, simulation, and techno-economic analysis of an integrated process plant that produces glucose and furfural from palm oil empty fruit bunches (EFB). In this work, an Aspen Plus-based simulation has been established to develop a process flow diagram of co-production of glucose and furfural along with the mass and energy balances. The plant's economics are analyzed by calculating the fixed capital income (FCI), operating costs, and working capital. In contrast, profitability is determined using cumulative cash flow (CCF), net present value (NPV), and internal rate of return (IRR). The findings show that the production capacity of 10 kilotons per year (ktpy) of glucose and 4.96 ktpy of furfural with a purity of 98.21 and 99.54%-weight, respectively, was achieved in this study. The FCI is calculated as United States Dollar (USD) 20.80 million, while the working and operating expenses are calculated as USD 3.74 million and USD 16.93 million, respectively. This project achieves USD 7.65 million NPV with a positive IRR of 14.25% and a return on investment (ROI) of 22.06%. The present work successfully develops a profitable integrated process plant that is established with future upscaling parameters and key cost drivers. The findings provided in this work offer a platform and motivation for future research on integrated plants in the food, environment, and energy nexus with the co-location principle.

Graphical Abstract

Process design and life cycle assessment of furfural and glucose co-production derived from palm oil empty fruit bunches

In light of environmental issues, lignocellulosic empty fruit bunch (EFB) biomass is promoted as a carbon-neutral, environmentally friendly, and renewable alternative feedstock. A comprehensive environmental assessment of EFB biorefineries is critical for determining their sustainability in parallel with the bioeconomy policy. Nonetheless, no life cycle assessment (LCA) has been performed on co-producing food and biochemicals (furfural and glucose) derived from EFB biomass. This research is the first to evaluate the environmental performance of the furfural and glucose co-production processes from EFB biomass. Environmental analysis is conducted using a prospective gate-to-gate LCA for four impact categories, including global warming potential (GWP), acidification (ADP), eutrophication (EP), and human toxicity (HT). Aspen Plus is used to simulate the co-production process of furfural and glucose as well as generate mass and energy balances for LCA inventory data usage. The findings suggest that the environmental footprint in respect of GWP, ADP, EP, and HT is 4846.85 kg CO2 equivalent per ton EFB, 7.24 kg SO2 equivalent per ton EFB, 1.52 kg PO4 equivalent per ton EFB, and 2.62E-05 kg 1,4-DB equivalent per ton EFB, respectively. The normalized overall impact scores for GWP, ADP, EP, and HT are 1.16E-10, 2.28E-11, 6.12E-10, and 2.18E-17 years/ton of EFB, respectively. In summary, the proposed integrated plant is not only economically profitable but also environmentally sustainable. In the attempt to enhance the Malaysian economic sector based on the EFB, this study has the potential to serve as an indicator of the environmental sustainability of the palm oil industry.

Graphical abstract

Supplementary Information

The online version contains supplementary material available at 10.1007/s10668-022-02633-8.

Effect of Ni(NO3)2 Pretreatment on the Pyrolysis of Organsolv Lignin Derived from Corncob Residue

The thermal degradation of lignin for value-added fuels and chemicals is important for environment improvement and sustainable development. The impact of pretreatment and catalysis of Ni(NO3)2 on the pyrolysis behavior of organsolv lignin were studied in the present work. Samples were pyrolyzed at 500 ∘C with an upward fixed bed, and the characteristics of bio-oil were determined. After pretreatment by Ni(NO3)2, the yield of monophenols increased from 23.3 wt.% to 30.2 wt.% in “Ni-washed” and decreased slightly from 23.3 wt.% to 20.3 wt.% in “Ni-unwashed”. Meanwhile, the selective formation of vinyl-monophenols was promoted in “Ni-unwashed”, which indicated that the existence of nickel species promoted the dehydration of C-OH and breakage of C-C in pyrolysis. In comparison with “Water”, HHV of bio-oil derived from “Ni-unwashed” slightly increased from 27.94 mJ/kg to 28.46 mJ/kg, suggesting that the lowering of oxygen content in bio-oil is associated with improved quality. Furthermore, the content of H2 in gas products dramatically increased from 2.0% to 7.6% and 17.1%, respectively.

