Purification of 2,3-butanediol from fermentation broth: process development and techno-economic analysis

Interdisciplinary development of an overall process concept from glucose to 4,5-dimethyl-1,3-dioxolane via 2,3-butanediol

To reduce carbon dioxide emissions, carbon-neutral fuels have recently gained renewed attention. Here we show the development and evaluation of process routes for the production of such a fuel, the cyclic acetal 4,5-dimethyl-1,3-dioxolane, from glucose via 2,3-butanediol. The selected process routes are based on the sequential use of microbes, enzymes and chemo-catalysts in order to exploit the full potential of the different catalyst systems through a tailor-made combination. The catalysts (microbes, enzymes, chemo-catalysts) and the reaction medium selected for each conversion step are key factors in the development of the respective production methods. The production of the intermediate 2,3-butanediol by combined microbial and enzyme catalysis is compared to the conventional microbial route from glucose in terms of specific energy demand and overall yield, with the conventional route remaining more efficient. In order to be competitive with current 2,3-butanediol production, the key performance indicator, enzyme stability to high aldehyde concentrations, needs to be increased. The target value for the enzyme stability is an acetaldehyde concentration of 600 mM, which is higher than the current maximum concentration (200 mM) by a factor of three.

Assessing the environmental footprints and material flow of 2,3-butanediol production in a wood-based biorefinery

This study aims to scrutinize and compare the environmental impacts of biobased 2,3-butanediol (BDO) and its fossil-based counterpart. BDO is a fundamental chemical in various industries, traditionally derived from petroleum sources. Wood residues, largely available in Nordic countries, are sustainable alternative feedstocks, offering potential environmental benefits. Material flow analysis followed by consequential life cycle assessment (LCA) were employed to quantify the potential environmental burdens associated with various biorefinery stages of wood-based BDO production. The findings indicated that refraining from wood combustion and, instead, utilizing wood in a biorefinery to produce BDO as the main product, with methane and fertilizer as coproducts from the waste residue, resulted in 125%, 52%, and 90% better environmental performance regarding human health, climate change, and resource scarcity, respectively, compared to fossil-based BDO production. The results offer valuable insights for technology developers and policymakers, empowering them to make informed decisions and support sustainable practices.

Recovery of 2,3-Butanediol from Fermentation Broth by Zeolitic Imidazolate Frameworks

The efficient separation of the 2,3-butanediol (2,3-BDO) intermediate from fermentation broth is an important issue in the production of biofuels from biomass-derived intermediates. Two zeolitic imidazolate frameworks ZIF-8 and ZIF-71 were investigated for the adsorption of 2,3-butanediol (2,3-BDO) from fermentation broth via liquid breakthrough adsorption measurements. While both ZIF materials initially show high separation performance, ZIF-71 retains robust separation performance even after aging in ethanol for two years, whereas the capacity of ZIF-8 decreases significantly. The robustness and stability of ZIF-71 are further confirmed with cyclic fixed bed adsorption measurements. The uptake of 2,3-BDO on ZIF-71 reaches >100 g/kg with negligible uptakes of sugars, organic acids, and other alcohols present in the fermentation broth. Excellent selectivity toward 2,3-BDO over water is also achieved. The 2,3-BDO-loaded ZIF-71 can be regenerated efficiently with ethanol as desorbent. These findings indicate that ZIF-71 shows considerable promise as an adsorbent to recover and purify diols from fermentation broths.

Techno-Economic Analysis of 2,3-Butanediol Production from Sugarcane Bagasse

Sugarcane bagasse (SCB) is a significant agricultural residue generated by sugar mills based on sugarcane crop. Valorizing carbohydrate-rich SCB provides an opportunity to improve the profitability of sugar mills with simultaneous production of value-added chemicals, such as 2,3-butanediol (BDO). BDO is a prospective platform chemical with multitude of applications and huge derivative potential. This work presents the techno-economic and profitability analysis for fermentative production of BDO utilizing 96 MT of SCB per day. The study considers plant operation in five scenarios representing the biorefinery annexed to a sugar mill, centralized and decentralized units, and conversion of only xylose or total carbohydrates of SCB. Based on the analysis, the net unit production cost of BDO in the different scenarios ranged from 1.13 to 2.28 US$/kg, while the minimum selling price varied from 1.86 to 3.99 US$/kg. Use of the hemicellulose fraction alone was shown to result in an economically viable plant; however, this was dependent on the condition that the plant would be annexed to a sugar mill which could supply utilities and the feedstock free of cost. A standalone facility where the feedstock and utilities were procured was predicted to be economically feasible with a net present value of about 72 million US$, when both hemicellulose and cellulose fractions of SCB were utilized for BDO production. Sensitivity analysis was also conducted to highlight some key parameters affecting plant economics.

