Assessment of Options for Selective 1-Butanol Recovery from Aqueous Solution

Zeolites in Adsorption Processes: State of the Art and Future Prospects

Zeolites have been widely used as catalysts, ion exchangers, and adsorbents since their industrial breakthrough in the 1950s and continue to be state-of the-art adsorbents in many separation processes. Furthermore, their properties make them materials of choice for developing and emerging separation applications. The aim of this review is to put into context the relevance of zeolites and their use and prospects in adsorption technology. It has been divided into three different sections, i.e., zeolites, adsorption on nanoporous materials, and chemical separations by zeolites. In the first section, zeolites are explained in terms of their structure, composition, preparation, and properties, and a brief review of their applications is given. In the second section, the fundamentals of adsorption science are presented, with special attention to its industrial application and our case of interest, which is adsorption on zeolites. Finally, the state-of-the-art relevant separations related to chemical and energy production, in which zeolites have a practical or potential applicability, are presented. The replacement of some of the current separation methods by optimized adsorption processes using zeolites could mean an improvement in terms of sustainability and energy savings. Different separation mechanisms and the underlying adsorption properties that make zeolites interesting for these applications are discussed.

PEBA/PDMS Composite Multilayer Hollow Fiber Membranes for the Selective Separation of Butanol by Pervaporation

The growing interest in the production of biofuels has motivated numerous studies on separation techniques that allow the separation/concentration of organics produced by fermentation, improving productivity and performance. In this work, the preparation and characterization of new butanol-selective membranes was reported. The prepared membranes had a hollow fiber configuration and consisted of two dense selective layers: a first layer of PEBA and a second (outer) layer of PDMS. The membranes were tested to evaluate their separation performance in the selective removal of organics from a synthetic ABE solution. Membranes with various thicknesses were prepared in order to evaluate the effect of the PDMS protective layer on permeant fluxes and membrane selectivity. The mass transport phenomena in the pervaporation process were characterized using a resistances-in-series model. The experimental results showed that PEBA as the material of the dense separating layer is the most favorable in terms of selectivity towards butanol with respect to the other components of the feed stream. The addition of a protective layer of PDMS allows the sealing of possible pinholes; however, its thickness should be kept as small as possible since permeation fluxes decrease with increasing thickness of PDMS and this material also has greater selectivity towards acetone compared to other feed components.

Energy and exergy optimization of oxidative steam reforming of acetone–butanol–ethanol–water mixture as a renewable source for H2 production via thermodynamic modeling

Acetone–butanol–ethanol–water mixture is obtained by fermentation of biomass namely, corncob, wheat straw, sugarbeets, sugarcane, etc. For using the individual components, one alternative is to separate the mixture by distillation, which is costly and energy intensive operation. This paper proposes its other use in available conditions to produce hydrogen fuel by oxidative steam reforming process. For the proposed process, thermodynamic equilibrium modeling has been performed by using non-stoichiometric approach of Gibbs free energy minimization. The compositions of acetone, butanol and ethanol in mixture are 0.33:0.52:0.15 on molar basis. The influence of pressure (1–10 atm), temperature (573–1473 K), steam to ABE mixture molar feed ratio (F ABE = 5.5–8.5), and oxygen to ABE mixture molar feed ratio (F OABE = 0.25–1) have been tested by simulations on the yield of products (at equilibrium) namely, H2, CH4, CO2, CO, and carbon as solid. The optimum conditions for maximum production of desired H2, minimization of undesired CH4, and elimination of carbon (solid) formation are T = 973 K, P = 1 atm, F ABE = 8.5, and F OABE = 0.25. Under same operating conditions, the maximum generation of H2 is 7.51 on molar basis with negligible carbon formation. The total energy requirement for the process (295.73 kJ/mol), the energy required/mol of hydrogen (39.37 kJ), and thermal efficiency (68.09%) of the reformer have been obtained at same operating conditions. The exergy analysis has also been investigated to measure the work potential of the energy implied in the reforming process.

