Valorizing recycled paper sludge by a bioethanol production process with cellulase recycling

Augmentation in polyhydroxybutyrate and biogas production from waste activated sludge through mild sonication induced thermo-fenton disintegration

In this study, an innovative approach was developed to enhance the hydrolysis through phase-separated pretreatment by removing exopolymeric substances via mild sonication followed by thermo-Fenton disintegration. The exopolymeric substances fragmentation was enhanced at the sonic specific energy input of 2.58 kJ/kg total solids. After exopolymeric substance removal, the disintegration of biomass by thermo-Fenton yield the solubilization of 29.8 % at Fe²⁺:H₂O₂ dosage and temperature of 0.009:0.036 g/g suspended solids and 80 °C as compared to thermo-Fenton alone disintegration. The polyhydroxybutyrate content of 93.1 % was accumulated by Bacillus aryabhattai at the optimum time of 42 h, while providing 70 % (v/v) pre-treated supernatant as a carbon source under nutrient-limiting condition. Moreover, the biogas generation of 0.187 L/g chemical oxygen demand was achieved using settled pretreated sludge. The pretreated sludge sample thus served as a carbon source for polyhydroxybutyrate producers as well as substrate for biogas production.

Strategies towards Reduction of Cellulases Consumption: Debottlenecking the Economics of Lignocellulosics Valorization Processes

Lignocellulosic residues have been receiving growing interest as a promising source of polysaccharides, which can be converted into a variety of compounds, ranging from biofuels to bioplastics. Most of these can replace equivalent products traditionally originated from petroleum, hence representing an important environmental advantage. Lignocellulosic materials are theoretically unlimited, cheaper and may not compete with food crops. However, the conversion of these materials to simpler sugars usually requires cellulolytic enzymes. Being still associated with a high cost of production, cellulases are commonly considered as one of the main obstacles in the economic valorization of lignocellulosics. This work provides a brief overview of some of the most studied strategies that can allow an important reduction of cellulases consumption, hence improving the economy of lignocellulosics conversion. Cellulases recycling is initially discussed regarding the main processes to recover active enzymes and the most important factors that may affect enzyme recyclability. Similarly, the potential of enzyme immobilization is analyzed with a special focus on the contributions that some elements of the process can offer for prolonged times of operation and improved enzyme stability and robustness. Finally, the emergent concept of consolidated bioprocessing (CBP) is also described in the particular context of a potential reduction of cellulases consumption.

Very High Gravity Bioethanol Revisited: Main Challenges and Advances

Over the last decades, the constant growth of the world-wide industry has been leading to more and more concerns with its direct impact on greenhouse gas (GHG) emissions. Resulting from that, rising efforts have been dedicated to a global transition from an oil-based industry to cleaner biotechnological processes. A specific example refers to the production of bioethanol to substitute the traditional transportation fuels. Bioethanol has been produced for decades now, mainly from energy crops, but more recently, also from lignocellulosic materials. Aiming to improve process economics, the fermentation of very high gravity (VHG) mediums has for long received considerable attention. Nowadays, with the growth of multi-waste valorization frameworks, VHG fermentation could be crucial for bioeconomy development. However, numerous obstacles remain. This work initially presents the main aspects of a VHG process, giving then special emphasis to some of the most important factors that traditionally affect the fermentation organism, such as nutrients depletion, osmotic stress, and ethanol toxicity. Afterwards, some factors that could possibly enable critical improvements in the future on VHG technologies are discussed. Special attention was given to the potential of the development of new fermentation organisms, nutritionally complete culture media, but also on alternative process conditions and configurations.

Nanocellulose Production: Exploring the Enzymatic Route and Residues of Pulp and Paper Industry

Increasing environmental and sustainability concerns, caused by current population growth, has promoted a raising utilization of renewable bio-resources for the production of materials and energy. Recently, nanocellulose (NC) has been receiving great attention due to its many attractive features such as non-toxic nature, biocompatibility, and biodegradability, associated with its mechanical properties and those related to its nanoscale, emerging as a promising material in many sectors, namely packaging, regenerative medicine, and electronics, among others. Nanofibers and nanocrystals, derived from cellulose sources, have been mainly produced by mechanical and chemical treatments; however, the use of cellulases to obtain NC attracted much attention due to their environmentally friendly character. This review presents an overview of general concepts in NC production. Especial emphasis is given to enzymatic hydrolysis processes using cellulases and the utilization of pulp and paper industry residues. Integrated process for the production of NC and other high-value products through enzymatic hydrolysis is also approached. Major challenges found in this context are discussed along with its properties, potential application, and future perspectives of the use of enzymatic hydrolysis as a pretreatment in the scale-up of NC production.