A comprehensive review on the framework to valorise lignocellulosic biomass as biorefinery feedstocks

An effective pretreatment is the first step to enhance the digestibility of lignocellulosic biomass - a source of renewable, eco-friendly and energy-dense materials - for biofuel and biochemical productions. This review aims to provide a comprehensive assessment on the advantages and disadvantages of lignocellulosic pretreatment techniques, which have been studied at the lab-, pilot- and full-scale levels. Biological pretreatment is environmentally friendly but time consuming (i.e. 15-40 days). Chemical pretreatment is effective in breaking down lignocellulose and increasing sugar yield (e.g. 4 to 10-fold improvement) but entails chemical cost and expensive reactors. Whereas the combination of physical and chemical (i.e. physicochemical) pretreatment is energy intensive (e.g. energy production can only compensate 80% of the input energy) despite offering good process efficiency (i.e. > 100% increase in product yield). Demonstrations of pretreatment techniques (e.g. acid, alkaline, and hydrothermal) in pilot-scale have reported 50-80% hemicellulose solubilisation and enhanced sugar yields. The feasibility of these pilot and full-scale plants has been supported by government subsidies to encourage biofuel consumption (e.g. tax credits and mandates). Due to the variability in their mechanisms and characteristics, no superior pretreatment has been identified. The main challenge lies in the capability to achieve a positive energy balance and great economic viability with minimal environmental impacts i.e. the energy or product output significantly surpasses the energy and monetary input. Enhancement of the current pretreatment techno-economic efficiency (e.g. higher product yield, chemical recycling, and by-products conversion to increase environmental sustainability) and the integration of pretreatment methods to effectively treat a range of biomass will be the steppingstone for commercial lignocellulosic biorefineries.

Integrated Biorefinery of Empty Fruit Bunch from Palm Oil Industries to Produce Valuable Biochemicals

Empty fruit bunch (EFB) utilization to produce valuable bio-chemicals is seen as an economical and sustainable alternative to waste management in palm oil industries. This work proposed an integrated biorefinery configuration of EFB valorization considering sustainability pillars—namely, economic, environmental, and safety criteria. Techno-economic analysis, life cycle assessment, and hazard identification ranking methods were used to estimate annual profit, global warming potential (GWP), fire explosion damage index (FEDI), and toxicity damage index (TDI) of the proposed integrated biorefinery. A multi-objective optimization problem was then formulated and solved for simultaneous maximization of profit and minimization of GWP, FEDI and TDI. The resulting Pareto-optimal solutions convey the trade-off among the economic, environmental, and safety performances. To choose one of these optimal solutions for implementation, a combined approach of fuzzy analytical hierarchy process and a technique for order preference by similarity to ideal solution was applied. For this selection, the economic criterion was more preferred, followed by the safety and environmental criterion; thus, the optimal solution selected for integrated biorefinery configuration had the highest annual profit, which was at the maximum capacity of 100 ton/h of EFB. It can fulfill the global demand of xylitol (by 55%), levulinic acid (by 98%), succinic acid (by 25%), guaiacol (by 90%), and vanillin (by 12%), and has annual profit, GWP, FEDI, and TDI of 932 M USD/year, 284 tonCO2-eq, 595, and 957, respectively.

Thermogravimetric analysis and kinetic modeling of low-transition-temperature mixtures pretreated oil palm empty fruit bunch for possible maximum yield of pyrolysis oil

The impacts of low-transition-temperature mixtures (LTTMs) pretreatment on thermal decomposition and kinetics of empty fruit bunch (EFB) were investigated by thermogravimetric analysis. EFB was pretreated with the LTTMs under different duration of pretreatment which enabled various degrees of alteration to their structure. The TG-DTG curves showed that LTTMs pretreatment on EFB shifted the temperature and rate of decomposition to higher values. The EFB pretreated with sucrose and choline chloride-based LTTMs had attained the highest mass loss of volatile matter (78.69% and 75.71%) after 18 h of pretreatment. For monosodium glutamate-based LTTMs, the 24 h pretreated EFB had achieved the maximum mass loss (76.1%). Based on the Coats-Redfern integral method, the LTTMs pretreatment led to an increase in activation energy of the thermal decomposition of EFB from 80.00 to 82.82-94.80 kJ/mol. The activation energy was mainly affected by the demineralization and alteration in cellulose crystallinity after LTTMs pretreatment.

