Mild-temperature dilute acid pretreatment for integration of first and second generation ethanol processes

Evolving Robust and Interpretable Enzymes for the Bioethanol Industry

Obtaining a robust and applicable enzyme for bioethanol production is a dream for biorefinery engineers. Herein, we describe a general method to evolve an all-round and interpretable enzyme that can be directly employed in the bioethanol industry. By integrating the transferable protein evolution strategy InSiReP 2.0 (In Silico guided Recombination Process), enzymatic characterization for actual production, and computational molecular understanding, the model cellulase PvCel5A (endoglucanase II Cel5A from Penicillium verruculosum) was successfully evolved to overcome the remaining challenges of low ethanol and temperature tolerance, which primarily limited biomass transformation and bioethanol yield. Remarkably, application of the PvCel5A variants in both first- and second-generation bioethanol production processes (i. Conventional corn ethanol fermentation combined with the in situ pretreatment process; ii. cellulosic ethanol fermentation process) resulted in a 5.7-10.1 % increase in the ethanol yield, which was unlikely to be achieved by other optimization techniques.

Bioconversion of corn fiber to bioethanol: Status and perspectives

Due to the rising demand for green energy, bioethanol has attracted increasing attention from academia and industry. Limited by the bottleneck of bioethanol yield in traditional corn starch dry milling processes, an increasing number of studies focus on fully utilizing all corn ingredients, especially kernel fiber, to further improve the bioethanol yield. This mini-review addresses the technological challenges and opportunities on the way to achieving the efficient conversion of corn fiber. Significant advances during the review period include the detailed characterization of different forms of corn kernel fiber and the development of off-line and in-situ conversion strategies. Lessons from cellulosic ethanol technologies offer new ways to utilize corn fiber in traditional processes. However, the commercialization of corn kernel fiber conversion may be hampered by enzyme cost, conversion efficiency, and overall process economics. Thus, future studies should address these technical limitations.

Cellulosic Ethanol Production Using Waste Wheat Stillage after Microwave-Assisted Hydrotropic Pretreatment

One of the key elements influencing the efficiency of cellulosic ethanol production is the effective pretreatment of lignocellulosic biomass. The aim of the study was to evaluate the effect of microwave-assisted pretreatment of wheat stillage in the presence of sodium cumene sulphonate (NaCS) hydrotrope used for the production of second-generation bioethanol. As a result of microwave pretreatment, the composition of the wheat stillage biomass changed significantly when compared with the raw material used, before treatment. Microwave-assisted pretreatment with NaCS effectively reduced the lignin content and hemicellulose, making cellulose the dominant component of biomass, which accounted for 42.91 ± 0.10%. In post pretreatment, changes in biomass composition were also visible on FTIR spectra. The peaks of functional groups and bonds characteristic of lignins (C-O vibration in the syringyl ring, asymmetric bending in CH₃, and aromatic skeleton C-C stretching) decreased. The pretreatment of the analyzed lignocellulosic raw material with NaCS resulted in the complete conversion of glucose to ethanol after 48 h of the process, with yield (in relation to the theoretical one) of above 91%. The highest observed concentration of ethanol, 23.57 ± 0.10 g/L, indicated the high effectiveness of the method used for the pretreatment of wheat stillage that did not require additional nutrient supplementation.

Production of cellulosic ethanol and value-added products from corn fiber

Corn fiber, a by-product from the corn processing industry, mainly composed of residual starch, cellulose, and hemicelluloses, is a promising raw material for producing cellulosic ethanol and value-added products due to its abundant reserves and low costs of collection and transportation. Now, several technologies for the production of cellulosic ethanol from corn fiber have been reported, such as the D3MAX process, Cellerate™ process, etc., and part of the technologies have also been used in industrial production in the United States. The ethanol yields range from 64 to 91% of the theoretical maximum, depending on different production processes. Because of the multicomponent of corn fiber and the complex structures highly substituted by a variety of side chains in hemicelluloses of corn fiber, however, there are many challenges in cellulosic ethanol production from corn fiber, such as the low conversion of hemicelluloses to fermentable sugars in enzymatic hydrolysis, high production of inhibitors during pretreatment, etc. Some technologies, including an effective pretreatment process for minimizing inhibitors production and maximizing fermentable sugars recovery, production of enzyme preparations with suitable protein compositions, and the engineering of microorganisms capable of fermenting hexose and pentose in hydrolysates and inhibitors tolerance, etc., need to be further developed. The process integration of cellulosic ethanol and value-added products also needs to be developed to improve the economic benefits of the whole process. This review summarizes the status and progresses of cellulosic ethanol production and potential value-added products from corn fiber and presents some challenges in this field at present.