Waste paper: An underutilized but promising source for nanocellulose mining

Nanocellulose has achieved an inimitable place and value in nano-materials research sector. Promising and exclusive physical, chemical and biological properties of nanocellulose make it an attractive and ideal material for various high end-user applications. Conventionally, the base material for nanocellulose i.e. cellulose is being extracted from various lignocellulosic raw materials (like wood, agro-industrial-residues, etc.) using pulping followed by bleaching sequences. As an alternate to lignocellulosic raw materials, waste paper also showed potential as a competent raw material due to its abundant availability and high cellulosic content (60-70%) with comparatively less hemicelluloses (10-20%) and lignin (5-10%) without any harsh treatments. The production yields of nanocellulose were reported to vary from 1.5% to 64% depending upon the waste papers and treatments given. The diameters of these nanocelluloses were reported in the range of 2-100 nm and crystallinity range around 54-95%. Thermal degradation of waste paper nanocellulose was varied from 187 °C to 371 °C. Although these properties are comparable with the nanocellulose obtained from lignocellulosic raw materials, yet waste paper is an underutilized source for nanocellulose preparation due to its ordinary fate of recycling, dumping and incineration. In the sight of necessity and possibility of waste paper utilization, this article reviews the outcomes of research carried out for preparation of nanocellulose using waste paper as a source of cellulose. There is a need of sincere investigation to convert this valuable waste to wealth i.e. waste papers to nanocellulose, which will be helpful in solid waste management to protect environment in economical way.

Optimization of bacterial nanocellulose fermentation using recycled paper sludge and development of novel composites

In this work, recycled paper sludge (RPS), composed of non-recyclable fibres, was used as a carbon source for bacterial nanocellulose (BNC) production. The biomass was enzymatically hydrolysed with Cellic CTec 2 to produce a sugar syrup with 45.40 g/L glucose, 1.69 g/L cellobiose and 2.89 g/L xylose. This hydrolysate was used for the optimization of BNC fermentation by static culture, using Komagataeibacter xylinus ATCC 700178, through response surface methodology (RSM). After analysis and validation of the model, a maximum BNC yield (5.69 g/L, dry basis) was obtained using 1.50% m/v RPS hydrolysate, 1.0% v/v ethanol and 1.45% m/v yeast extract/peptone (YE/P). Further, the BNC obtained was used to produce composites. A mixture of an amino-PolyDiMethylSiloxane-based softener, polyethyleneglycol (PEG) 400 and acrylated epoxidized soybean oil (AESO), was incorporated into the BNC membranes through an exhaustion process. The results show that BNC composites with distinct performances can be easily designed by simply varying the polymers percentage contents. This strategy represents a simple approach towards the production of BNC and BNC-based composites.

Enzymatic treatment of deinking sludge - effect on fibre and drainage properties

This work focused on the enzymatic treatment of deinking sludge (DS), a waste stream arising from German deinked pulp mills. Three industrial DS samples were characterised with respect to chemical composition and fibre morphology. In this study, four cellulase enzyme preparations were tested under neutral pH conditions and one cellulase was identified as suitable for DS conditioning with no need of pH adjustment. Additionally, our approach shows that inorganic particles contained in the DS samples do not negatively affect cellulase activity, as illustrated by respectable hydrolysis yields of up to 61%. Enzymatic treatment of DS led to fibre shortening and fibre fines generation with increasing enzyme dose and incubation time. The dewaterability of enzyme-treated DS samples was tested and the results showed that high amounts of fibre fines enhanced filter cake consolidation during dewatering, resulting in higher cake solids. A 10-14 percentage point increase in cake solids was obtained depending upon the enzyme dose applied, the origin of the DS sample, and the exposure period. Through the enzymatic treatment the annually generated amount of DS in Germany could be reduced by up to 20%, which would mean considerable disposal cost savings.

Insights into the economic viability of cellulases recycling on bioethanol production from recycled paper sludge

The economics of Recycled Paper Sludge conversion into ethanol was here assessed with emphasis on integrating a cellulase recycling system. Without cellulases recycling this process presented positive economic outputs (payback period of 7.85 years; 10.90 Million US$ of accumulated NPV) despite the modest ethanol titers. Recycling both free and solid-bound enzymes allowed considerable savings of enzyme but also an increase on annual costs (0.88%), resulting on a superior economic output: payback period decreased to 7.25 years; accumulated NPV increased to 14.44 Million US$. Recycling exclusively the liquid fraction enabled a clear costs reduction, however, also total ethanol decreased, attenuating the abovementioned benefits. Targeting higher ethanol concentrations, superior solids consistencies were also evaluated. Despite a costs reduction, total ethanol decreased due to a higher ethanol retention on the solid. A sensitivity analysis further revealed that the cost of enzymes and ultrafiltration membrane may be critical on enzyme recycling economic feasibility.

