Comminution of Dry Lignocellulosic Biomass: Part II. Technologies, Improvement of Milling Performances, and Security Issues

Solubilization of sugarcane bagasse by mono and cocultures of thermophilic anaerobes with and without cotreatment

Cotreatment, mechanical disruption of lignocellulosic biomass during microbial fermentation, is a potential alternative to thermochemical pretreatment as a means of increasing the accessibility of lignocellulose to biological attack. Successful implementation of cotreatment requires microbes that can withstand milling, while solubilizing and utilizing carbohydrates from lignocellulose. In this context, cotreatment with thermophilic, lignocellulose-fermenting bacteria has been successfully evaluated for a number of lignocellulosic feedstocks. Here, cotreatment was applied to sugarcane bagasse using monocultures of the cellulose-fermenting Clostridium thermocellum and cocultures with the hemicellulose-fermenting Thermoanaerobacterium thermosaccharolyticum. This resulted in 76 % carbohydrate solubilization (a 1.8-fold increase over non-cotreated controls) on 10 g/L solids loading, having greater effect on the hemicellulose fraction. With cotreatment, fermentation by wild-type cultures at low substrate concentrations increased cumulative product formation by 45 % for the monoculture and 32 % for the coculture. These findings highlight the potential of cotreatment for enhancing deconstruction of sugarcane bagasse using thermophilic bacteria.

Biogas from lignocellulosic feedstock: current status and challenges

The organic wastes and residues generated from agricultural, industrial, and domestic activities have the potential to be converted to bioenergy. One such energy is biogas, which has already been included in rural areas as an alternative cooking energy source and agricultural activities. It is produced via anaerobic digestion of a wide range of organic nutrient sources and is an essential renewable energy source. The factors influencing biogas yield, i.e., the various substrate, their characteristics, pretreatment methods involved, different microbial types, sources, and inoculum properties, are analyzed. Furthermore, the optimization of these parameters, along with fermentation media optimization, such as optimum pH, temperature, and anaerobic digestion strategies, is discussed. Novel approaches of bioaugmentation, co-digestion, phase separation, co-supplementation, nanotechnology, and biorefinery approach have also been explored for biogas production. Finally, the current challenges and prospects of the process are discussed in the review.

Wheat bran layers: composition, structure, fractionation, and potential uses in foods

Wheat bran, the main by-product of dry milling of wheat, is currently mainly used in the animal feed industry, but has attracted attention as a food ingredient owing to its high dietary fiber and phytochemical contents, providing excellent physiological effects. The bran layers (aleurone layer, outer pericarp and intermediate layer) contain different compositions, structures, and nutrients, and have different properties. Each layer, when separated and isolated, potentially could find more extensive applications in foods. This triggered interest in isolating the bran layers using milling and wet- or dry-fractionation techniques based on their chemical or physical properties. The recent progress has allowed the production of commercial products from wheat bran layers, particularly aleurone-rich products, enhancing the value of wheat bran layers and their applications in food. The present review highlights the recent advances in studying the chemical composition including distribution of chemical components, physical structure, biopolymer matrix, and physicochemical properties of each wheat bran layer. Technologies to fractionate wheat bran layers and utilization of different bran layers in foods are discussed and reviewed, providing new strategies for improving the value of wheat bran and utilization of wheat bran in foods.

Recent advances in metagenomic analysis of different ecological niches for enhanced biodegradation of recalcitrant lignocellulosic biomass