Ionic liquid-based in situ product removal design exemplified for an acetone-butanol-ethanol fermentation

Selecting an appropriate separation technique is essential for the application of in situ product removal (ISPR) technology in biological processes. In this work, a three-stage systematic design method is proposed as a guide to integrate ionic liquid (IL)-based separation techniques into ISPR. This design method combines the selection of a suitable ISPR processing scheme, the optimal design of an IL-based liquid-liquid extraction (LLE) system followed by process simulation and evaluation. As a proof of concept, results for a conventional acetone-butanol-ethanol fermentation are presented (40,000 ton/year butanol production). In this application, ILs tetradecyl(trihexyl)phosphonium tetracyanoborate ([TDPh][TCB]) and tetraoctylammonium 2-methyl-1-naphthoate ([TOA] [MNaph]) are identified as the optimal solvents from computer-aided IL design (CAILD) method and reported experimental data, respectively. The dynamic simulation results for the fermentation process show that, the productivity of IL-based in situ (fed-batch) process and in situ (batch) process is around 2.7 and 1.8fold that of base case. Additionally, the IL-based in situ (fed-batch) process and in situ (batch) process also have significant energy savings (79.6% and 77.6%) when compared to the base case.

Bioprivileged Molecules: Integrating Biological and Chemical Catalysis for Biomass Conversion

Further development of biomass conversions to viable chemicals and fuels will require improved atom utilization, process efficiency, and synergistic allocation of carbon feedstock into diverse products, as is the case in the well-developed petroleum industry. The integration of biological and chemical processes, which harnesses the strength of each type of process, can lead to advantaged processes over processes limited to one or the other. This synergy can be achieved through bioprivileged molecules that can be leveraged to produce a diversity of products, including both replacement molecules and novel molecules with enhanced performance properties. However, important challenges arise in the development of bioprivileged molecules. This review discusses the integration of biological and chemical processes and its use in the development of bioprivileged molecules, with a further focus on key hurdles that must be overcome for successful implementation.

Pathway dissection, regulation, engineering and application: lessons learned from biobutanol production by solventogenic clostridia

The global energy crisis and limited supply of petroleum fuels have rekindled the interest in utilizing a sustainable biomass to produce biofuel. Butanol, an advanced biofuel, is a superior renewable resource as it has a high energy content and is less hygroscopic than other candidates. At present, the biobutanol route, employing acetone-butanol-ethanol (ABE) fermentation in Clostridium species, is not economically competitive due to the high cost of feedstocks, low butanol titer, and product inhibition. Based on an analysis of the physiological characteristics of solventogenic clostridia, current advances that enhance ABE fermentation from strain improvement to product separation were systematically reviewed, focusing on: (1) elucidating the metabolic pathway and regulation mechanism of butanol synthesis; (2) enhancing cellular performance and robustness through metabolic engineering, and (3) optimizing the process of ABE fermentation. Finally, perspectives on engineering and exploiting clostridia as cell factories to efficiently produce various chemicals and materials are also discussed.

Techno-Economic Analysis (TEA) of Different Pretreatment and Product Separation Technologies for Cellulosic Butanol Production from Oil Palm Frond

Among the driving factors for the high production cost of cellulosic butanol lies the pretreatment and product separation sections, which often demand high amounts of energy, chemicals, and water. In this study, techno-economic analysis of several pretreatments and product separation technologies were conducted and compared. Among the pretreatment technologies evaluated, low-moisture anhydrous ammonia (LMAA) pretreatment has shown notable potential with a pretreatment cost of $0.16/L butanol. Other pretreatment technologies evaluated were autohydrolysis, soaking in aqueous ammonia (SAA), and soaking in sodium hydroxide solution (NaOH) with pretreatment costs of $1.98/L, $3.77/L, and $0.61/L, respectively. Evaluation of different product separation technologies for acetone-butanol-ethanol (ABE) fermentation process have shown that in situ stripping has the lowest separation cost, which was $0.21/L. Other product separation technologies tested were dual extraction, adsorption, and membrane pervaporation, with the separation costs of $0.38/L, $2.25/L, and $0.45/L, respectively. The evaluations have shown that production of cellulosic butanol using combined LMAA pretreatment and in situ stripping or with dual extraction recorded among the lowest butanol production cost. However, dual extraction model has a total solvent productivity of approximately 6% higher than those of in situ stripping model.

