Optimization of Agitation and Aeration for Very High Gravity Ethanol Fermentation from Sweet Sorghum Juice by Saccharomyces cerevisiae Using an Orthogonal Array Design

Potential Use of Native Yeasts to Produce Bioethanol and Other Byproducts from Black Sugarcane, an Alternative to Increment the Subsistence Farming in Northern Ecuador

The high consumption of energy, mainly in the automotive sector, is supplied by fossil fuels, which, when combusted, generate polluting gases leading to the great problem of climate change. This has led society to seek alternatives. Bioethanol is a biofuel that can be obtained from the fermentation of different raw materials rich in sucrose such as sugarcane, which can be mixed with gasoline and used to reduce polluting emissions. The following investigation focused on studying the efficiency of three selected native yeasts in the fermentation of black sugarcane POJ 27-14 variety juice to produce bioethanol and other byproducts of biotechnological interest. A comparison between the size of the inoculum of three selected native yeasts (Lev6, Lev9, and Lev30) and two reference commercial controls in the fermentation process was performed. The phylogenetic classification was carried out based on the analysis of the internal transcribed spacer 1 sequence, 5.8S ribosomal RNA, and internal transcribed spacer 2. Lev6 and Lev30 were classified as Saccharomyces cerevisiae, while Lev9 was Candida intermedia, with 99% nucleotide sequence identity. The results showed that the optimal growth temperature was 30 °C with constant agitation (200 rpm) for biomass production. The Lev30 strain presented the highest yield in the production of biomass from sugarcane juice fermentation, while the Lev6 strain presented the highest yield in ethanol production. Additionally, among native yeasts, Lev6 registered the highest ethanol concentration (Q) and volumetric productivity (Qp) values of 0.61 (g/L/h) and 43.92 g/L, respectively, which were comparable with the control yeasts. The gas chromatography coupled to mass spectrometry (GC-MS) indicated the presence of ethanol in all samples (98% to 99% relative percentages) along with some therapeutic substances such as (2-aziridinylethyl) amine and tetraacetyl-d-xylonic nitrile with greater efficiency than commercial controls from the alcoholic fermentation of black sugarcane juice.

Real-time and on-line monitoring of ethanol fermentation process by viable cell sensor and electronic nose

In this study, introduction of a viable cell sensor and electronic nose into ethanol fermentation was investigated, which could be used in real-time and on-line monitoring of the amount of living cells and product content, respectively. Compared to the conventional off-line biomass determination, the capacitance value exhibited a completely consistent trend with colony forming units, indicating that the capacitance value could reflect the living cells in the fermentation broth. On the other hand, in comparison to the results of off-line determination by high-performance liquid chromatography, the ethanol concentration measured by electronic nose presented an excellent consistency, so as to realize the on-line monitoring during the whole process. On this basis, a dynamic feeding strategy of glucose guided by the changes of living cells and ethanol content was developed. And consequently, the ethanol concentration, productivity and yield were enhanced by 15.4%, 15.9% and 9.0%, respectively. The advanced sensors adopted herein to monitor the key parameters of ethanol fermentation process could be readily extended to an industrial scale and other similar fermentation processes.

Systematic engineering of Saccharomyces cerevisiae for D-lactic acid production with near theoretical yield

D-lactic acid is a chiral three-carbon organic acid that can improve the thermostability of polylactic acid. Here, we systematically engineered Saccharomyces cerevisiae to produce D-lactic acid from glucose, a renewable carbon source, at near theoretical yield. Specifically, we screened D-lactate dehydrogenase (DLDH) variants from lactic acid bacteria in three different genera and identified the Leuconostoc pseudomesenteroides variant (LpDLDH) as having the highest activity in yeast. We then screened single-gene deletions to minimize the production of the side products ethanol and glycerol as well as prevent the conversion of D-lactic acid back to pyruvate. Based on the results of the DLDH screening and the single-gene deletions, we created a strain called ASc-d789M which overexpresses LpDLDH and contains deletions in glycerol pathway genes GPD1 and GPD2 and lactate dehydrogenase gene DLD1, as well as downregulation of ethanol pathway gene ADH1 using the L-methionine repressible promoter to minimize impact on growth. ASc-d789M produces D-lactic acid at a titer of 17.09 g/L in shake-flasks (yield of 0.89 g/g glucose consumed or 89% of the theoretical yield). Fed-batch fermentation resulted in D-lactic acid titer of 40.03 g/L (yield of 0.81 g/g glucose consumed). Altogether, our work represents progress towards efficient microbial production of D-lactic acid.