Lignocellulose wastes stemming from agricultural residues can offer an excellent opportunity as alternative energy solutions in addition to fossil fuels. Besides, the unrestrained burning of agricultural residues can lead to the destruction of the soil microflora and associated soil sterilization. However, the difficulties associated with the biodegradation of lignocellulose biomasses remain as a formidable challenge for their sustainable management. In this respect, metagenomics can be used as an effective option to resolve such dilemma because of its potential as the next generation sequencing technology and bioinformatics tools to harness novel microbial consortia from diverse environments (e.g., soil, alpine forests, and hypersaline/acidic/hot sulfur springs). In light of the challenges associated with the bulk-scale biodegradation of lignocellulose-rich agricultural residues, this review is organized to help delineate the fundamental aspects of metagenomics towards the assessment of the microbial consortia and novel molecules (such as biocatalysts) which are otherwise unidentifiable by conventional laboratory culturing techniques. The discussion is extended further to highlight the recent advancements (e.g., from 2011 to 2022) in metagenomic approaches for the isolation and purification of lignocellulolytic microbes from different ecosystems along with the technical challenges and prospects associated with their wide implementation and scale-up. This review should thus be one of the first comprehensive reports on the metagenomics-based analysis of different environmental samples for the isolation and purification of lignocellulose degrading enzymes.

Polyhydroxybutyrate Rice Hull and Torrefied Rice Hull Biocomposites

Raw and torrefied rice hulls (RRH and TRH) were incorporated into polyhydroxybutyrate (PHB) as fillers using extrusion and injection molding to produce biomass-polymer composites. Filler and composite materials were characterized by particle size analysis, thermomechanical analysis, thermogravimetric analysis, differential scanning calorimetry, FTIR analysis, CHNSO analysis, and mechanical testing. Heat distortion temperature of the RRH composites were 16–22 °C higher than TRH composites. The RRH composite samples showed a 50–60% increase in flexural modulus and 5% increase in stress at yield compared to PHB, while TRH composite samples showed nearly equal flexural modulus and a 24% decrease in stress at yield. The improved mechanical properties of the RRH composites in comparison to TRH composites were due to better particle-matrix adhesion. FTIR analysis showed RRH particles contained more surface functional groups containing oxygen than TRH particles, indicating that RRHs should be more compatible with the polar PHB plastic. SEM images showed space between filler and plastic in TRH composites and better wetted filler particles in the RRH composites.

Dust and Particulate Matter Generated during Handling and Pelletization of Herbaceous Biomass: A Review

Using straw and herbaceous crops to replace or augment fossil fuels is becoming popular as access to forest biomass becomes environmentally stricter and more expensive. The low bulk density raw biomass is pre-processed and densified into pellets to facilitate handling and use. Dust is generated during collection, baling and debaling, grinding, drying, and densifying processed herbaceous biomass. Abundant literature deals with dust generated during the industrial handling of woody biomass, grains, and other crops like cotton. But the information on handling herbaceous biomass in the open literature is scarce. This paper reviews the available literature on dust generation from handling and processing of herbaceous biomass. Limited available data shows that herbaceous biomass species have a lower ignition temperature than woody biomass. The paper identifies several crucial pieces of information needed to ensure safety in the handling and pelleting of herbaceous crops.

Properties of biomass powders resulting from the fine comminution of lignocellulosic feedstocks by three types of ball-mill set-up

Background: Lignocellulosic biomass has many functionalities that hold huge potential for material, energy or chemistry applications. To support advanced applications, the biomass must be milled into ultrafine powder to increase reactivity. This milling unit operation needs to be fully mastered to deliver high-quality standard end-products. Here we studied the relationship between the characteristics of the starting lignocellulosic plant material and the properties of the resulting ultrafine powder in different ball-mill process routes. Methods: Two lignocellulosic biomasses (pine bark and wheat straw) with contrasted compositional and mechanical properties were milled using three ball-mill set-ups delivering different balances of impact force and attrition force. The resulting powders were analysed for particle characteristics (size, agglomeration extent, shape) and powder flow properties (compressibility, cohesion) using a dynamic powder rheometer. Results: Pine bark is more amenable to a fast particle size reduction than the fibrous wheat straw. The resulting pine bark powders appear less compressible but much more cohesive than the straw powders due to particle shape, density and composition factors. The mill set-up working by attrition as dominant mechanical force (vibratory ball mill) produced a mix of large, elongated particles and higher amounts of fines as it acts mainly by erosion, the resulting powder being more prone to agglomerate due to the abundance of fines. The mill set-up working by impact as dominant mechanical force (rotary ball mill) produced more evenly distributed particle sizes and shapes. The resulting powder is less prone to agglomerate due to a preferential fragmentation mechanism. Conclusions: The attrition-dominant mill yields powders with dispersed particle sizes and shapes and the poorest flow properties, while the impact-dominant mill yields more agglomeration-prone powders. The mill set-up working with impact and attrition as concomitant mechanical forces (stirred ball mill) produces powders with better reactivity and flow properties compared to rotary and vibratory mills.

