Scaling up of renewable chemicals

Techniques for recovery and recycling of ionic liquids: A review

Due to beneficial properties like non-flammability, thermal stability, low melting point and low vapor pressure, ionic liquids (ILs) have gained great interest from engineers and researchers in the past decades to replace conventional solvents. The superior characteristics of ILs make them promising for applications in fields as wide-ranging as pharmaceuticals, foods, nanoparticles synthesis, catalysis, electrochemistry and so on. To alleviate the high cost and environmental impact of ILs, various technologies have been reported to recover and purify the used ILs, as well as recycling the ILs. The aim of this article is to overview the state-of-the-art research on the recovery and recycling technologies for ILs including membrane technology, distillation, extraction, aqueous two-phase system (ATPS) and adsorption. In addition, challenges and future perspectives on ILs recovery are discussed. This review is expected to provide valuable insights for developing effective and environmentally friendly recovery methods for ILs.

Sustainable utilization of fruit and vegetable waste bioresources for bioplastics production

Nowadays, rapidly increasing production, use and disposable of plastic products has become one of the utmost environmental issues. Our current circumstances in which the food supply chain is demonstrated as containing plastic particles and other plastic-based impurities, represents a significant health risk to humans, animals, and environmental alike. According to this point of view, biodegradable plastic material aims to produce a more sustainable and greener world with a lower ecological impact. Bioplastics are being investigated as an environmentally friendly candidate to address this problem and hence global bioplastic production has seen significant growth and expansion in recent years. This article focuses on a few critical issues that must be addressed for bioplastic production to become commercially viable. Although the reduction of fruit and vegetable waste biomass has an apparent value in terms of environmental benefits and sustainability, commercial success at industrial scale has remained flat. This is due to various factors, including biomass feedstocks, pretreatment technologies, enzymatic hydrolysis, and scale-up issues in the industry, all of which contribute to high capital and operating costs. This review paper summarizes the global overview of bioplastics derived from fruit and vegetable waste biomass. Furthermore, economic and technical challenges associated with industrialization and diverse applications of bioplastics in biomedical, agricultural, and food-packaging fields due to their excellent biocompatibility properties are reviewed.HighlightsReview of the diverse types and characteristics of sustainability of biobased plasticsImproved pretreatment technologies can develop to enhance greater yieldEnzyme hydrolysis process used for bioplastic extraction & hasten industrial scale-upFocus on technical challenges facing commercialized the bioplasticsDetailed discussion on the application for sustainability of biodegradable plastics.

Toward a modeling, optimization, and predictive control framework for fed-batch metabolic cybergenetics

Biotechnology offers many opportunities for the sustainable manufacturing of valuable products. The toolbox to optimize bioprocesses includes extracellular process elements such as the bioreactor design and mode of operation, medium formulation, culture conditions, feeding rates, and so on. However, these elements are frequently insufficient for achieving optimal process performance or precise product composition. One can use metabolic and genetic engineering methods for optimization at the intracellular level. Nevertheless, those are often of static nature, failing when applied to dynamic processes or if disturbances occur. Furthermore, many bioprocesses are optimized empirically and implemented with little-to-no feedback control to counteract disturbances. The concept of cybergenetics has opened new possibilities to optimize bioprocesses by enabling online modulation of the gene expression of metabolism-relevant proteins via external inputs (e.g., light intensity in optogenetics). Here, we fuse cybergenetics with model-based optimization and predictive control for optimizing dynamic bioprocesses. To do so, we propose to use dynamic constraint-based models that integrate the dynamics of metabolic reactions, resource allocation, and inducible gene expression. We formulate a model-based optimal control problem to find the optimal process inputs. Furthermore, we propose using model predictive control to address uncertainties via online feedback. We focus on fed-batch processes, where the substrate feeding rate is an additional optimization variable. As a simulation example, we show the optogenetic control of the ATPase enzyme complex for dynamic modulation of enforced ATP wasting to adjust product yield and productivity.

