Membrane bioreactors for the production of value-added products: Recent developments, challenges and perspectives

Single-cell protein: overcoming technological and biological challenges towards improved industrialization

The commercialization of single-cell protein (SCP) obtained from microbial fermentation in large-scale bioreactors emerged almost 50 years ago, with Pruteen marketed as animal feed in the 1970s and Quorn®, released for human nutrition in 1985. SCP holds great promises to feed the meanwhile doubled world population in a sustainable way, but its application is still limited by price and availability on scale. There is a need to optimize the underlying manufacturing processes with enhanced affordability and productivity. From the industrial perspective, it is crucial to identify key process components and prioritize innovations that best promote cost efficiency and large-scale production. Here, we present the state-of-art in SCP manufacturing and provide a comprehensive insight into recent techno-economic analyses and life-cycle assessments of different production scenarios. Thereby, we identified the most influential technical hotspots and challenges for each of the main production scenarios and evaluated the technological opportunities to overcome them.

Comparative assessment of treatment technologies for minimizing reverse osmosis concentrate volume for industrial applications: A review

Desalination of seawater, brackish water, and reclaimed water is becoming increasingly prevalent worldwide to supplement and diversify fresh water supplies. However, particularly for industrial wastewater, the need for environment-friendly and economically viable alternatives for concentrate management is the major impediment to deploying large-scale desalination. This review covers various strategies and technologies for managing reverse osmosis concentrate (ROC) and also includes their disposal, treatment, and potential applications. Developing energy-efficient, economical, and ecologically sound ROC management systems is essential if desalination and wastewater treatment are being implemented for a sustainable water future, particularly for industrial wastewater. The limitations and benefits of various concentrate management strategies are examined in this review. Moreover, it explores the potential of innovative technologies in reducing concentrate volume, enhancing water recovery, eliminating organic pollutants, and extracting valuable resources. This review critically discusses concentrate management approaches and technologies, including disposal, treatment, and reuse, including new technologies for reducing concentrate volume, boosting water recovery, eliminating organic contaminants, recovering valuable commodities, and minimizing energy consumption.

Investigating Mass Transfer and Reaction Engineering Characteristics in a Membrane Biofilm Using Cupriavidus necator H16

Membrane biofilm reactors are a growing trend in wastewater treatment whereby gas-transfer membranes provide efficient bubbleless aeration. Recently, there has been a growing interest in using these bioreactors for industrial biotechnology using microorganisms that can metabolise gaseous substrates. Since gas fermentation is limited by the low solubilities of gaseous substrates in liquid media, it is critical to characterise mass transfer rates of gaseous substrates to enable the design of membrane biofilm reactors. The objective of this study is to measure and analyse mass transfer rates and reaction engineering characteristics for a single tube membrane biofilm reactor using Cupriavidus necator H16. At elevated Reynolds numbers, the dominant resistance for gas diffusion shifts from the liquid boundary layer to the membrane. The biofilm growth rate was observed to decrease after 260 μm at 96 h. After 144 h, some sloughing of the biofilm occurred. Oxygen uptake rate and substrate utilisation rate for the biofilm developed showed that the biofilm changes from a single-substrate limited regime to a dual-substrate-limited regime after 72 h which alters the localisation of the microbial activity within the biofilm. This study shows that this platform technology has potential applications for industrial biotechnology.

Methanotrophs: Metabolic versatility from utilization of methane to multi-carbon sources and perspectives on current and future applications

The development of biorefineries for a sustainable bioeconomy has been driven by the concept of utilizing environmentally friendly and cost-effective renewable energy sources. Methanotrophic bacteria with a unique capacity to utilize methane as a carbon and energy source can serve as outstanding biocatalysts to develop C1 bioconversion technology. By establishing the utilization of diverse multi-carbon sources, integrated biorefinery platforms can be created for the concept of the circular bioeconomy. An understanding of physiology and metabolism could help to overcome challenges for biomanufacturing. This review summaries fundamental gaps for methane oxidation and the capability to utilize multi-carbon sources in methanotrophic bacteria. Subsequently, breakthroughs and challenges in harnessing methanotrophs as robust microbial chassis for industrial biotechnology were compiled and overviewed. Finally, capabilities to exploit the inherent advantages of methanotrophs to synthesize various target products in higher titers are proposed.