High-Efficiency Conversion of Bread Residues to Ethanol and Edible Biomass Using Filamentous Fungi at High Solids Loading: A Biorefinery Approach

Bread residues represent a significant fraction of retail food wastes, becoming a severe environmental challenge and an economic loss for the food sector. They are, however, an attractive resource for bioconversion into value-added products. In this study, the edible filamentous fungi Neurospora intermedia and Aspergillus oryzae were employed for the production of bioethanol and high-protein biomass by cultivation on enzymatically liquefied bread-waste medium at 150 g/L solids. The fermentation of hydrolysate by N. intermedia resulted in the ethanol titer of 32.2 g/L and biomass yield of 19.2 g/L with ca. 45% protein. However, the fermentation ended with a considerable amount of residual fermentable sugars; therefore, the liquid medium after the first fermentation was distilled and fermented again by two fungal strains (N. intermedia and A. oryzae). The fermentations resulted in the production of additional ethanol and biomass. A. oryzae showed better performance in the production of biomass, while the other strain yielded more ethanol. The final products’ yield ranged 0.29–0.32 g EtOH/g and 0.20–0.22 g biomass/g bread waste depending on the strain used in the second fermentation. The study shows that valorization of bread residuals by fungi is a promising option for the production of biofuels and foodstuff within the circular bioeconomy approach.

Recent advancements in prebiotic oligomers synthesis via enzymatic hydrolysis of lignocellulosic biomass

Interest in functional food, such as non-digestible prebiotic oligosaccharides is increasing day by day and their production is shifting toward sustainable manufacturing. Due to the presence of high carbohydrate content, lignocellulosic biomass (LCB) is the most-potential, cost-effective and sustainable substrate for production of many useful products, including lignocellulose-derived prebiotic oligosaccharides (LDOs). These have the same worthwhile properties as other common oligosaccharides, such as short chain carbohydrates digestible to the gut flora but not to humans mainly due to their resistance to the low pH and high temperature and their demand is constantly increasing mainly due to increased awareness about their potential health benefits. Despite several advantages over the thermo-chemical route of synthesis, comprehensive and updated information on the conversion of lignocellulosic biomass to prebiotic oligomers via controlled enzymatic saccharification is not available in the literature. Thus, the main objective of this review is to highlight recent advancements in enzymatic synthesis of LDOs, current challenges, and future prospects of sustainably producing prebiotic oligomers via enzymatic hydrolysis of LCB substrates. Enzyme reaction engineering practices, custom-made enzyme preparations, controlled enzymatic hydrolysis, and protein engineering approaches have been discussed with regard to their applications in sustainable synthesis of lignocellulose-derived oligosaccharide prebiotics. An overview of scale-up aspects and market potential of LDOs has also been provided.

Acid-based lignocellulosic biomass biorefinery for bioenergy production: Advantages, application constraints, and perspectives

The production of chemicals and fuels from renewable biomass with the primary aim of reducing carbon footprints has recently become one of the central points of interest. The use of lignocellulosic biomass for energy production is believed to meet the main criteria of maximizing the available global energy source and minimizing pollutant emissions. However, before usage in bioenergy production, lignocellulosic biomass needs to undergo several processes, among which biomass pretreatment plays an important role in the yield, productivity, and quality of the products. Acid-based pretreatment, one of the existing methods applied for lignocellulosic biomass pretreatment, has several advantages, such as short operating time and high efficiency. A thorough analysis of the characteristics of acid-based biomass pretreatment is presented in this review. The environmental concerns and future challenges involved in using acid pretreatment methods are discussed in detail to achieve clean and sustainable bioenergy production. The application of acid to biomass pretreatment is considered an effective process for biorefineries that aim to optimize the production of desired products while minimizing the by-products.