Lignocellulosic Biorefinery Technologies: A Perception into Recent Advances in Biomass Fractionation, Biorefineries, Economic Hurdles and Market Outlook

Lignocellulosic biomasses (LCB) are sustainable and abundantly available feedstocks for the production of biofuel and biochemicals via suitable bioconversion processing. The main aim of this review is to focus on strategies needed for the progression of viable lignocellulosic biomass-based biorefineries (integrated approaches) to generate biofuels and biochemicals. Processing biomass in a sustainable manner is a major challenge that demands the accomplishment of basic requirements relating to cost effectiveness and environmental sustainability. The challenges associated with biomass availability and the bioconversion process have been explained in detail in this review. Limitations associated with biomass structural composition can obstruct the feasibility of biofuel production, especially in mono-process approaches. In such cases, biorefinery approaches and integrated systems certainly lead to improved biofuel conversion. This review paper provides a summary of mono and integrated approaches, their limitations and advantages in LCB bioconversion to biofuel and biochemicals.

Microbial chassis engineering drives heterologous production of complex secondary metabolites

The cryptic secondary metabolite biosynthetic gene clusters (BGCs) far outnumber currently known secondary metabolites. Heterologous production of secondary metabolite BGCs in suitable chassis facilitates yield improvement and discovery of new-to-nature compounds. The two juxtaposed conventional model microorganisms, Escherichia coli, Saccharomyces cerevisiae, have been harnessed as microbial chassis to produce a bounty of secondary metabolites with the help of certain host engineering. In last decade, engineering non-model microbes to efficiently biosynthesize secondary metabolites has received increasing attention due to their peculiar advantages in metabolic networks and/or biosynthesis. The state-of-the-art synthetic biology tools lead the way in operating genetic manipulation in non-model microorganisms for phenotypic optimization or yields improvement of desired secondary metabolites. In this review, we firstly discuss the pros and cons of several model and non-model microbial chassis, as well as the importance of developing broader non-model microorganisms as alternative programmable heterologous hosts to satisfy the desperate needs of biosynthesis study and industrial production. Then we highlight the lately advances in the synthetic biology tools and engineering strategies for optimization of non-model microbial chassis, in particular, the successful applications for efficient heterologous production of multifarious complex secondary metabolites, e.g., polyketides, nonribosomal peptides, as well as ribosomally synthesized and post-translationally modified peptides. Lastly, emphasis is on the perspectives of chassis cells development to access the ideal cell factory in the artificial intelligence-driven genome era.

Recent advances, current issues and future prospects of bioenergy production: A review

With the immense potential of bioenergy to drive carbon neutrality and achieve the climate targets of the Paris Agreement, this paper aims to present the recent advances in bioenergy production as well as their limitations. The novelty of this review is that it covers a comprehensive range of strategies in bioenergy production and it provides the future prospects for improvement. This paper reviewed more than 200 peer-reviewed scholarly papers mainly published between 2010 and 2021. Bioenergy is derived from biomass, which, through thermochemical and biochemical processes, is converted into various forms of biofuels. This paper reveals that bioenergy production is temperature-dependent and thermochemical processes currently have the advantage of higher efficiency over biochemical processes in terms of lower response time and higher conversion. However, biochemical processes produce more volatile organic compounds and have lower energy and temperature requirements. The combination of the two processes could fill the shortcomings of a single process. The choices of feedstock are diverse as well. In the future, it can be anticipated that continuous technological development to enhance the commercial viability of different processes, as well as approaches of ensuring their sustainability, will be among the main aspects to be studied in greater detail.

Synergy of Cellulase Systems between Acetivibrio thermocellus and Thermoclostridium stercorarium in Consolidated-Bioprocessing for Cellulosic Ethanol

Anaerobes harbor some of the most efficient biological machinery for cellulose degradation, especially thermophilic bacteria, such as Acetivibrio thermocellus and Thermoclostridium stercorarium, which play a fundamental role in transferring lignocellulose into ethanol through consolidated bioprocessing (CBP). In this study, we compared activities of two cellulase systems under varying kinds of hemicellulose and cellulose. A. thermocellus was identified to contribute specifically to cellulose hydrolysis, whereas T. stercorarium contributes to hemicellulose hydrolysis. The two systems were assayed in various combinations to assess their synergistic effects using cellulose and corn stover as the substrates. Their maximum synergy degrees on cellulose and corn stover were, respectively, 1.26 and 1.87 at the ratio of 3:2. Furthermore, co-culture of these anaerobes on the mixture of cellulose and xylan increased ethanol concentration from 21.0 to 40.4 mM with a high cellulose/xylan-to-ethanol conversion rate of up to 20.7%, while the conversion rates of T. stercorarium and A. thermocellus monocultures were 19.3% and 15.2%. The reason is that A. thermocellus had the ability to rapidly degrade cellulose while T. stercorarium co-utilized both pentose and hexose, the metabolites of cellulose degradation, to produce ethanol. The synergistic effect of cellulase systems and metabolic pathways in A. thermocellus and T. stercorarium provides a novel strategy for the design, selection, and optimization of ethanol production from cellulosic biomass through CBP.