In vitro and in silico characterization of metagenomic soil-derived cellulases capable of hydrolyzing oil palm empty fruit bunch

Diversification of raw material for biofuel production is of interest to both academia and industry. One attractive substrate is a renewable lignocellulosic material such as oil palm (Elaeis guineensis Jacq.) empty fruit bunch (OPEFB), which is a byproduct of the palm oil industry. This study aimed to characterize cellulases active against this substrate. Cellulases with activity against OPEFB were identified from a metagenomic library obtained from DNA extracted from a high-Andean forest ecosystem. Our findings show that the highest cellulolytic activities were obtained at pH and temperature ranges of 4-10 and 30 °C-60 °C, respectively. Due to the heterogeneous character of the system, degradation profiles were fitted to a fractal-like kinetic model, evidencing transport mass transfer limitations. The sequence analysis of the metagenomic library inserts revealed three glycosyl hydrolase families. Finally, molecular docking simulations of the cellulases were carried out corroborating possible exoglucanase and β-glucosidase activity.

Directed evolution of a β-mannanase from Rhizomucor miehei to improve catalytic activity in acidic and thermophilic conditions

BACKGROUND

β-Mannanase randomly cleaves the β-1,4-linked mannan backbone of hemicellulose, which plays the most important role in the enzymatic degradation of mannan. Although the industrial applications of β-mannanase have tremendously expanded in recent years, the wild-type β-mannanases are still defective for some industries. The glycoside hydrolase (GH) family 5 β-mannanase (RmMan5A) from Rhizomucor miehei shows many outstanding properties, such as high specific activity and hydrolysis property. However, owing to the low catalytic activity in acidic and thermophilic conditions, the application of RmMan5A to the biorefinery of mannan biomasses is severely limited.

RESULTS

To overcome the limitation, RmMan5A was successfully engineered by directed evolution. Through two rounds of screening, a mutated β-mannanase (mRmMan5A) with high catalytic activity in acidic and thermophilic conditions was obtained, and then characterized. The mutant displayed maximal activity at pH 4.5 and 65 °C, corresponding to acidic shift of 2.5 units in optimal pH and increase by 10 °C in optimal temperature. The catalytic efficiencies (k_cat/K_m) of mRmMan5A towards many mannan substrates were enhanced more than threefold in acidic and thermophilic conditions. Meanwhile, the high specific activity and excellent hydrolysis property of RmMan5A were inherited by the mutant mRmMan5A after directed evolution. According to the result of sequence analysis, three amino acid residues were substituted in mRmMan5A, namely Tyr233His, Lys264Met, and Asn343Ser. To identify the function of each substitution, four site-directed mutations (Tyr233His, Lys264Met, Asn343Ser, and Tyr233His/Lys264Met) were subsequently generated, and the substitutions at Tyr233 and Lys264 were found to be the main reason for the changes of mRmMan5A.

CONCLUSIONS

Through directed evolution of RmMan5A, two key amino acid residues that controlled its catalytic efficiency under acidic and thermophilic conditions were identified. Information about the structure-function relationship of GH family 5 β-mannanase was acquired, which could be used for modifying β-mannanases to enhance the feasibility in industrial application, especially in biorefinery process. This is the first report on a β-mannanase from zygomycete engineered by directed evolution.

Suitability assessment of a continuous process combining thermo-mechano-chemical and bio-catalytic action in a single pilot-scale twin-screw extruder for six different biomass sources

A process has been validated for the deconstruction of lignocellulose on a pilot scale installation using six types of biomass selected for their sustainability, accessibility, worldwide availability, and differences of chemical composition and physical structure. The process combines thermo-mechano-chemical and bio-catalytic action in a single twin-screw extruder. Three treatment phases were sequentially performed: an alkaline pretreatment, a neutralization step coupled with an extraction-separation phase and a bioextrusion treatment. Alkaline pretreatment destructured the wall polymers after just a few minutes and allowed the initial extraction of 18-54% of the hemicelluloses and 9-41% of the lignin. The bioextrusion step induced the start of enzymatic hydrolysis and increased the proportion of soluble organic matter. Extension of saccharification for 24h at high consistency (20%) and without the addition of new enzyme resulted in the production of 39-84% of the potential glucose.

Two-stage, acetic acid-aqueous ammonia, fractionation of empty fruit bunches for increased lignocellulosic biomass utilization

Fractionation of EFB was conducted in two consecutive steps using a batch reaction system: hemicellulose hydrolysis using acetic acid (AA; 3.0-7.0 wt.%) at 170-190°C for 10-20 min in the first stage, and lignin solubilization using ammonium hydroxide (5-20 wt.%) at 140-220°C for 5-25 min in the second stage. The two-stage process effectively fractionated empty fruit bunches (EFB) in terms of hemicellulose hydrolysis (53.6%) and lignin removal (59.5%). After the two-stage treatment, the fractionated solid contained 65.3% glucan. Among three investigated process parameters, reaction temperature and ammonia concentration had greater impact on the delignification reaction in the second stage than reaction time. The two-stage fractionation processing improved the enzymatic digestibility to 72.9% with 15 FPU of cellulase/g of glucan supplemented with 70 pNPG of β-glycosidase (Novozyme 188)/g-glucan, which was significantly enhanced from the equivalent digestibility of 28.3% for untreated EFB and 45.7% for AAH-fractionated solid.