Very high gravity ethanol fermentation from sweet sorghum stem juice using a stirred tank bioreactor coupled with a column bioreactor

A stirred tank bioreactor (STR) coupled with two column bioreactors (CRs) was used for ethanol production from sweet sorghum stem juice by Saccharomyces cerevisiae SSJ01KKU in a very high gravity fermentation. The effects of the medium circulation rate between the STR and CRs (2.6 and 5.2 mL/min, corresponding to 25 and 50 % of the S. cerevisiae specific growth rate), the starting time of medium circulation (0 and 4 h) and cell inoculation were investigated. The results showed that a medium circulation rate of 5.2 mL/min, starting the medium circulation at the beginning of fermentation (0 h) with cell inoculation into the STR only were appropriate conditions for ethanol production. This yielded an average ethanol concentration (P_E) of 120.96 g/L and ethanol productivity (Q_P) of 2.52 g/L⋅h. When a repeated-batch (RB) ethanol fermentation in the STR coupled with CR was carried out using a drain and fill technique at different volumes (75 and 90 %, referenced as RB1 and RB2, respectively), it was found that at least eight successive cycles could be operated under both RB1 and RB2. The average P_E and Q_P for RB1 and RB2 were not significantly different. However, the average total ethanol production rate in RB2 (3.25 g/h) over the eight cycles was significantly higher than that of RB1 (2.60 g/h).

Very High Gravity Bioethanol Revisited: Main Challenges and Advances

Over the last decades, the constant growth of the world-wide industry has been leading to more and more concerns with its direct impact on greenhouse gas (GHG) emissions. Resulting from that, rising efforts have been dedicated to a global transition from an oil-based industry to cleaner biotechnological processes. A specific example refers to the production of bioethanol to substitute the traditional transportation fuels. Bioethanol has been produced for decades now, mainly from energy crops, but more recently, also from lignocellulosic materials. Aiming to improve process economics, the fermentation of very high gravity (VHG) mediums has for long received considerable attention. Nowadays, with the growth of multi-waste valorization frameworks, VHG fermentation could be crucial for bioeconomy development. However, numerous obstacles remain. This work initially presents the main aspects of a VHG process, giving then special emphasis to some of the most important factors that traditionally affect the fermentation organism, such as nutrients depletion, osmotic stress, and ethanol toxicity. Afterwards, some factors that could possibly enable critical improvements in the future on VHG technologies are discussed. Special attention was given to the potential of the development of new fermentation organisms, nutritionally complete culture media, but also on alternative process conditions and configurations.

Feasibility Study on Long-Term Continuous Ethanol Production from Cassava Supernatant by Immobilized Yeast Cells in Packed Bed Reactor

In this study, yeast cell immobilization was carried out in a packed bed reactor (PBR) to investigate the effects of the volumetric capacity of carriers as well as the different fermentation modes on fuel ethanol production. An optimal volumetric capacity of 10 g/l was found to obtain a high cell concentration. The productivity of immobilized cell fermentation was 16% higher than that of suspended-cell fermentation in batch and it reached a higher value of 4.28 g/l/h in repeated batches. Additionally, using this method, the ethanol yield (95.88%) was found to be higher than that of other tested methods due to low concentrations of residual sugars and free cells. Continuous ethanol production using four bioreactors showed a higher productivity (9.57 g/l/h) and yield (96.96%) with an ethanol concentration of 104.65 g/l obtained from 219.42 g/l of initial total sugar at a dilution rate of 0.092 h^-1. Furthermore, we reversed the substrate-feed flow directions in the in-series bioreactors to keep the cells at their highest activity and to extend the length of continuous fermentation. Our study demonstrates an effective method of ethanol production with a new immobilized approach, and that by switching the flow directions, traditional continuous fermentation can be greatly improved, which could have practical and broad implications in industrial applications.