A Brief Review of Poly (Butylene Succinate) (PBS) and Its Main Copolymers: Synthesis, Blends, Composites, Biodegradability, and Applications

PBS, an acronym for poly (butylene succinate), is an aliphatic polyester that is attracting increasing attention due to the possibility of bio-based production, as well as its balanced properties, enhanced processability, and excellent biodegradability. This brief review has the aim to provide the status concerning the synthesis, production, thermal, morphological and mechanical properties underlying biodegradation ability, and major applications of PBS and its principal copolymers.

A critical insight into the development, regulation and future prospects of biofuels in Canada

Renewable biofuel has a great potential in replacing the conventional transportation fuels as well as aiding the current issue of climate change and global warming. In the present scenario, tremendous initiatives have been implemented to encourage large-scale biofuel production and reduce greenhouse gas emissions. However, the information on the current biofuel status specifically in Canada and where it lacks in biofuel production, tax rebate and policies in comparison with other countries is limited. In this sense, the current work focuses on the liquid biofuel status, recent advancements and evaluation of programs aimed at reducing greenhouse gas emissions in coming years. Additionally, the role of private and government programs in scaling up the projects is elaborated using several examples of successful as well as failed attempts to commercialize biofuels. Moreover, the Canadian government regulations and policies for greenhouse gas mitigation, and biofuel blending policies are also briefly described. In summary, future aspects and suggestions to further increase biofuel production are portrayed in this review.

Process modelling and life cycle assessment coupled with experimental work to shape the future sustainable production of chemicals and fuels

Meeting the sustainable development goals and carbon neutrality targets requires transitioning to cleaner products, which poses significant challenges to the future chemical industry. Identifying alternative pathways to cover the growing demand for chemicals and fuels in a more sustainable manner calls for close collaborative programs between experimental and computational groups as well as new tools to support these joint endeavours. In this broad context, we here review the role of process systems engineering tools in assessing and optimising alternative chemical production patterns based on renewable resources, including renewable carbon and energy. The focus is on the use of process modelling and optimisation combined with life cycle assessment methodologies and network analysis to underpin experiments and generate insight into how the chemical industry could optimally deliver chemicals and fuels with a lower environmental footprint. We identify the main gaps in the literature and provide directions for future work, highlighting the role of PSE concepts and tools in guiding the future transition and complementing experimental studies more effectively.

Engineering of xylose metabolism in Escherichia coli for the production of valuable compounds

The lignocellulosic sugar d-xylose has recently gained prominence as an inexpensive alternative substrate for the production of value-added compounds using genetically modified organisms. Among the prokaryotes, Escherichia coli has become the de facto host for the development of engineered microbial cell factories. The favored status of E. coli resulted from a century of scientific explorations leading to a deep understanding of its systems. However, there are limited literature reviews that discuss engineered E. coli as a platform for the conversion of d-xylose to any target compounds. Additionally, available critical review articles tend to focus on products rather than the host itself. This review aims to provide relevant and current information about significant advances in the metabolic engineering of d-xylose metabolism in E. coli. This focusses on unconventional and synthetic d-xylose metabolic pathways as several review articles have already discussed the engineering of native d-xylose metabolism. This paper, in particular, is essential to those who are working on engineering of d-xylose metabolism using E. coli as the host.

Clean manufacturing powered by biology: how Amyris has deployed technology and aims to do it better

Amyris is a fermentation product company that leverages synthetic biology and has been bringing novel fermentation products to the market since 2009. Driven by breakthroughs in genome editing, strain construction and testing, analytics, automation, data science, and process development, Amyris has commercialized nine separate fermentation products over the last decade. This has been accomplished by partnering with the teams at 17 different manufacturing sites around the world. This paper begins with the technology that drives Amyris, describes some key lessons learned from early scale-up experiences, and summarizes the technology transfer procedures and systems that have been built to enable moving more products to market faster. Finally, the breadth of the Amyris product portfolio continues to expand; thus the steps being taken to overcome current challenges (e.g. automated strain engineering can now outpace the rest of the product commercialization timeline) are described.