Rod Mill Product Control and Its Relation to Energy Consumption: A Case Study

Energy consumption and pollution are current strategic issues that need to be addressed in the mining industry. Both have an economic and environmental impact on production, so their optimization, control, and mitigation are, at the very least, mandatory. Although rod milling has fallen into disuse in recent decades, some companies still use it in their processing plants. This is due to the ability of rod milling to reduce particle size while avoiding overgrinding. In this study, a material that is particularly difficult to characterize was used to study how to control rod-milling particle size distribution product: potash ore, which is deliquescent and soluble under certain conditions. A laboratory-scale tumbling rod mill was designed for this study, and six operative parameters were tested and analyzed in order to detect the main influences on the mill product, attending to material requirements for further processes such as recirculation load or froth flotation for beneficiation. Although the rotational speed of the mill is the parameter that shows the greatest reduction in energy consumption, reaching almost 40% improvement in specific energy applied to the particles, it is not possible to control particle size reduction ratio. However, when a low percentage of grinding media is used, it reduces around 25% of the energy used and, in turn, reduces the amount of overgrinding (40% reduction in the F300 control parameter, for example), which is a strategic objective of this study. In addition, by controlling other process parameters, such as slurry density or lifter geometry, energy consumption and its subsequent saving and pollution can be controlled, depending on process plant requirements.

Research on the Grinding Energy Density in a Jet Mill

Raw materials are used in many industrial technologies. The raw material frequently has to be prepared as an intermediate with an appropriate particle size distribution, which requires the use of grinding. In grinding processes, energy consumption is a very important profitability criterion for the applied particular size reduction technology. The paper describes the comminution process that takes place in the jet mill using a modified form of the thermodynamic theory of grinding. In this theory, new material characteristics have been added: the surface and volumetric density of grinding energy. The thermodynamic theory is a combination of the classical Kick’s theory and the modified form of Rittinger’s theory. The tested physical magnitudes are a measure of the energy consumption of the grinding process. They describe the energy that must be provided in the grinding process to overcome interactions between particles related to the volume and surface of the material. Knowledge of these magnitudes is necessary to model thermomechanical phenomena in the solid state. The paper presents the results of research on comminution in a jet mill, on the basis of which the values of the tested material magnitudes were determined. It is graphically shown how the values of the tested magnitudes depend on the grain size of the ground samples.

Lignocellulosic Biomass as a Substrate for Oleaginous Microorganisms: A Review

Microorganisms capable of accumulating lipids in high percentages, known as oleaginous microorganisms, have been widely studied as an alternative for producing oleochemicals and biofuels. Microbial lipid, so-called Single Cell Oil (SCO), production depends on several growth parameters, including the nature of the carbon substrate, which must be efficiently taken up and converted into storage lipid. On the other hand, substrates considered for large scale applications must be abundant and of low acquisition cost. Among others, lignocellulosic biomass is a promising renewable substrate containing high percentages of assimilable sugars (hexoses and pentoses). However, it is also highly recalcitrant, and therefore it requires specific pretreatments in order to release its assimilable components. The main drawback of lignocellulose pretreatment is the generation of several by-products that can inhibit the microbial metabolism. In this review, we discuss the main aspects related to the cultivation of oleaginous microorganisms using lignocellulosic biomass as substrate, hoping to contribute to the development of a sustainable process for SCO production in the near future.