From Agricultural Wastes to Fermentation Nutrients: A Case Study of 2,3-Butanediol Production

The goal of this study was to improve resource use efficiency in agricultural systems and agro-based industries, reduce wastes that go to landfills and incinerators, and consequently, improve the economics of 2,3-butanediol (2,3-BD) production. This study evaluated the feasibility of 2,3-BD production by replacing the mineral nutrients, and buffers with anaerobic digestate (ADE), poultry-litter (PLBC)- and forage-sorghum (FSBC)-derived biochars. Fermentation media formulations with ADE and 5–20 g/L PLBC or FSBC were evaluated for 2,3-BD production using Paenibacillus polymyxa as a biocatalyst. An optimized medium containing nutrients and buffers served as control. While 2,3-BD production in the ADE cultures was 0.5-fold of the maximum generated in the control cultures, 2,3-BD produced in the PLBC and FSBC cultures were ~1.3-fold more than the control (33.6 g/L). Cost analysis showed that ADE and biochar can replace mineral nutrients and buffers in the medium with the potential to make bio-based 2,3-BD production profitably feasible.

Energy-efficient recovery of fermented butyric acid using octyl acetate extraction

Background

A butyric acid recovery process using octyl acetate is proposed, and the design details of the extraction and subsequent distillation processes were investigated. Ternary equilibrium data for the extractor design were derived from molecular simulations and experimental measurements.

Results

A new procedure for estimating the thermodynamic parameters was introduced to determine the effect of the parameters on extractor design by comparison with previously reported parameters. Using the proposed recovery process with the newly estimated thermodynamic model, 99.8% butyric acid was recovered from the fermentation broth at a recovery rate of 99%. The energy demand for the proposed process was found to be lower than the average demand for several reported butyric acid recovery processes.

Conclusions

The investment cost is projected to be lower than that of other butyric acid processes due to the high efficiency of extraction solvent. The recovery cost of butyric acid was comparable to its selling price.

Supplementary Information

The online version contains supplementary material available at 10.1186/s13068-022-02146-6.

Bioengineering for the industrial production of 2,3-butanediol by the yeast, Saccharomyces cerevisiae

Owing to issues, such as the depletion of petroleum resources and price instability, the development of biorefinery related technologies that produce fuels, electric power, chemical substances, among others, from renewable resources is being actively promoted. 2,3-Butanediol (2,3-BDO) is a key compound that can be used to produce various chemical substances. In recent years, 2,3-BDO production using biological processes has attracted extensive attention for achieving a sustainable society through the production of useful compounds from renewable resources. With the development of genetic engineering, metabolic engineering, synthetic biology, and other research field, studies on 2,3-BDO production by the yeast, Saccharomyces cerevisiae, which is safe and can be fabricated using an established industrial-scale cultivation technology, have been actively conducted. In this review, we sought to describe 2,3-BDO and its derivatives; discuss 2,3-BDO production by microorganisms, in particular S. cerevisiae, whose research and development has made remarkable progress; describe a method for separating and recovering 2,3-BDO from a microbial culture medium; and propose future prospects for the industrial production of 2,3-BDO by microorganisms.

Current Advances in Microbial Production of Acetoin and 2,3-Butanediol by Bacillus spp

The growing need for industrial production of bio-based acetoin and 2,3-butanediol (2,3-BD) is due to both environmental concerns, and their widespread use in the food, pharmaceutical, and chemical industries. Acetoin is a common spice added to many foods, but also a valuable reagent in many chemical syntheses. Similarly, 2,3-BD is an indispensable chemical on the platform in the production of synthetic rubber, printing inks, perfumes, antifreeze, and fuel additives. This state-of-the-art review focuses on representatives of the genus Bacillus as prospective producers of acetoin and 2,3-BD. They have the following important advantages: non-pathogenic nature, unpretentiousness to growing conditions, and the ability to utilize a huge number of substrates (glucose, sucrose, starch, cellulose, and inulin hydrolysates), sugars from the composition of lignocellulose (cellobiose, mannose, galactose, xylose, and arabinose), as well as waste glycerol. In addition, these strains can be improved by genetic engineering, and are amenable to process optimization. Bacillus spp. are among the best acetoin producers. They also synthesize 2,3-BD in titer and yield comparable to those of the pathogenic producers. However, Bacillus spp. show relatively lower productivity, which can be increased in the course of challenging future research.