Optogenetic control of the lac operon for bacterial chemical and protein production

Control of the lac operon with isopropyl β-D-1-thiogalactopyranoside (IPTG) has been used to regulate gene expression in Escherichia coli for countless applications, including metabolic engineering and recombinant protein production. However, optogenetics offers unique capabilities, such as easy tunability, reversibility, dynamic induction strength and spatial control, that are difficult to obtain with chemical inducers. We have developed a series of circuits for optogenetic regulation of the lac operon, which we call OptoLAC, to control gene expression from various IPTG-inducible promoters using only blue light. Applying them to metabolic engineering improves mevalonate and isobutanol production by 24% and 27% respectively, compared to IPTG induction, in light-controlled fermentations scalable to at least two-litre bioreactors. Furthermore, OptoLAC circuits enable control of recombinant protein production, reaching yields comparable to IPTG induction but with easier tunability of expression. OptoLAC circuits are potentially useful to confer light control over other cell functions originally designed to be IPTG-inducible.

Towards the sustainable production of bulk-chemicals using biotechnology

The design and development of new routes for the production of sustainable bulk-chemicals requires focus on feedstock, conversion technology and downstream product recovery. This brief article discusses some of the constraints with using fermentation and suggests the removal of some constraints by using microbial biocatalysis or enzyme biocatalysis, which give a number of benefits in the context of the requirements for bulk-chemical production. Some potential process concepts are described, for products in the suitable low-price range. These examples (biodiesel, furfurals and amines) are used to illustrate the power of biocatalysis. Suggestions for future research efforts beyond molecular biology, involving process-based concepts, are also discussed.

Advances in biological conversion technologies: new opportunities for reaction engineering

Reaction engineering needs to embrace biological conversion technologies, on the road to identify more sustainable routes for chemical manufacture.

Pretreatment for biorefineries: a review of common methods for efficient utilisation of lignocellulosic materials

The implementation of biorefineries based on lignocellulosic materials as an alternative to fossil-based refineries calls for efficient methods for fractionation and recovery of the products. The focus for the biorefinery concept for utilisation of biomass has shifted, from design of more or less energy-driven biorefineries, to much more versatile facilities where chemicals and energy carriers can be produced. The sugar-based biorefinery platform requires pretreatment of lignocellulosic materials, which can be very recalcitrant, to improve further processing through enzymatic hydrolysis, and for other downstream unit operations. This review summarises the development in the field of pretreatment (and to some extent, of fractionation) of various lignocellulosic materials. The number of publications indicates that biomass pretreatment plays a very important role for the biorefinery concept to be realised in full scale. The traditional pretreatment methods, for example, steam pretreatment (explosion), organosolv and hydrothermal treatment are covered in the review. In addition, the rapidly increasing interest for chemical treatment employing ionic liquids and deep-eutectic solvents are discussed and reviewed. It can be concluded that the huge variation of lignocellulosic materials makes it difficult to find a general process design for a biorefinery. Therefore, it is difficult to define "the best pretreatment" method. In the end, this depends on the proposed application, and any recommendation of a suitable pretreatment method must be based on a thorough techno-economic evaluation.

Coupled metabolic-hydrodynamic modeling enabling rational scale-up of industrial bioprocesses