Progress in microbial biomass conversion into green energy

The increase in global population size over the past 100 decades has doubled the requirements for energy resources. To mitigate the limited fossil fuel available, new clean energy sources being environmental sustainable for replacement of traditional energy sources are explored to supplement the current scarcity. Biomass containing lignin and cellulose is the main raw material to replace fossil energy given its abundance and lower emission of greenhouse gases and NOx when transformed into energy. Bacteria, fungi and algae decompose lignocellulose leading to generation of hydrogen, methane, bioethanol and biodiesel being the clean energy used for heating, power generation and the automobile industry. Microbial Fuel Cell (MFC) uses microorganisms to decompose biomass in wastewater to generate electricity and remove heavy metals in wastewater. Biomass contains cellulose, hemicellulose, lignin and other biomacromolecules which need hydrolyzation for conversion into small molecules by corresponding enzymes in order to be utilized by microorganisms. This paper discusses microbial decomposition of biomass into clean energy and the five major ways of clean energy production, and its economic benefits for future renewable energy security.

Cellulosic Ethanol: Improving Cost Efficiency by Coupling Semi-Continuous Fermentation and Simultaneous Saccharification Strategies

A novel approach to improve ethanol production from sugarcane bagasse is proposed. Biomass was pretreated with sodium hydroxide, sulfuric, oxalic, and maleic acids (1% w/v) at different temperatures (130–170 °C) and times (10–30 min). The pretreatment with NaOH at 160 °C for 20 min was found to be the most efficient for further enzymatic saccharification. A semi-continuous fermentation system coupled with a simultaneous saccharification and fermentation strategy was used, attaining fermented liquor every 24 h. The amount of enzymes needed for saccharification was optimized, as well as the production time and ethanol concentration. The process occurred with near to complete depletion of glucose, obtaining ethanol concentrations ranging from 8.36 to 10.79% (v/v). The whole system, at bench scale, showed stability over 30 days, and ease of management and control. This strategy may improve cost efficiency in the production of cellulosic ethanol at industrial scale.

Lignocellulosic biomass: Acid and alkaline pretreatments and their effects on biomass recalcitrance - Conventional processing and recent advances

Lignocellulosic biomass is one of the most abundant organic resources worldwide and is a promising source of renewable energy and bioproducts. It basically consists of three fractions, cellulose, hemicelluloses and lignin, which confer a recalcitrant structure. As such, pretreatment steps are required to make each fraction available for further use, with acidic, alkaline and combined acidic-alkaline treatments being the most common techniques. This review focuses on recent strategies for lignocellulosic biomass pretreatment, with a critical discussion and comparison of their efficiency based on the composition of the materials. Mild pretreatments usually allow the recovery of the three biomass fractions for further transformation and valorisation. An insight is provided of newly developed technologies from recently filed patents on lignocellulosic biomass pretreatment and the transformation of agro-industrial residues into high value-added products, such as biofuels and organic acids.

Improving the economy of lignocellulose-based biorefineries with organosolv pretreatment

Lignocellulose-based processes for production of value-added products still face bottlenecks to attain feasibility. The key might lie on the biorefining of all lignocellulose main polymers, that is, cellulose, hemicellulose and lignin. Lignin, considered an impediment in the access of cellulose and normally considered for energy recovery purposes, can give a higher contribution towards profitability of lignocellulosic biorefineries. Organosolv pretreatment allows selective fractionation of lignocellulose into separate cellulose-, hemicellulose- and lignin-rich streams. Ethanol organosolv and wood substrates dominated the research studies, while a wide range of substrates need definition on the most suitable organosolv pretreatment systems. Techno-economic and environmental analyses of organosolv-based processes as well as proper valorization strategies of the hemicellulose-rich fraction are still scarce. In view of dominance of ethanol organosolv with high delignification yields and high-purity of the recovered cellulose-rich fractions, close R & D collaboration with 1st generation ethanol plants might boost commercialization.

Highly Efficient Extraction of Ferulic Acid from Cereal Brans by a New Type A Feruloyl Esterase from Eupenicillium parvum in Combination with Dilute Phosphoric Acid Pretreatment

Feruloyl esterase (FAE) is a critical enzyme in bio-extraction of ferulic acid (FA) from plant cell wall. A new FAE (EpFAE1) encoding gene was isolated from Eupenicillium parvum and heterologously expressed in Pichia pastoris cells. Based on phylogenetic tree analysis, the protein EpFAE1 belongs to type A of the seventh FAE subfamily. Using methyl ferulate as substrate, the optimum temperature and pH for the catalytic activity of EpFAE1 were 50 °C and 5.5, respectively. The enzyme exhibited high stability at 50 °C, in a wide pH range (3.0-11.0), or in the presence of 2 M of NaCl. Together with the endo-xylanase EpXYN1, EpFAE1 released 72.32% and 4.00% of the alkali-extractable FA from de-starched wheat bran (DSWB) or de-starched corn bran (DSCB), respectively. Meanwhile, the substrates were pretreated with 1.75% (for DSWB) or 1.0% (for DSCB) of phosphoric acid (PA) at 90 °C for 12 h, followed by enzymatic hydrolysis of the soluble and insoluble fractions. The release efficiencies of FA were up to 84.64% for DSWB and 66.73% for DSCB. Combined dilute PA pretreatment with enzymatic hydrolysis is a low-cost and highly efficient method for the extraction of FA from cereal brans.