High yield recovery of 2,3-butanediol from fermented broth accumulated on xylose rich sugarcane bagasse hydrolysate using aqueous two-phase extraction system

Downstream processing of chemicals obtained from fermentative route is challenging and cost-determining factor of any bioprocess. 2,3-Butanediol (BDO) is a promising chemical building block with myriad applications in the polymer, food, pharmaceuticals, and fuel sector. The current study focuses on the recovery and purification of BDO produced (68.2 g/L) from detoxified xylose-rich sugarcane bagasse hydrolysate by a mutant strain of Enterobacter ludwigii. Studies involving screening and optimization of aqueous-two phase system (ATPS) revealed that 30% w/v (NH₄)₂SO₄ addition to clarified fermented broth facilitated BDO extraction in isopropanol (0.5 v/v), with maximum recovery and partition coefficient being 97.9 ± 4.6% and 45.5 ± 3.5, respectively. The optimized protocol was repeated with unfiltered broth containing 68.2 g/L BDO, cell biomass, and unspent protein, which led to the partitioning of 66.7 g/L BDO, 2.0 g/L xylose and 9.0 g/L acetic acid into organic phase with similar BDO recovery (97%) and partition coefficient (45).

Prospects on bio-based 2,3-butanediol and acetoin production: Recent progress and advances

The bio-based platform chemicals 2,3-butanediol (BDO) and acetoin have various applications in chemical, cosmetics, food, agriculture, and pharmaceutical industries, whereas the derivatives of BDO could be used as fuel additives, polymer and synthetic rubber production. This review summarizes the novel technological developments in adapting genetic and metabolic engineering strategies for selection and construction of chassis strains for BDO and acetoin production. The valorization of renewable feedstocks and bioprocess development for the upstream and downstream stages of bio-based BDO and acetoin production are discussed. The techno-economic aspects evaluating the viability and industrial potential of bio-based BDO production are presented. The commercialization of bio-based BDO and acetoin production requires the utilization of crude renewable resources, the chassis strains with high fermentation production efficiencies and development of sustainable purification or conversion technologies.

C4 Bacterial Volatiles Improve Plant Health

Plant growth-promoting rhizobacteria (PGPR) associated with plant roots can trigger plant growth promotion and induced systemic resistance. Several bacterial determinants including cell-wall components and secreted compounds have been identified to date. Here, we review a group of low-molecular-weight volatile compounds released by PGPR, which improve plant health, mostly by protecting plants against pathogen attack under greenhouse and field conditions. We particularly focus on C4 bacterial volatile compounds (BVCs), such as 2,3-butanediol and acetoin, which have been shown to activate the plant immune response and to promote plant growth at the molecular level as well as in large-scale field applications. We also disc/ uss the potential applications, metabolic engineering, and large-scale fermentation of C4 BVCs. The C4 bacterial volatiles act as airborne signals and therefore represent a new type of biocontrol agent. Further advances in the encapsulation procedure, together with the development of standards and guidelines, will promote the application of C4 volatiles in the field.

Phase equilibria modeling of biorefinery-related systems: a systematic review

The search for sustainable ideas has gained prominence in recent decades at all levels of society since it has become imperative an economic, social, and environmental development in an integrated manner. In this context, biorefineries are currently present as the technology that best covers all these parameters, as they add the benefits of waste reuse, energy cogeneration, and fossil fuel substitution. Thus, the study of the various applicable biological matrices and exploring the technical capabilities of these processes become highly attractive. Thermodynamic modeling acts in this scenario as a fundamental tool for phase behavior predictions in process modeling, design, and optimization. Thus, this work aimed to systematize, using the PRISMA statement for systematic reviews, the information published between 2010 and 2020 on phase equilibria modeling in systems related to biorefineries to organize what is already known about the subject. As a result, 236 papers were categorized in terms of the year, country, type of phase equilibria, and thermodynamic model used. Also, the phase behavior predictions of different thermodynamic models under the same process conditions were qualitatively compared, establishing PC-SAFT as the model that best represents the great diversity of interest systems for biorefineries in a wide range of conditions.