Metabolomics aims to address what and how regulatory mechanisms are coordinated to achieve flux optimality, different metabolic objectives as well as appropriate adaptations to dynamic nutrient availability. Recent decades have witnessed that the integration of metabolomics and fluxomics within the goal of synthetic biology has arrived at generating the desired bioproducts with improved bioconversion efficiency. Absolute metabolite quantification by isotope dilution mass spectrometry represents a functional readout of cellular biochemistry and contributes to the establishment of metabolic (structured) models required in systems metabolic engineering. In industrial practices, population heterogeneity arising from fluctuating nutrient availability frequently leads to performance losses, that is reduced commercial metrics (titer, rate, and yield). Hence, the development of more stable producers and more predictable bioprocesses can benefit from a quantitative understanding of spatial and temporal cell-to-cell heterogeneity within industrial bioprocesses. Quantitative metabolomics analysis and metabolic modeling applied in computational fluid dynamics (CFD)-assisted scale-down simulators that mimic industrial heterogeneity such as fluctuations in nutrients, dissolved gases, and other stresses can procure informative clues for coping with issues during bioprocessing scale-up. In previous studies, only limited insights into the hydrodynamic conditions inside the industrial-scale bioreactor have been obtained, which makes case-by-case scale-up far from straightforward. Tracking the flow paths of cells circulating in large-scale bioreactors is a highly valuable tool for evaluating cellular performance in production tanks. The "lifelines" or "trajectories" of cells in industrial-scale bioreactors can be captured using Euler-Lagrange CFD simulation. This novel methodology can be further coupled with metabolic (structured) models to provide not only a statistical analysis of cell lifelines triggered by the environmental fluctuations but also a global assessment of the metabolic response to heterogeneity inside an industrial bioreactor. For the future, the industrial design should be dependent on the computational framework, and this integration work will allow bioprocess scale-up to the industrial scale with an end in mind.

Overcoming challenges in lignocellulosic biomass pretreatment for second-generation (2G) sugar production: emerging role of nano, biotechnological and promising approaches

Production of green chemicals and biofuels in biorefineries is the potential alternative for petrochemicals and gasoline in transitioning of petro-economy into bioeconomy. However, an efficient biomass pretreatment process must be considered for the successful deployment of biorefineries, mainly for use of lignocellulosic raw materials. However, biomass recalcitrance plays a key role in its saccharification to obtain considerable sugar which can be converted into ethanol or other biochemicals. In the last few decades, several pretreatment methods have been developed, but their feasibility at large-scale operations remains as a persistent bottleneck in biorefineries. Pretreatment methods such as hydrodynamic cavitation, ionic liquids, and supercritical fluids have shown promising results in terms of either lignin or hemicellulose removal, thus making remaining carbohydrate fraction amenable to the enzymatic hydrolysis for clean and high amount of fermentable sugar production. However, their techno-economic feasibility at industrial scale has not been yet studied in detail. Besides, nanotechnological-based technologies could play an important role in the economically viable 2G sugar production in future. Considering these facts, in the present review, we have discussed the existing promising pretreatment methods for lignocellulosic biomass and their challenges, besides this strategic role of nano and biotechnological approaches towards the viability and sustainability of biorefineries is also discussed.

Flexibility Options for Absorption and Distillation to Adapt to Raw Material Supply and Product Demand Uncertainties: A Review

The chemical industry has to deal with increasing uncertainties regarding the boundary conditions of their production processes. On the one hand, uncertainties affect the availability, quality, and prizes of raw material and energy. On the other hand, the demand side is affected by increasing volatilities in product demand and increasing requirements for product variety. These changing boundary conditions lead to higher needs for flexibility in production processes of the chemical industry. Within this article technical solutions for an enhancement of different forms of flexibility are presented for production concepts and apparatus concepts, respectively. The latter focuses on unit operations for the separation of gas–liquid mixtures. This includes a review regarding transformable, modular production processes and a classification of their field of application. Additionally, concepts for named unit operations on different scales are presented and discussed. The presented concepts are also classified with respect to the different types of flexibility.

Efficient production of 3-hydroxypropionate from fatty acids feedstock in Escherichia coli

The production of chemicals from renewable biomass resources is usually limited by factors including high-cost processes and low efficiency of biosynthetic pathways. Fatty acids (FAs) are an ideal alternative biomass. Their advantages include high-efficiently producing acetyl-CoA and reducing power, coupling chemical production with CO₂ fixation, and the fact that they are readily obtained from inexpensive feedstocks. The important platform chemical 3-hydroxypropionate (3HP) can be produced from FAs as the feedstock with a theoretical yield of 2.49 g/g, much higher than the theoretical yield from other feedstocks. In this study, we first systematically analyzed the limiting factors in FA-utilization pathways in Escherichia coli. Then, we optimized FA utilization in Escherichia coli by using a combination of metabolic engineering and optimization of fermentation conditions. The 3HP biosynthesis module was introduced into a FA-utilizing strain, and the flux balance was finely optimized to maximize 3HP production. The resulting strain was able to produce 3HP from FAs with a yield of 1.56 g/g, and was able to produce 3HP to a concentration of 52 g/L from FAs in a 5-L fermentation process. The strain also could produce 3HP from various type of FAs feedstock including gutter oil. This is the first report of a technique for the efficient production of the platform chemical 3HP from FAs.