Recent Advances in the Application of Inorganic Salt Pretreatment for Transforming Lignocellulosic Biomass into Reducing Sugars

Currently, the transformation of lignocellulosic biomass into value-added products such as reducing sugars is garnering attention worldwide. However, efficient hydrolysis is usually hindered by the recalcitrant structure of the biomass. Many pretreatment technologies have been developed to overcome the recalcitrance of lignocellulose such that the components can be reutilized more effectively to enhance sugar recovery. Among all of the utilized pretreatment methods, inorganic salt pretreatment represents a more novel method and offers comparable sugar recovery with the potential for reducing costs. The use of inorganic salt also shows improved performance when it is integrated with other pretreatment technologies. Hence, this paper is aimed to provide a detailed overview of the current situation for lignocellulosic biomass and its physicochemical characteristics. Furthermore, this review discusses some recent studies using inorganic salt for pretreating biomass and the mechanisms involved during the process. Finally, some prospects and challenges using inorganic salt are highlighted.

Hierarchical economic potential approach for techno-economic evaluation of bioethanol production from palm empty fruit bunches

A hierarchical four-level approach to determine economic potential (4-level EP) is proposed for preliminary techno-economic analysis of new processes. The 4-level EP includes input/output structure, process flow structure, heat integration (HI), and economic feasibility. Two case studies on a 30.2 t/d (or 12.7 million l/yr) bioethanol plant with and without jet fuel production from palm empty fruit bunches (EFB) were investigated by applying the 4-level EP. The plant flowsheet was established based on experiments in a 0.1t/d pilot plant, including sequential dilute acid and alkali pretreatment, and separate hydrolysis and fermentation (SHF). EP approached a more reliable value through the hierarchical 4-level EP. The heating energy was reduced considerably by HI. The product value was estimated at $0.8-$1.3/kg of equivalent bioethanol. It was suggested through sensitivity analysis that a large plant size, enhanced production yields, and capital cost reduction were necessary for the lignocellulosic bioethanol production to be profitable.

Role of pretreatment with acid and base on the distribution of the products obtained via lignocellulosic biomass pyrolysis

Analysis of chemicals distribution in pyrolysis liquid following different content of acid and base in pretreatment.

Ethanol and lignin production from Brazilian empty fruit bunch biomass

Brazil Government is promoting palm plantations to use degraded land for biofuels. Palm production is expected to increase 35 per cent in future and there would be profuse biomass available that needs to be handled efficiently. Therefore, in this study the potential of EFB from Brazil as raw material for biorefinery was explored by compositional analysis and pretreatment conditions optimization to produce ethanol and co-products. EFB from Brazil contains significant cellulose, hemicellulose, lignin and low ash content. The optimized dilute sulfuric acid pretreatment conditions for efficient cellulose and hemicellulose separation were 160°C temperature, 1.025% v/v acid concentration, 10.5min and 20% solid loading. Under optimum pretreatment process conditions, low enzyme loading (10FPU, 20IU cellulase and glucosidase enzyme/g glucan) and 15% solid loading, 51.1g ethanol, 344.1g solid residue (65% lignin and 24.87MJ/kg LHV) and 3.7l xylose rich liquid could be produced per kg dry EFB.

Effects of acid and alkali promoters on compressed liquid hot water pretreatment of rice straw

In this study, effects of homogeneous acid and alkali promoters on efficiency and selectivity of LHW pretreatment of rice straw were studied. The presences of acid (0.25%v/v H2SO4, HCl, H3PO4, and oxalic acid) and alkali (0.25 w/v NaOH) efficiently promoted hydrolysis of hemicellulose, improved enzymatic digestibility of the solids, and lower the required LHW temperature. Oxalic acid was a superior promoter under the optimal LHW conditions at 160 °C, leading to the highest glucose yield from enzymatic hydrolysis (84.2%) and the lowest formation of furans. Combined with hydrolyzed glucose in the liquid, this resulted in the maximal 91.6% glucose recovery from the native rice straw. This was related to changes in surface area and crystallinity of pretreated biomass. The results showed efficiency of external promoters on increasing sugar recovery and saving energy in LHW pretreatment.