Improvement of Bioethanol Production from Sweet Sorghum Juice under Very High Gravity Fermentation: Effect of Nitrogen, Osmoprotectant, and Aeration

To improve ethanol production fermentation efficiency from sweet sorghum juice under a very high gravity (VHG, 280 g/L of total sugar) condition by Saccharomyces cerevisiae NP01, dried spent yeast (DSY), yeast extract, and glycine concentrations were optimized using an L9 (34) orthogonal array design. The results showed that the order of influence on the ethanol concentration (PE) was yeast extract > glycine > DSY. The optimal nutrient concentrations for ethanol production were determined as follows: yeast extract, 3; DSY, 4; and glycine, 5 g/L. When a verification experiment under the projected optimal conditions was done, the P, ethanol yield (Yp/s), and ethanol productivity (Qp) values were 120.1 g/L, 0.47, and 2.50 g/L·h, respectively. These values were similar to those of the positive control experiment with yeast extract supplementation at 9 g/L. The yeast viability under the optimal condition was higher than that of the control experiment. To improve sugar utilization and ethanol production, aeration at 2.5 vvm for 4 h was applied under the optimal nutrient supplementation. The P, Yp/s, and Qp values were significantly increased to 134.3 g/L, 0.50, and 2.80 g/L·h, respectively.

THE EFFECT OF THE INTENSITY OF AERATING THE MEDIUM ON THE METABOLIC ACTIVITY OF ALCOHOL YEAST

The article presents the results of investigating how the intensity of aerating the medium effects on the cultivation process and the metabolic activity of alcoholic yeast Saccharomyces cerevisiae, strain U-563, in the modern technology of alcohol and baking yeast from molasses. The chemical and technological parameters of media at the aerobic and anaerobic stages of the process, the level of accumulation of the major and secondary products of yeast metabolism, and their enzymatic activity have been determined by methods commonly employed in science and in the practice of alcohol biotechnology. The objects of research were the yeast Saccharomyces cerevisiae, molasses wort, the medium in the process of yeast cultivation, and fermented wash. It has been established that two factors are the most important in the accumulation of alcoholic yeast biomass: the intensity of aerating the medium, and the staged introduction of the substrate during biomass cultivation. The more aerated the medium, the more intensively secondary metabolites of yeast Saccharomyces cerevisiae are formed (glycerol, aldehydes, higher alcohols, volatile acids, and esters) – both at the yeast generation stage and during anaerobic fermentation. When yeast Saccharomyces cerevisiae is grown in a gradient-continuous manner in a battery of series-connected apparatuses, with undiluted substrate (molasses) added by degrees, yeast biosynthesis is significantly enhanced compared to the traditional homogeneous-continuous method. The results obtained indicate the active metabolism of carbohydrates in the Krebs cycle, when the medium is intensively aerated. Besides, the results reveal the high reactivity of aldehydes and esters that results in their transformation into other compounds, and in a great decrease in their amount at the anaerobic stage of the process. However, a progressive increase is observed in glycerol, higher alcohols, and volatile acids, starting from the first yeast generator and up to the last fermentation apparatus, irrespective of the level of aerating the medium during yeast cultivation. These findings can be effectively used to manufacture food, technical, and fuel ethanol industrially from sugar-based raw materials in the course of co-production of alcohol and baking yeast.