Life-Cycle Assessment (LCA) of Different Pretreatment and Product Separation Technologies for Butanol Bioprocessing from Oil Palm Frond

Environmental impact assessment is a crucial aspect of biofuels production to ensure that the process generates emissions within the designated limits. In typical cellulosic biofuel production process, the pretreatment and downstream processing stages were reported to require a high amount of chemicals and energy, thus generating high emissions. Cellulosic butanol production while using low moisture anhydrous ammonia (LMAA) pretreatment was expected to have a low chemical, water, and energy footprint, especially when the process was combined with more efficient downstream processing technologies. In this study, the quantification of environmental impact potentials from cellulosic butanol production plants was conducted with modeled different pretreatment and product separation approaches. The results have shown that LMAA pretreatment possessed a potential for commercialization by having low energy requirements when compared to the other modeled pretreatments. With high safety measures that reduce the possibility of anhydrous ammonia leaking to the air, LMAA pretreatment resulted in GWP of 5.72 kg CO2 eq./L butanol, ecotoxicity potential of 2.84 × 10−6 CTU eco/L butanol, and eutrophication potential of 0.011 kg N eq./L butanol. The lowest energy requirement in biobutanol production (19.43 MJ/L), as well as better life-cycle energy metrics performances (NEV of 24.69 MJ/L and NER of 2.27) and environmental impacts potentials (GWP of 3.92 kg N eq./L butanol and ecotoxicity potential of 2.14 × 10−4 CTU eco/L butanol), were recorded when the LMAA pretreatment was combined with the membrane pervaporation process in the product separation stage.

Using poly(vinyldodecylimidazolium bromide) for the in-situ product recovery of n-butanol

The mitigation of end-product inhibition during the biosynthesis of n-butanol is demonstrated for an in-situ product recovery (ISPR) system employing a poly(ionic liquid) (PIL) absorbent. The thermodynamic affinity of poly(vinyldodecylimidazolium bromide) [P(VC₁₂ ImBr)] for n-butanol, acetone and ethanol versus water was measured at conditions experienced in a typical acetone-ethanol-butanol (ABE) fermentation. In addition to providing a high n-butanol partition coefficient (PC = 6.5) and selectivity (α_BuOH/water = 46), P(VC₁₂ ImBr) is shown to be biocompatible with Saccharomyces cerevisiae and Clostridium acetobutylicum. Furthermore, the diffusivity of n-butanol in a hydrated PIL provides absorption rates that support ISPR applications. Using a 5 wt% PIL phase fraction relative to the aqueous phase mass, P(VC₁₂ ImBr) improved the volumetric productivity of a batch ABE ISPR process by 31% relative to a control fermentation. The concentration of n-butanol in the P(VC₁₂ ImBr) phase was sufficient to increase the alcohol concentration from 1.5 wt% in the fermentation medium to 25 wt% in the saturated PIL, thereby facilitating downstream n-butanol recovery.

Deep neural network learning of complex binary sorption equilibria from molecular simulation data

We employed deep neural networks (NNs) as an efficient and intelligent surrogate of molecular simulations for complex sorption equilibria using probabilistic modeling. Canonical (N ₁ N ₂ VT) Gibbs ensemble Monte Carlo simulations were performed to model a single-stage equilibrium desorptive drying process for (1,4-butanediol or 1,5-pentanediol)/water and 1,5-pentanediol/ethanol from all-silica MFI zeolite and 1,5-pentanediol/water from all-silica LTA zeolite. A multi-task deep NN was trained on the simulation data to predict equilibrium loadings as a function of thermodynamic state variables. The NN accurately reproduces simulation results and is able to obtain a continuous isotherm function. Its predictions can be therefore utilized to facilitate optimization of desorption conditions, which requires a laborious iterative search if undertaken by simulation alone. Furthermore, it learns information about the binary sorption equilibria as hidden layer representations. This allows for application of transfer learning with limited data by fine-tuning a pretrained NN for a different alkanediol/solvent/zeolite system.

Utilization of acetone-butanol-ethanol-water mixture obtained from biomass fermentation as renewable feedstock for hydrogen production via steam reforming: Thermodynamic and energy analyses

A thermodynamic equilibrium analysis on steam reforming process to utilize acetone-butanol-ethanol-water mixture obtained from biomass fermentation as biorenewable fuel has been performed to produce clean energy carrier H₂ via non-stoichiometric approach namely Gibbs free energy minimization method. The effect of process variables such as temperature (573-1473 K), pressure (1-10 atm), and steam/fuel molar feed ratio (F_ABE = 5.5-12) have been investigated on equilibrium compositions of products, H₂, CO, CO₂, CH₄ and solid carbon. The best suitable conditions for maximization of desired product H₂, suppression of CH₄, and inhibition of solid carbon are 973 K, 1 atm, steam/fuel molar feed ratio = 12. Under these conditions, the maximum molar production of hydrogen is 8.35 with negligible formation of carbon and methane. Furthermore, the energy requirement per mol of H₂ (48.96 kJ), thermal efficiency (69.13%), exergy efficiency (55.09%), exergy destruction (85.36 kJ/mol), and generated entropy (0.29 kJ/mol.K) have been achieved at same operating conditions.