Turning Carbon Dioxide into Sustainable Food and Chemicals: How Electrosynthesized Acetate Is Paving the Way for Fermentation Innovation

ConspectusThe agricultural and chemical industries are major contributors to climate change. To address this issue, hybrid electrocatalytic-biocatalytic systems have emerged as a promising solution for reducing the environmental impact of these key sectors while providing economic onboarding for carbon capture technology. Recent advancements in the production of acetate via CO₂/CO electrolysis as well as advances in precision fermentation technology have prompted electrochemical acetate to be explored as an alternative carbon source for synthetic biology. Tandem CO₂ electrolysis coupled with improved reactor design has accelerated the commercial viability of electrosynthesized acetate in recent years. Simultaneously, innovations in metabolic engineering have helped leverage pathways that facilitate acetate upgrading to higher carbons for sustainable food and chemical production via precision fermentation. Current precision fermentation technology has received much criticism for reliance upon food crop-derived sugars and starches as feedstock which compete with the human food chain. A shift toward electrosynthesized acetate feedstocks could help preserve arable land for a rapidly growing population.Technoeconomic analysis shows that using electrochemical acetate instead of glucose as a fermentation feedstock reduces the production costs of food and chemicals by 16% and offers improved market price stability. Moreover, given the rapid decline in utility-scale renewable electricity prices, electro-synthesized acetate may become more affordable than conventional production methods at scale. This work provides an outlook on strategies to further advance and scale-up electrochemical acetate production. Additional perspective is offered to help ensure the successful integration of electrosynthesized acetate and precision fermentation technologies. In the electrocatalytic step, it is critical that relatively high purity acetate can be produced in low-concentration electrolyte to help ensure that minimal treatment of the electrosynthesized acetate stream is needed prior to fermentation. In the biocatalytic step, it is critical that microbes with increased tolerances to elevated acetate concentrations are engineered to help promote acetate uptake and accelerate product formation. Additionally, tighter regulation of acetate metabolism via strain engineering is essential to improving cellular efficiency. The implementation of these strategies would allow the coupling of electrosynthesized acetate with precision fermentation to offer a promising approach to sustainably produce chemicals and food. Reducing the environmental impact of the chemical and agricultural sectors is necessary to avoid climate catastrophe and preserve the habitability of the planet for future generations.

A review of hybrid enzymatic-chemical treatment for wastewater containing antiepileptic drugs

Epilepsy is one of the most common neurological diseases worldwide and requires treatment with antiepileptic drugs for many years or for life. This fact leads to the need for constant production and use of these compounds, placing them among the four pharmaceutical classes most found in wastewater. Even at low concentrations, antiepileptics pose risks to human and environmental health and are considered organic contaminants of emerging concern. Conventional treatments have shown low removal of these drugs, requiring advanced and innovative approaches. In this context, this review covers the results and perspectives on (1) consumption and occurrence of antiepileptics in water, (2) toxicological effects in aquatic ecosystems, (3) enzymatic and advanced oxidation processes for degrading antiepileptics drugs from a molecular point of view (biochemical and chemical phenomena), (4) improvements in treatment efficiency by hybridization, and (5) technical aspects of the enzymatic-AOP reactors.

Recent Advances in Responsive Membrane Functionalization Approaches and Applications

In recent years, significant advances have been made in the field of functionalized membranes. With the functionalization using various materials, such as polymers and enzymes, membranes can exhibit property changes in response to an environmental stimulation, such as heat, light, ionic strength, or pH. The resulting responsive nature allows for an increased breadth of membrane uses, due to the developed functionalization properties, such as smart-gating filtration for size-selective water contaminant removal, self-cleaning antifouling surfaces, increased scalability options, and highly sensitive molecular detection. In this review, new advances in both fabrication and applications of functionalized membranes are reported and summarized, including temperature-responsive, pH-responsive, light-responsive, enzyme-functionalized, and two-dimensional material-functionalized membranes. Specific emphasis was given to the most recent technological improvements, current limitations, advances in characterization techniques, and future directions for the field of functionalized membranes.

Continuous antibiotic attenuation in algal membrane photobioreactor: Performance and kinetics

The attenuation of 10 mixed antibiotics along with nutrients in a continuous flow mode by four freshwater microalgae (Haematococcus pluvialis, Selenastrum capricornutum, Scenedesmus quadricauda, and Chlorella vulgaris) was examined in membrane photobioreactors (MPBRs). At lab-scale, consistent removal of both antibiotic and nutrient was shown by H. pluvialis and S. quadricauda, respectively. The system exhibited better performance with enhanced removal at HRT 24 h compared to 12 h and 48 h. The highest removal efficiency of antibiotics was observed in H. pluvialis MPBR, with the mean antibiotic removal values of 53.57%- 96.33%. Biodegradation was the major removal pathway of the antibiotics in the algal-MPBR (AMPBR), while removal by bioadsorption, bioaccumulation, membrane rejection, and abiotic was minor. Then, the bacterial feature was studied and showed significant influence from system hydrodynamics. The kinetics of continuous flow antibiotic removal followed Stover-Kincannon and Grau second-order models, which revealed great potential of AMPBR to withstand antibiotic load. The latter coupled with the computational fluid dynamic simulation was successfully applied for the residual antibiotic prediction and potential system optimization. Overall, these results provide an important reference for continuous flow antibiotic removal using AMPBR.