Improvement of a continuous ethanol fermentation from sweet sorghum stem juice using a cell recycling system

The process variables (aeration rate and recycle ratio) of a continuous ethanol fermentation with a cell recycling system (CRS) by Saccharomyces cerevisiae NP 01 from sweet sorghum stem juice were optimized using response surface methodology (RSM). The relationship between intracellular composition and fermentation efficiency was also investigated. RSM results revealed that the optimum aeration rate and recycle ratio were 0.25vvm and 0.625, respectively. The validation experiment under the optimum conditions indicated high precision and reliability of the experiment, achieving an actual ethanol concentration (P_E) of 99.28g/l, which was very close to the predicted value (98.01g/l), and a very high ethanol productivity (Q_P) of 7.94g/lh. The intracellular composition of the yeast cells (i.e., unsaturated fatty acids (UFAs), total fatty acids (TFAs), ergosterol and trehalose) was positively related to the fermentation efficiency and yeast adaptive response under ethanol stress. A higher ratio of UFAs/TFAs and ergosterol strongly promoted yeast viability and ethanol fermentation. Additionally, high trehalose content was observed when the yeast was subjected to stress conditions.

Optimization of simultaneous saccharification and fermentation conditions with amphipathic lignin derivatives for concentrated bioethanol production

Amphipathic lignin derivatives (A-LDs) prepared from the black liquor of soda pulping of Japanese cedar are strong accelerators for bioethanol production under a fed-batch simultaneous enzymatic saccharification and fermentation (SSF) process. To improve the bioethanol production concentration, conditions such as reaction temperature, stirring program, and A-LDs loadings were optimized in both small scale and large scale fed-batch SSF. The fed-batch SSF in the presence of 3.0g/L A-LDs at 38°C gave the maximum ethanol production and a high enzyme recovery rate. Furthermore, a jar-fermenter equipped with a powerful mechanical stirrer was designed for 1.5L-scale fed-batch SSF to achieve rigorous mixing during high substrate loading. Finally, the 1.5L fed-batch SSF with a substrate loading of 30% (w/v) produced a high ethanol concentration of 87.9g/L in the presence of A-LDs under optimized conditions.

Preparation and characterisation of chitosan microcapsules loaded with Cortex Moutan

The process of preparation and characterisation of chitosan microcapsules loaded with Cortex Moutan was studied and the optimum condition for microcapsule preparation was investigated by orthogonal array analysis. Based on the yield percentage of microcapsule, the optimum condition for microcapsule preparation was (i) core-shell ratio=1:2; (ii) chitosan concentration=6% (w/v); (iii) agitation speed=1100 rpm; and (iv) cross-linking time=90 min. Meanwhile, relative importance of the preparation parameters was in the order: core-shell ratio, agitation speed, chitosan concentration and cross-linking time. The Fourier transform infrared spectroscopy analysis revealed that Cortex Moutan has been completely encapsulated into chitosan microcapsule. The release rate of Cortex Moutan from microcapsules in pH 5.4 phosphate buffered saline (PBS) was slightly better than that in pH 5.0 PBS after the initial 48 h and the release rate became steady after that.

Efficiency of Blenke cascade system for continuous bio-ethanol fermentation

A gas lift-system with inserts (so-called Blenke cascade system) for continuous bio-ethanol fermentation was constructed. Gas introduced at the bottom of the column created toroidal vortices in the fluid cells between inserts, enhancing mixing and improving residence time behavior without stirring equipment being necessary. The parameters mash type, start-up strategy, yeast-recycle model and yeast separation were studied concerning the efficiency of the ethanol production. The best results obtained were for a filtered mash, a double saccharification principle (DSP), a batch start-up strategy, an activation-recycle model and a lamella settler connected in series with a small conventional gravitational settler for yeast cells separation. Using this system, the fermentation residence time was τ=4-5.5h, depending on substrate type. Eighty five percent of the yeast cells could be separated. High volumetric ethanol productivity (Q(p)=20.43g/Lh) and yield E(y)=98% were achieved. Continuous fermentation, yeast recycling and sedimentation were contamination-free processes.