Disruption of the lactate dehydrogenase and acetate kinase genes in Klebsiella pneumoniae HD79 to enhance 2,3-butanediol production, and related transcriptomics analysis

OBJECTIVES

2,3-Butanediol (2,3-BD) is widely used in several chemical syntheses as well as the manufacture of plastics, solvents, and antifreeze formulations, and can be manufactured by microbial glucose fermentation. Conventional (2,3-BD) fermentation typically has low productivity, yield, and purity, and is expensive for commercial applications. We aimed to delete the lactate dehydrogenase and acetate kinase (ldhA and ack) genes in Klebsiella pneumoniae HD79 by using λRed homologous recombination technology, to eliminate by-products and thereby improve (2,3-BD) production. We also analyzed the resulting gene changes by using transcriptomics.

RESULTS

The yield of (2,3-BD) from the mutant Klebsiella strain was 46.21 g/L, the conversion rate was 0.47 g/g, and the productivity was 0.64 g/L·h, which represented increases of 54.9%, 20.5%, and 106.5% respectively, compared to (WT) strains. Lactate and acetate decreased by 48.2% and 62.8%, respectively. Transcriptomics analysis showed that 4628 genes were differentially expressed (404 significantly up-regulated and 162 significantly down-regulated). Moreover, the (2,3-BD) operon genes were differentially expressed.

CONCLUSION

Our data showed that the biosynthesis of (2,3-BD) was regulated by inducers (lactate and acetate), a regulator (BudR), and carbon flux. Elimination of acidic by-products by ldhA and ack knockdown significantly improved (2,3-BD) production. Our results provide a deeper understanding of the mechanisms underlying (2,3-BD) production, and form a molecular basis for the improvement this process by genetic modification in the future.

The current strategies and parameters for the enhanced microbial production of 2,3-butanediol

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2,3-Butanediol (2,3-BD) is a propitious compound with many industrial uses.

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2,3-BD production has always been hampered by low fermentation yields and high production costs.

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2,3-BD production may be enhanced by optimization of culture conditions and use of high-producing strains.

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TMetabolic engineering tools are currently used to generate high-yielding strains.

2,3-Butanediol (2,3-BD) is a propitious compound with many industrial uses ranging from rubber, fuels, and cosmetics to food additives. Its microbial production has especially attracted as an alternative way to the petroleum-based production. However, 2,3-BD production has always been hampered by low yields and high production costs. The enhanced production of 2,3-butanediol requires screening of the best strains and a systematic optimization of fermentation conditions. Moreover, the metabolic pathway engineering is essential to achieve the best results and minimize the production costs by rendering the strains to use efficiently low cost substrates. This review is to provide up-to-date information on the current strategies and parameters for the enhanced microbial production of 2,3-BD.

Improvement of 1,3-Butadiene Separation in 2,3-Butanediol Dehydration Using Extractive Distillation

This study was performed to investigate the extractive distillation for 1,3-butadiene (1,3-BD) purification as a part of the 2,3-butanediol (2,3-BDO) dehydration process. The separation of 1,3-BD from 1-butene produced as a 2,3-BDO dehydration by-product while using distillation is complicated due to the similar volatilities of the two compounds. Thus, an extractive distillation system is proposed for the effective recovery of 1,3-BD, and is compared with a conventional distillation system in terms of its performance and economic feasibility. A higher 1,3-BD recovery rate was achieved while using the proposed system and the relative profitabilities of both separation systems were analyzed according to the market price of 1,3-BD, which is a decisive variable for economic feasibility.

Eco-efficient recovery of bio-based volatile C2-6 fatty acids

BACKGROUND

Volatile fatty acids (VFAs) are produced by fermentation of various bio-sources and human wastes at minimal cost; sometimes, even sources having a prepaid processing fee were used. However, low concentrations of VFAs in water have prevented their commercial production, even with modern separation technologies, due to the high operating costs. We have applied newly developed solvents, selected by chemical structure similarity, to the separation of five different VFAs.

RESULTS

Since most of the water was separated by extraction using hexyl acetate and nonyl acetate, the utilities necessary for solvent recovery and product purification were a fraction of those required by the existing VFAs' separation processes. The solvents separated almost all the water in the feed at the extraction stage, consuming no energy. The energy use in this study is only 34% of the lowest case use among various processes of either distillation-only or combined extraction-distillation.

CONCLUSIONS

The performance evaluation of the proposed VFAs separation process showed that product recovery was 99% and acid purity was 99.5% with eco-scores of 70% lower than those of the current processes.