Construction of a trifunctional cellulase and expression in Saccharomyces cerevisiae using a fusion protein

Background

Cellulose is the most important component of lignocellulose, and its degradation requires three different types of enzymes to act synergistically. There have been reports of single gene duality, but no gene has been described to have more than two functions. Cloning and expression of fusion cellulases containing more than two kinds of catalytic domains has not been reported thus far.

Results

We synthesized three different cellulase genes and linked the three catalytic domains with a (G₄S)₃ flexible linker. The trifunctional cellulase gene (BCE) containing three types of cellulase functions was constructed and expressed in S. cerevisiae successfully. The β-glucosidase, the exoglucanase and the endoglucanase activity of the trifunctional cellulase BCE reached 16.80 IU/mg, 2.26 IU/mg and 20.67 IU/mg, which was 46.27, 6.73 and 46.20% higher than the activities of the β-glucosidase BG, the endoglucanase CBH and the endoglucanase EG. The filter paper enzyme activity of BCE was higher than those of BG, CBH and EG, reached 2.04 IU/mg.

Conclusions

The trifunctional cellulase BCE was designed based on β-glucosidase BG, endoglucanase EG and exoglucanase CBH, and it possessed β-glucosidase activity, endoglucanase activity and exoglucanase activity simultaneously. The BCE has better filter paper activity, it means the potential practical application.

Electronic supplementary material

The online version of this article (10.1186/s12896-018-0454-x) contains supplementary material, which is available to authorized users.

Determinants on an efficient cellulase recycling process for the production of bioethanol from recycled paper sludge under high solid loadings

BACKGROUND

In spite of the continuous efforts and investments in the last decades, lignocellulosic ethanol is still not economically competitive with fossil fuels. Optimization is still required in different parts of the process. Namely, the cost effective usage of enzymes has been pursued by different strategies, one of them being recycling.

RESULTS

Cellulase recycling was analyzed on recycled paper sludge (RPS) conversion into bioethanol under intensified conditions. Different cocktails were studied regarding thermostability, hydrolysis efficiency, distribution in the multiphasic system and recovery from solid. Celluclast showed inferior stability at higher temperatures (45-55 °C), nevertheless its performance at moderate temperatures (40 °C) was slightly superior to other cocktails (ACCELLERASE^®1500 and Cellic^®CTec2). Celluclast distribution in the solid-liquid medium was also more favorable, enabling to recover 88% of final activity at the end of the process. A central composite design studied the influence of solid concentration and enzyme dosage on RPS conversion by Celluclast. Solids concentration showed a significant positive effect on glucose production, no major limitations being found from utilizing high amounts of solids under the studied conditions. Increasing enzyme loading from 20 to 30 FPU/g_cellulose had no significant effect on sugars production, suggesting that 22% solids and 20 FPU/g_cellulose are the best operational conditions towards an intensified process. Applying these, a system of multiple rounds of hydrolysis with enzyme recycling was implemented, allowing to maintain the steady levels of enzyme activity with only 50% of enzyme on each recycling stage. Additionally, interesting levels of solid conversion (70-81%) were also achieved, leading to considerable improvements on glucose and ethanol production comparatively with the reports available so far (3.4- and 3.8-fold, respectively).

CONCLUSIONS

Enzyme recycling viability depends on enzyme distribution between the solid and liquid phases at the end of hydrolysis, as well as enzymes thermostability. Both are critical features to be observed for a judicious choice of enzyme cocktail. This work demonstrates that enzyme recycling in intensified biomass degradation can be achieved through simple means. The process is possibly much more effective at larger scale, hence novel enzyme formulations favoring this possibility should be developed for industrial usage.

Enhancing bioethanol production from water hyacinth by new combined pretreatment methods

This study investigated the possibility of enhancing bioethanol production by combined pretreatment methods for water hyacinth. Three different kinds of pretreatment methods, including microbial pretreatment, microbial combined dilute acid pretreatment, and microbial combined dilute alkaline pretreatment, were investigated for water hyacinth degradation. The results showed that microbial combined dilute acid pretreatment is the most effective method, resulting in the highest cellulose content (39.4 ± 2.8%) and reducing sugars production (430.66 mg·g^-1). Scanning Electron Microscopy and Fourier Transform Infrared Spectrometer analysis indicated that the basic tissue of water hyacinth was significantly destroyed. Compared to the other previously reported pretreatment methods for water hyacinth, which did not append additional cellulase and microbes for hydrolysis process, the microbial combined dilute acid pretreatment of our research could achieve the highest reducing sugars. Moreover, the production of bioethanol could achieve 1.40 g·L^-1 after fermentation, which could provide an extremely promising way for utilization of water hyacinth.