1-Butanol as a Solvent for Efficient Extraction of Polar Compounds from Aqueous Medium: Theoretical and Practical Aspects

The extraction of polar molecules from aqueous solution is a challenging task in organic synthesis. 1-Butanol has been used sporadically as an eluent for polar molecules, but it is unclear which molecular features drive its efficiency. Here, we employ free energy simulations to study the partitioning of 15 solutes between water and 1-butanol. The simulations demonstrate that the high affinity of polar molecules to the wet 1-butanol phase is associated with its nanostructure. Small inverse micelles of water are able to accommodate polar solutes and locally mimic an aqueous environment. We verify the simulations based on partition coefficients between water and 1-octanol, and include a blind prediction of the water/1-butanol partition coefficient of cyclohexane-1,2-diol. The calculations are in excellent agreement with experiment, reaching root-mean-square deviations below 0.7 kcal/mol. Actual extractions of cyclohexane-1,2-diol from buffer solutions that mimic cell lysates and suspensions in biocatalytic reactions further exemplify our findings. The yields highlight that extractions with 1-butanol can be significantly more efficient than the conventional protocol based on ethyl acetate.

Improved production of isobutanol in pervaporation-coupled bioreactor using sugarcane bagasse hydrolysate in engineered Enterobacter aerogenes

A process of isobutanol production from sugarcane bagasse hydrolysates in Enterobacter aerogenes was developed here with a pervaporation-integrated procedure. Isobutanol pathway was overexpressed in a mutant strain with eliminated byproduct-forming enzymes (LdhA, BudA, and PflB). A glucose-and-xylose-coconsuming ptsG mutant was constructed for effective utilization of lignocellulosic biomass. Toxic effects of isobutanol were alleviated by in situ recovery via a pervaporation procedure. Compared to single-batch fermentation, cell growth and isobutanol titer were improved by 60% and 100%, respectively, in the pervaporation-integrated fermentation process. A lab-made cross-linked polydimethylsiloxane membrane was cast on polyvinylidene fluoride and used in the pervaporation process. The membrane-penetrating condensate contained 55-226 g m^-2 h^-1 isobutanol with 6-25 g L^-1 ethanol after separation. This study offers improved fermentative production of isobutanol from lignocellulosic biomass with a pervaporation procedure.

A novel close-circulating vapor stripping-vapor permeation technique for boosting biobutanol production and recovery

BACKGROUND

Butanol derived from renewable resources by microbial fermentation is considered as one of not only valuable platform chemicals but alternative advanced biofuels. However, due to low butanol concentration in fermentation broth, butanol production is restricted by high energy consumption for product recovery. For in situ butanol recovery techniques, such as gas stripping and pervaporation, the common problem is their low efficiency in harvesting and concentrating butanol. Therefore, there is a necessity to develop an advanced butanol recovery technique for cost-effective biobutanol production.

RESULTS

A close-circulating vapor stripping-vapor permeation (VSVP) process was developed with temperature-difference control for single-stage butanol recovery. In the best scenario, the highest butanol separation factor of 142.7 reported to date could be achieved with commonly used polydimethylsiloxane membrane, when temperatures of feed solution and membrane surroundings were 70 and 0 °C, respectively. Additionally, more ABE (31.2 vs. 17.7 g/L) were produced in the integrated VSVP process, with a higher butanol yield (0.21 vs. 0.17 g/g) due to the mitigation of butanol inhibition. The integrated VSVP process generated a highly concentrated permeate containing 212.7 g/L butanol (339.3 g/L ABE), with the reduced energy consumption of 19.6 kJ/g-butanol.

CONCLUSIONS

Therefore, the present study demonstrated a well-designed energy-efficient technique named by vapor stripping-vapor permeation for single-stage butanol removal. The butanol separation factor was multiplied by the temperature-difference control strategy which could double butanol recovery performance. This advanced VSVP process can completely eliminate membrane fouling risk for fermentative butanol separation, which is superior to other techniques.