Scaling behavior of particle breakage in granular flows inside rotating drums

We perform systematic particle dynamics simulations of granular flows composed of breakable particles in a 2D rotating drum to investigate the evolution of the mean particle size and specific surface as a function of system parameters such as drum size, rotation speed, filling degree, and particle shape and size. The specific surface increases at a nearly constant rate up to a point where particle breakage begins to slow down. The rates of particle breakage for all values of system parameters are found to collapse on a master curve when the times are scaled by the characteristic time defined in the linear regime. We determine the characteristic time as a function of all system parameters, and we show that the rate of particle breakage can be expressed as a linear function of a general scaling parameter that incorporates all our system parameters. This scaling behavior provides a general framework for the upscaling of drum grinding process from laboratory to industrial scale.

Fine Comminution of Pine Bark: How Does Mechanical Loading Influence Particles Properties and Milling Efficiency?

The use of lignocellulosic plant biomass as an alternative to fossil feedstocks for chemistry, energy and materials often involves an intense dry comminution step, for which the energy consumed can vary significantly according to the process parameters, the particle size targeted, and the properties of the biomass. Here we studied the fine milling of maritime pine bark in an impact-mill configuration and in an attrition-mill configuration. The properties of the resulting powders (particle size distribution, particle shape, specific surface area, agglomeration level) obtained in each configuration were compared in relation to process energy consumption. Results evidenced that the agglomeration phenomena drive milling efficiency and limit the possibilities for reaching ultrafine particles. Interestingly, impact loading proved more effective at breaking down coarse particles but tended to generate high agglomeration levels, whereas attrition milling led to less agglomeration and thus to finer particles.

Choosing Physical, Physicochemical and Chemical Methods of Pre-Treating Lignocellulosic Wastes to Repurpose into Solid Fuels

Various methods of physical, chemical and combined physicochemical pre-treatments for lignocellulosic biomass waste valorisation to value-added feedstock/solid fuels for downstream processes in chemical industries have been reviewed. The relevant literature was scrutinized for lignocellulosic waste applicability in advanced thermochemical treatments for either energy or liquid fuels. By altering the overall naturally occurring bio-polymeric matrix of lignocellulosic biomass waste, individual components such as cellulose, hemicellulose and lignin can be accessed for numerous downstream processes such as pyrolysis, gasification and catalytic upgrading to value-added products such as low carbon energy. Assessing the appropriate lignocellulosic pre-treatment technology is critical to suit the downstream process of both small- and large-scale operations. The cost to operate the process (temperature, pressure or energy constraints), the physical and chemical structure of the feedstock after pre-treatment (decomposition/degradation, removal of inorganic components or organic solubilization) or the ability to scale up the pre-treating process must be considered so that the true value in the use of bio-renewable waste can be revealed.

Energy Consumption at Size Reduction of Lignocellulose Biomass for Bioenergy

In order to obtain bioenergy (biogas, biofuel) or pellets, different types of lignocellulosic biomass are subjected to a mechanical pretreatment, first by size reduction, then by separating, and ultimately by fracturing or bio-refining. Biomass processing mainly refers to a grinding process that occurs until reaching certain limits. The size reduction process, such as grinding, is an operation that is executed with different levels of energy consumption, considering biomass mechanical characteristics and the necessary grinding level. This paper, illustrates a comparative analysis of experimental results obtained by grinding multiple types of vegetal biomass (Miscanthus, corn stalks, alfalfa, willow) used in the process of bio-refining and bio-fracturing. Experiments were realized using both a laboratory knife mill Grindomix GM200 (Retsch GmbH, Haan, Germany), and a 22 kW articulated hammer mill, using different grinding system speeds and different hammer mill sieves. Results have shown that biomass mechanical pre-processing grinding leads to supplementary costs in the overall process through bio-refining or bio-fracturing in order to obtain bio-products or bio-energy. So, specific energy consumption for grinding using a hammer mill can reach 50–65 kJ/kg for harvested Miscanthus biomass, and 35–50 kJ/kg for dried energetic willow, using a 10 mm orifice sieve, values which increase processing costs.