The path forward for lignocellulose biorefineries: Bottlenecks, solutions, and perspective on commercialization

Lignocellulose biorefinery encompasses process engineering and biotechnology tools for the processing of lignocellulosic biomass for the manufacturing of bio-based products (such as biofuels, bio-chemicals, biomaterials). While, lignocellulose biorefinery offers clear value proposition, success at industrial level has not been vibrant for the commercial production of renewable chemicals and fuels. This is because of high capital and operating expenditures, irregularities in biomass supply chain, technical process immaturity, and scale up challenges. As a result, commercial production of biochemicals and biofuels with right economics is still lagging behind. To hit the market place, efforts are underway by bulk and specialty chemicals producing companies like DSM (Succinic acid, Cellulosic ethanol), Dow-DuPont (1,3-Propanediol, 1,4-Butanediol), Clariant-Global bioenergies-INEOS (bio-isobutene), Braskem (Ethylene, polypropylene), Raizen, Gran-bio and POET-DSM (Cellulosic ethanol), Amyris (Farnesene), and several other potential players. This paper entails the concept of lignocellulose biorefinery, technical challenges for industrialization of renewable fuels and bulk chemicals and future directions.

Aqueous Two-Phase Systems at Large Scale: Challenges and Opportunities

Aqueous two-phase systems (ATPS) have proved to be an efficient and integrative operation to enhance recovery of industrially relevant bioproducts. After ATPS discovery, a variety of works have been published regarding their scaling from 10 to 1000 L. Although ATPS have achieved high recovery and purity yields, there is still a gap between their bench-scale use and potential industrial applications. In this context, this review paper critically analyzes ATPS scale-up strategies to enhance the potential industrial adoption. In particular, large-scale operation considerations, different phase separation procedures, the available optimization techniques (univariate, response surface methodology, and genetic algorithms) to maximize recovery and purity and economic modeling to predict large-scale costs, are discussed. ATPS intensification to increase the amount of sample to process at each system, developing recycling strategies and creating highly efficient predictive models, are still areas of great significance that can be further exploited with the use of high-throughput techniques. Moreover, the development of novel ATPS can maximize their specificity increasing the possibilities for the future industry adoption of ATPS. This review work attempts to present the areas of opportunity to increase ATPS attractiveness at industrial levels.

A mathematical framework for yield (vs. rate) optimization in constraint-based modeling and applications in metabolic engineering

BACKGROUND

The optimization of metabolic rates (as linear objective functions) represents the methodical core of flux-balance analysis techniques which have become a standard tool for the study of genome-scale metabolic models. Besides (growth and synthesis) rates, metabolic yields are key parameters for the characterization of biochemical transformation processes, especially in the context of biotechnological applications. However, yields are ratios of rates, and hence the optimization of yields (as nonlinear objective functions) under arbitrary linear constraints is not possible with current flux-balance analysis techniques. Despite the fundamental importance of yields in constraint-based modeling, a comprehensive mathematical framework for yield optimization is still missing.

RESULTS

We present a mathematical theory that allows one to systematically compute and analyze yield-optimal solutions of metabolic models under arbitrary linear constraints. In particular, we formulate yield optimization as a linear-fractional program. For practical computations, we transform the linear-fractional yield optimization problem to a (higher-dimensional) linear problem. Its solutions determine the solutions of the original problem and can be used to predict yield-optimal flux distributions in genome-scale metabolic models. For the theoretical analysis, we consider the linear-fractional problem directly. Most importantly, we show that the yield-optimal solution set (like the rate-optimal solution set) is determined by (yield-optimal) elementary flux vectors of the underlying metabolic model. However, yield- and rate-optimal solutions may differ from each other, and hence optimal (biomass or product) yields are not necessarily obtained at solutions with optimal (growth or synthesis) rates. Moreover, we discuss phase planes/production envelopes and yield spaces, in particular, we prove that yield spaces are convex and provide algorithms for their computation. We illustrate our findings by a small example and demonstrate their relevance for metabolic engineering with realistic models of E. coli.