In situ biobutanol recovery from clostridial fermentations: a critical review

Butanol is a precursor of many industrial chemicals, and a fuel that is more energetic, safer and easier to handle than ethanol. Fermentative biobutanol can be produced using renewable carbon sources such as agro-industrial residues and lignocellulosic biomass. Solventogenic clostridia are known as the most preeminent biobutanol producers. However, until now, solvent production through the fermentative routes is still not economically competitive compared to the petrochemical approaches, because the butanol is toxic to their own producer bacteria, and thus, the production capability is limited by the butanol tolerance of producing cells. In order to relieve butanol toxicity to the cells and improve the butanol production, many recovery strategies (either in situ or downstream of the fermentation) have been attempted by many researchers and varied success has been achieved. In this article, we summarize in situ recovery techniques that have been applied to butanol production through Clostridium fermentation, including liquid-liquid extraction, perstraction, reactive extraction, adsorption, pervaporation, vacuum fermentation, flash fermentation and gas stripping. We offer a prospective and an opinion about the past, present and the future of these techniques, such as the application of advanced membrane technology and use of recent extractants, including polymer solutions and ionic liquids, as well as the application of these techniques to assist the in situ synthesis of butanol derivatives.

Comparative Study of the Effect of Defects on Selective Adsorption of Butanol from Butanol/Water Binary Vapor Mixtures in Silicalite-1 Films

A promising route for sustainable 1-butanol (butanol) production is ABE (acetone, butanol, ethanol) fermentation. However, recovery of the products is challenging because of the low concentrations obtained in the aqueous solution, thus hampering large-scale production of biobutanol. Membrane and adsorbent-based technologies using hydrophobic zeolites are interesting alternatives to traditional separation techniques (e.g., distillation) for energy-efficient separation of butanol from aqueous mixtures. To maximize the butanol over water selectivity of the material, it is important to reduce the number of hydrophilic adsorption sites. This can, for instance, be achieved by reducing the density of lattice defect sites where polar silanol groups are found. The density of silanol defects can be reduced by preparing the zeolite at neutral pH instead of using traditional synthesis solutions with high pH. In this work, binary adsorption of butanol and water in two silicalite-1 films was studied using in situ attenuated total reflectance-Fourier transform infrared (ATR-FTIR) spectroscopy under equal experimental conditions. One of the films was prepared in fluoride medium, whereas the other one was prepared at high pH using traditional synthesis conditions. The amounts of water and butanol adsorbed from binary vapor mixtures of varying composition were determined at 35 and 50 °C, and the corresponding adsorption selectivities were also obtained. Both samples showed very high selectivities (100-23 000) toward butanol under the conditions studied. The sample having low density of defects, in general, showed ca. a factor 10 times higher butanol selectivity than the sample having a higher density of defects at the same experimental conditions. This difference was due to a much lower adsorption of water in the sample with low density of internal defects. Analysis of molecular simulation trajectories provides insights on the local selectivities in the zeolite channel network and at the film surface.

Intensified Biobutanol Recovery by using Zeolites with Complementary Selectivity

A vapor-phase adsorptive recovery process is proposed as an alternative way to isolate biobutanol from acetone-butanol-ethanol (ABE) fermentation media, offering several advantages compared to liquid phase separation. The effect of water, which is still present in large quantities in the vapor phase, on the adsorption of the organics could be minimized by using hydrophobic zeolites. Shape-selective all-silica zeolites CHA and LTA were prepared and evaluated with single-component isotherms and breakthrough experiments. These zeolites show opposite selectivities; adsorption of ethanol is favorable on all-silica CHA, whereas the LTA topology has a clear preference for butanol. The molecular sieving properties of both zeolites allow easy elimination of acetone from the mixture. The molecular interaction mechanisms are studied by density functional theory (DFT) simulations. The effects of mixture composition, humidity and total pressure of the vapor stream on the selectivity and separation behavior are investigated. Desorption profiles are studied to maximize butanol purity and recovery. The combination of LTA with CHA-type zeolites (Si-CHA or SAPO-34) in sequential adsorption columns with alternating adsorption and desorption steps allows butanol to be recovered in unpreceded purity and yield. A butanol purity of 99.7 mol % could be obtained at nearly complete butanol recovery, demonstrating the effectiveness of this technique for biobutanol separation processes.