Membrane Fouling Mitigation in MBR via the Feast–Famine Strategy to Enhance PHA Production by Activated Sludge

Fouling is considered one of the main drawbacks of membrane bioreactor (MBR) technology. Among the main fouling agents, extracellular polymeric substances (EPS) are considered one of the most impactful since they cause the decrease of sludge filterability and decline of membrane flux in the long term. The present study investigated a biological strategy to reduce the membrane-fouling tendency in MBR systems. This consisted of seeding the reactor with activated sludge enriched in microorganisms with polyhydroxyalkanoate (PHA) storage ability and by imposing proper operating conditions to drive the carbon toward intracellular (PHA) rather than extracellular (EPS) accumulation. For that purpose, an MBR lab-scale plant was operated for 175 days, divided into four periods (1–4) according to different food to microorganisms’ ratios (F/M) (0.80 kg COD kg TSS⁻¹ d⁻¹ (Period 1), 0.13 kg COD kg TSS⁻¹ d⁻¹ (Period 2), 0.28 kg COD kg TSS⁻¹ d⁻¹ (Period 3), and 0.38 kg COD kg TSS⁻¹ d⁻¹ (Period 4)). The application of the feast/famine strategy favored the accumulation of intracellular polymers by bacteria. The increase of the PHA accumulation inside the cells corresponded to the decrease of EPS and an F/M of 0.40–0.50 kg COD kg TSS⁻¹ d⁻¹ was found as optimum to maximize the PHA production, while minimizing EPS. The lowest EPS content in the sludge (18% of total suspended solids) that corresponded to the maximum content of PHA (9.3%) was found in Period 4 and determined significant mitigation of the fouling rate, whose value was close to 0.10 × 10¹¹ m⁻¹ h⁻¹. Thus, by imposing proper operating conditions, it was possible to drive the organic matter toward PHA accumulation. Moreover, a lower EPS content corresponded to a decrease in the irreversible fouling mechanism, which would imply a lower frequency of the extraordinary cleaning operations. This study highlighted the possibility of obtaining a double benefit by applying an MBR system in the frame of wastewater valorization: minimizing the fouling tendency of the membrane and recovery precursors of bioplastics from wastewater in line with the circular economy model.

Energy-Efficient AnMBRs Technology for Treatment of Wastewaters: A Review

In recent years, anaerobic membrane bioreactor (AnMBRs) technology, a combination of a biological reactor and a selective membrane process, has received increasing attention from both industrialists and researchers. Undoubtedly, this is due to the fact that AnMBRs demonstrate several unique advantages. Firstly, this paper addresses fundamentals of the AnMBRs technology and subsequently provides an overview of the current state-of-the art in the municipal and domestic wastewaters treatment by AnMBRs. Since the operating conditions play a key role in further AnMBRs development, the impact of temperature and hydraulic retention time (HRT) on the AnMBRs performance in terms of organic matters removal is presented in detail. Although membrane technologies for wastewaters treatment are known as costly in operation, it was clearly demonstrated that the energy demand of AnMBRs may be lower than that of typical wastewater treatment plants (WWTPs). Moreover, it was indicated that AnMBRs have the potential to be a net energy producer. Consequently, this work builds on a growing body of evidence linking wastewaters treatment with the energy-efficient AnMBRs technology. Finally, the challenges and perspectives related to the full-scale implementation of AnMBRs are highlighted.

Submerged membrane photobioreactor for the cultivation of Haslea ostrearia and the continuous extraction of extracellular marennine

Haslea ostrearia is a marine diatom known to produce and excrete the marenine blue pigment. Its controlled, continuous and intensified cultivation remains a challenge. Thus, a submerged membrane photobioreactor (MPBR) was implemented in order to simultaneously and continuously cultivate H. ostrearia and extract marennine. The MPBR was compared with a similar air-lift photobioreactor (without membrane), both working at a dilution rate equal to 0.1, 0.3 and 0.5 d^-1. Contrary to the air-lift photobioreactor, the MPBR successfully operated at high dilution rate without biomass washout. The MPBR allowed continuously recovering marennine and reaching high cell density (555 ± 25 × 10⁶ cells L^-1 at D = 0.1 d^-1), marennine concentration (36.00 ± 0.02 mg L^-1 at D = 0.1 d^-1) and marenine productivity (7.20 ± 0.01 mg L^-1 d^-1 at D = 0.5 d^-1).

