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

Enzymatic treatment processes for the production of cellulose nanomaterials: A review

Cellulose nanomaterials have attracted much attention in recent years because of their unique properties. Commercial or semi-commercial production of nanocellulose has been reported in recent years. Mechanical treatments for nanocellulose production are viable but highly energy-intensive. Chemical processes are well reported; however, these chemical processes are not only costly, but also cause environmental concerns and end-use related challenges. This review summarizes recent researches on enzymatic treatment of cellulose fibers for the production of cellulose nanomaterials, with focus on novel enzymatic processes with xylanase and lytic polysaccharide monooxygenases (LPMO) to enhance the efficacy of cellulase. Different enzymes are discussed, including endoglucanase, exoglucanase and xylanase, as well as LPMO, with emphasis on the accessibility and hydrolytic specificity of LPMO enzymes to cellulose fiber structures. LPMO acts in a synergistic way with cellulase to cause significant physical and chemical changes to the cellulose fiber cell-wall structures, which facilitate the nano-fibrillation of the fibers.

Pressurised disc refining of wheat straw as a pre-treatment approach for agricultural residues: A preliminary assessment of energy consumption and fibre composition

This preliminary study assesses a potential pre-treatment approach for agricultural residues, in order to improve enzyme access and cellulose digestibility that increased with increasing refining pressure. Wheat straw, an important European agri-residue, was chopped then refined at pilot-scale under different pressures (4-10 bar) and two refiner plate configurations. The most energy efficient runs used 0.94-0.96 kWh electricity; 8.9-11.0 MJ heat per kg dry matter fibre. A scaling factor specific to the machinery used in the trial suggested that wheat straw could be refined using approximately 160 kWh electricity and 980-1900 MJ heat per tonne DM yield at commercial-scale. Hemicellulose content in wheat straw at 31.8% decreased to the lowest level of 14.6% after refining at 10 bar. Pressurised disc refining did not appear to produce significant quantities of acetic acid, a key fermentation inhibitor, that could limit microbial fermentation.

Comparative study on different pretreatment on enzymatic hydrolysis of corncob residues

Under the situation of increasingly severe challenge of energy consumption, it is of great importance to make full use of bioresources such as forestry and agricultural residues. Herein, the corncob residues generated after processing corncob were enzymatically hydrolyzed to yield fermentable sugars. To overcome the recalcitrance of corncob residues, three kinds of pretreatment methods, i.e., sulfonation, PFI refining, and wet grinding, were applied; their effects on enzymatic hydrolysis and main characteristics of corncob residues substrate were investigated. The results showed that the enzymatic digestibility of the substrate was greatly enhanced by employing each method. The wet grinding exhibited obvious advantages, e.g., the conversion yield of cellulose to glucose and glucose concentration reached 96.7% and 32.2 g/L after 59 h of enzymatic hydrolysis, respectively. The improvement in enzymatic hydrolysis was mainly attributed to the altered characteristics of the substrate such as swelling ability, specific surface area, and particle size and distribution.

Fiber fractionation to understand the effect of mechanical refining on fiber structure and resulting enzymatic digestibility of biomass

Mechanical refining results in fiber deconstruction and modifications that enhance enzyme accessibility to carbohydrates. Further understanding of the morphological changes occurring to biomass during mechanical refining and the impacts of these changes on enzymatic digestibility is necessary to maximize yields and reduce energy consumption. Although the degree of fiber length reduction relative to fibrillation/delamination can be impacted by manipulating refining variables, mechanical refining of any type (PFI, disk, and valley beater) typically results in both phenomena. Separating the two is not straightforward. In this study, fiber fractionation based on particle size performed after mechanical refining of high-lignin pulp was utilized to successfully elucidate the relative impact of fibrillation/delamination and fiber cutting phenomena during mechanical refining. Compositional analysis showed that fines contain significantly more lignin than larger size fractions. Enzymatic hydrolysis results indicated that within fractions of uniform fiber length, fibrillation/delamination due to mechanical refining increased enzymatic conversion by 20-30 percentage points. Changes in fiber length had little effect on digestibility for fibers longer than ~0.5 mm. However, the digestibility of the fines fractions was high for all levels of refining even with the high-lignin content.

Toward an understanding of the increase in enzymatic hydrolysis by mechanical refining

BACKGROUND

Mechanical refining is a low-capital and well-established technology used in pulp and paper industry to improve fiber bonding for product strength. Refining can also be applied in a biorefinery context to overcome the recalcitrance of pretreated biomass by opening up the biomass structure and modifying substrate properties (e.g., morphology, particle size, porosity, crystallinity), which increases enzyme accessibility to substrate and improves carbohydrate conversion. Although several characterization methods have been used to identify the changes in substrate properties, there is no systematic approach to evaluate the extent of fiber cell wall disruption and what physical properties can explain the improvement in enzymatic digestibility when pretreated lignocellulosic biomass is mechanically refined. This is because the fiber cell wall is complex across multiple scales, including the molecular scale, nano- and meso-scale (microfibril), and microscale (tissue level). A combination of advanced characterization tools is used in this study to better understand the effect of mechanical refining on the meso-scale microfibril assembly and the relationship between those meso-scale modifications and enzymatic hydrolysis.

RESULTS

Enzymatic conversion of autohydrolysis sugarcane bagasse was improved from 69.6 to 77.2% (11% relative increase) after applying mechanical refining and an increase in enzymatic digestibility is observed with an increase in refining intensity. Based on a combination of advanced characterizations employed in this study, it was found that the refining action caused fiber size reduction, internal delamination, and increase in pores and swellability.

CONCLUSIONS

A higher level of delamination and higher increase in porosity, analyzed by TEM and DSC, were clearly demonstrated, which explain the faster digestibility rate during the first 72 h of enzymatic hydrolysis for disc-refined samples when compared to the PFI-refined samples. In addition, an increased inter-fibrillar distance between cellulose microfibrils at the nano-meso-scale was also revealed by SFG analysis, while no evidence was found for a change in crystalline structure by XRD and solid-state NMR analysis.

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.

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.

Effects of fibrillation on the wood fibers' enzymatic hydrolysis enhanced by mechanical refining

The hardwood bleached kraft pulp (HBKP) fibers were pretreated by PFI mill to obtain the substrates, the effects of fibrillation on HBKP fibers' enzymatic hydrolysis was studied. The results showed that the enzymatic hydrolysis efficiency was enhanced obviously by mechanical refining. The mechanical refining alterated the fibers' characteristics such as fibrillation degree, specific surface area, swelling ability, crystallinity, fiber length and fines content. All these factors correlating to the enzymatic hydrolysis were evaluated through mathematical analysis. Among these factors, the fibrillation degree has the profoundest impact on the enzymatic hydrolysis of wood fibers. Consequently, the mechanical refining aiming for a high fibrillation degree was feasible to enhance the enzymatic hydrolysis of lignocellulosic biomass.

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.