CONCLUSIONS

We develop a comprehensive mathematical framework for yield optimization in metabolic models. Our theory is particularly useful for the study and rational modification of cell factories designed under given yield and/or rate requirements.

Techno-economic analysis of the industrial production of a low-cost enzyme using E. coli: the case of recombinant β-glucosidase

BACKGROUND

The enzymatic conversion of lignocellulosic biomass into fermentable sugars is a promising approach for producing renewable fuels and chemicals. However, the cost and efficiency of the fungal enzyme cocktails that are normally employed in these processes remain a significant bottleneck. A potential route to increase hydrolysis yields and thereby reduce the hydrolysis costs would be to supplement the fungal enzymes with their lacking enzymatic activities, such as β-glucosidase. In this context, it is not clear from the literature whether recombinant E. coli could be a cost-effective platform for the production of some of these low-value enzymes, especially in the case of on-site production. Here, we present a conceptual design and techno-economic evaluation of the production of a low-cost industrial enzyme using recombinant E. coli.

RESULTS

In a simulated baseline scenario for β-glucosidase demand in a hypothetical second-generation ethanol (2G) plant in Brazil, we found that the production cost (316 US$/kg) was higher than what is commonly assumed in the literature for fungal enzymes, owing especially to the facility-dependent costs (45%) and to consumables (23%) and raw materials (25%). Sensitivity analyses of process scale, inoculation volume, and volumetric productivity indicated that optimized conditions may promote a dramatic reduction in enzyme cost and also revealed the most relevant factors affecting production costs.

CONCLUSIONS

Despite the considerable technical and economic uncertainties that surround 2G ethanol and the large-scale production of low-cost recombinant enzymes, this work sheds light on some relevant questions and supports future studies in this field. In particular, we conclude that process optimization, on many fronts, may strongly reduce the costs of E. coli recombinant enzymes, in the context of tailor-made enzymatic cocktails for 2G ethanol production.

Advances in cellulosic conversion to fuels: engineering yeasts for cellulosic bioethanol and biodiesel production

Cellulosic fuels are expected to have great potential industrial applications in the near future, but they still face technical challenges to become cost-competitive fuels, thus presenting many opportunities for improvement. The economical production of viable biofuels requires metabolic engineering of microbial platforms to convert cellulosic biomass into biofuels with high titers and yields. Fortunately, integrating traditional and novel engineering strategies with advanced engineering toolboxes has allowed the development of more robust microbial platforms, thus expanding substrate ranges. This review highlights recent trends in the metabolic engineering of microbial platforms, such as the industrial yeasts Saccharomyces cerevisiae and Yarrowia lipolytica, for the production of renewable fuels.

Optimal design of upstream processes in biotransformation technologies

In this work a mathematical programming model for the optimal design of the bioreaction section of biotechnological processes is presented. Equations for the estimation of the equipment cost derived from a recent publication by the US National Renewable Energy Laboratory (NREL) are also summarized. The cost-optimal design of process units and the optimal scheduling of their operation can be obtained using the proposed formulation that has been implemented in software available from the journal web page or the corresponding author. The proposed optimization model can be used to quantify the effects of decisions taken at a lab scale on the industrial scale process economics. It is of paramount important to note that this can be achieved at the early stage of the development of a biotechnological project. Two case studies are presented that demonstrate the usefulness and potential of the proposed methodology.

Biofuels 2020: Biorefineries based on lignocellulosic materials

The production of liquid biofuels to blend with gasoline is of worldwide importance to secure the energy supply while reducing the use of fossil fuels, supporting the development of rural technology with knowledge‐based jobs and mitigating greenhouse gas emissions. Today, engineering for plant construction is accessible and new processes using agricultural residues and municipal solid wastes have reached a good degree of maturity and high conversion yields (almost 90% of polysaccharides are converted into monosaccharides ready for fermentation). For the complete success of the 2G technology, it is still necessary to overcome a number of limitations that prevent a first‐of‐a‐kind plant from operating at nominal capacity. We also claim that the triumph of 2G technology requires the development of favourable logistics to guarantee biomass supply and make all actors (farmers, investors, industrial entrepreneurs, government, others) aware that success relies on agreement advances. The growth of ethanol production for 2020 seems to be secured with a number of 2G plants, but public/private investments are still necessary to enable 2G technology to move on ahead from its very early stages to a more mature consolidated technology.