Occurrence of Microplastics in Waste Sludge of Wastewater Treatment Plants: Comparison between Membrane Bioreactor (MBR) and Conventional Activated Sludge (CAS) Technologies

In this study, the presence of microplastics in the sludge of three wastewater treatment plants (WWTPs) was examined. The investigated WWTPs operated based on a conventional activated sludge (CAS) process, with (W1) or without (W2) primary clarification, and a membrane bioreactor process (MBR) (W3). The microplastics (MPs) concentration in the samples of W3 was approximately 81.1 ± 4.2 × 103 particles/kg dry sludge, whereas MPs concentrations in W1 and W2 were 46.0 ± 14.8 × 103 particles/kg dry sludge and 36.0 ± 5.2 × 103 particles/kg dry sludge, respectively. Moreover, MPs mainly consisted of fragments (66–68%) in the CAS plants, whereas the fractions of MPs shapes in the MBR sludge were more evenly distributed, although fiber (47%) was the most abundant fraction. Furthermore, samples from the MBR showed a greater diversity in MPs composition. Indeed, all the main polyesters (i.e., textile fibers and polyethylene terephthalate), polyolefins (i.e., polyethylene and polypropylene) and rubber (i.e., polybutadiene) were observed, whereas only polybutadiene, cellulose acetate and polyester were detected in the CAS plants. These findings confirmed that MPs from wastewater are transferred and concentrated in the waste sludge. This is a critical finding since sludge disposal could become a new pathway for microplastic release into the environment and because MPs might affect the fouling behavior of the membrane.

Modification strategies of membranes with enhanced Anti-biofouling properties for wastewater Treatment: A review

This review addresses composite membranes used for wastewater treatment, focusing heavily on the anti-biofouling properties of such membranes. Biofouling caused by the development of a thick biofilm on the membrane surface is a major issue that reduces water permeance and reduces its lifetime. Biofilm formation and adhesion are mitigated by modifying membranes with two-dimensional or zero-dimensional carbon-based nanomaterials or their modified substituents. In particular, nanomaterials based on graphene, including graphene oxide and carbon quantum dots, are mainly used as nanofillers in the membrane. Functionalization of the nanofillers with various organic ligands or compositing the nanofiller with other materials, such as silver nanoparticles, enhances the bactericidal ability of composite membranes. Moreover, such membrane modifications reduce biofilm adhesion while increasing water permeance and salt/dye rejection. This review discusses the recent literature on developing graphene oxide-based and carbon quantum dot-based composite membranes for biofouling-resistant wastewater treatment.

Application of Natural Coagulants for Pharmaceutical Removal from Water and Wastewater: A Review

Pharmaceutical contamination threatens both humans and the environment, and several technologies have been adapted for the removal of pharmaceuticals. The coagulation-flocculation process demonstrates a feasible solution for pharmaceutical removal. However, the chemical coagulation process has its drawbacks, such as excessive and toxic sludge production and high production cost. To overcome these shortcomings, the feasibility of natural-based coagulants, due to their biodegradability, safety, and availability, has been investigated by several researchers. This review presented the recent advances of using natural coagulants for pharmaceutical compound removal from aqueous solutions. The main mechanisms of natural coagulants for pharmaceutical removal from water and wastewater are charge neutralization and polymer bridges. Natural coagulants extracted from plants are more commonly investigated than those extracted from animals due to their affordability. Natural coagulants are competitive in terms of their performance and environmental sustainability. Developing a reliable extraction method is required, and therefore further investigation is essential to obtain a complete insight regarding the performance and the effect of environmental factors during pharmaceutical removal by natural coagulants. Finally, the indirect application of natural coagulants is an essential step for implementing green water and wastewater treatment technologies.

The Use of NaOH Solutions for Fouling Control in a Membrane Bioreactor: A Feasibility Study

Nowadays, the microbial production of 1,3-propanediol (1,3-PD) is recognized as preferable to the chemical synthesis. However, finding a technological approach allowing the production of 1,3-PD in the membrane bioreactor (MBR) is a great challenge. In the present study, a ceramic ultrafiltration (UF) membrane (8 kDa) for treatment of 1,3-PD broths was used. It has been demonstrated that the membrane used provides the stable permeate flux that is necessary to ensure the stability of the fermentation process in MBR technology. It was noticed that the broth pH has a significant impact on both the final 1,3-PD concentration and permeate flux. Moreover, the feasibility of using NaOH for fouling control in the MBR was evaluated. It has been shown that 1% NaOH solution is effective in restoring the initial membrane performance. To the best of our knowledge, this study is the first to shed light onto the possibility of reducing the amount of the alkaline solutions generated during the MBR operation. Indeed, it has been found that 1% NaOH solution can be successfully used several times for both membrane cleaning and to stabilize the broth pH. Finally, based on the results obtained, the technological conceptions of the MBR technology were designed.