Sugarcane Bagasse Hydrolysis Enhancement by Microwave-Assisted Sulfolane Pretreatment

Sugarcane bagasse is the major by-product of the sugarcane industry and, due to its abundant availability, it has been extensively studied for lignocellulosic bioconversion in the production of bioethanol and other value-added commercial products. In the study presented herein, a combined pretreatment using sulfolane, TiO2 and alkali microwave irradiation (MW-A) was assessed for the dissolution of lignin prior to enzymatic saccharification of holocellulose. Total reducing sugars (TRS) and saccharinic acid yields were investigated. The increase in NaOH concentration up to 5% and in temperature from 120 °C to 140 °C were found to have a positive influence on both yields. While increasing the reaction time from 5 to 60 min only led to an increase in TRS yield <2%, a reaction time of 30 min almost doubled the saccharinic acids production. TRS yields and saccharinic acid production were approximately 5% and 33% higher when the sulfolane-TiO2 reaction medium was used, as compared to MW-A in water, reaching up to 64.8% and 15.24 g/L of saccharinic acids, respectively. The proposed MW-A pretreatment may hold promise for industrial applications, given the good TRS yields obtained, and the associated enzyme and time/energy savings. The use of sulfolane-TiO2 reaction medium is encouraged if saccharinic acids are to be recovered too.

Lignocellulose derived functional oligosaccharides: production, properties, and health benefits

Lignocellulosic biomass (LB) is the renewable feedstock for the production of fuel/energy, feed/food, chemicals, and materials. LB could also be the versatile source of the functional oligosaccharides, which are non-digestible food ingredients having numerous applications in food, cosmetics, pharmaceutical industries, and others. The burgeoning functional food demand is expected to be more than US$440 billion in 2022. Because of higher stability at low pH and high temperature, oligosaccharides stimulate the growth of prebiotic bifidobacteria and lactic acid bacteria. Xylooligosaccharides (XOS) are major constituents of oligosaccharides consisting of 2-7 xylose monomeric units linked via β-(1,4)-linkages. XOS can be obtained from various agro-residues by thermochemical pretreatment, enzymatic or chemoenzymatic methods. While thermochemical methods are fast, reproducible, enzymatic methods are substrate specific, costly, and produce minimum side products. Enzymatic methods are preferred for the production of food grade and pharmaceutically important oligosaccharides. XOS are potent prebiotics having antioxidant properties and enhance the bio-adsorption of calcium and improving bowel functions, etc. LB can cater to the increasing demand of oligosaccharides because of their foreseeable amount and the advancements in technology to recover oligosaccharides. This paper summarizes the methods for oligosaccharides production from LB, classification, and benefits of oligosaccharides on human health.

Amylase and Xylanase from Edible Fungus Neurospora intermedia: Production and Characterization

Integrated enzyme production in the biorefinery can significantly reduce the cost of the entire process. The purpose of the present study is to evaluate the production of two hydrolyzing enzymes (amylase and xylanase) by an edible fungus used in the biorefinery, Neurospora intermedia. The enzyme production was explored through submerged fermentation of synthetic media and a wheat-based waste stream (thin stillage and wheat bran). The influence of a nitrogen source on N. intermedia was investigated and a combination of NaNO₃ and yeast extract has been identified as the best nitrogen source for extracellular enzyme production. N. intermedia enzymes showed maximum activity at 65 °C and pH around 5. Under these conditions, the maximum velocity of amylase and xylanase for starch and xylan hydrolysis was found to be 3.25 U mL⁻¹ and 14.77 U mL⁻¹, respectively. Cultivation of N. intermedia in thin stillage and wheat bran medium resulted in relatively high amylase (8.86 ± 0.41 U mL⁻¹, 4.68 ± 0.23) and xylanase (5.48 ± 0.21, 2.58 ± 0.07 U mL⁻¹) production, respectively, which makes this fungus promising for enzyme production through a wheat-based biorefinery.