Continuous Ethanol Production from Synthesis Gas by Clostridium ragsdalei in a Trickle-Bed Reactor

Biofilms for Production of Chemicals and Energy

The twenty-first century will be the century of biology. This is not only because of breakthrough advances in molecular biology tools but also because we need to reinvent our economy based on the biological principles of energy efficiency and sustainability. Consequently, new tools for production routines must be developed to help produce platform chemicals and energy sources based on sustainable resources. In this context, biofilm-based processes have the potential to impact future production processes, because they can be carried out continuously and with robust stationary biocatalysts embedded in an extracellular matrix with different properties. We review productive biofilm systems used for heterotrophic and lithoautotrophic production and attempt to identify fundamental reasons why they may be particularly suitable as future production systems.

Acetate Production from Syngas Produced from Lignocellulosic Biomass Materials along with Gaseous Fermentation of the Syngas: A Review

Biotransformation of lignocellulose-derived synthetic gas (syngas) into acetic acid is a promising way of creating biochemicals from lignocellulosic waste materials. Acetic acid has a growing market with applications within food, plastics and for upgrading into a wide range of biofuels and bio-products. In this paper, we will review the microbial conversion of syngas to acetic acid. This will include the presentation of acetate-producing bacterial strains and their optimal fermentation conditions, such as pH, temperature, media composition, and syngas composition, to enhance acetate production. The influence of syngas impurities generated from lignocellulose gasification will further be covered along with the means to alleviate impurity problems through gas purification. The problem with mass transfer limitation of gaseous fermentation will further be discussed as well as ways to improve gas uptake during the fermentation.

Repeated-Batch Ethanol Fermentation from Sweet Sorghum Stem Juice under a Very High Gravity Condition Using a Stirred Tank Bioreactor Coupled with a Column Bioreactor by Immobilized Saccharomyces cerevisiae

The ethanol fermentation efficiency of sweet sorghum stem juice (SSJ) under a very high gravity (VHG) condition (250 g/L of sugar) was improved by immobilized Saccharomyces cerevisiae SSJKKU01, using a stirred tank bioreactor (STR) coupled with a column bioreactor (CR). Dried rattan pieces (as carriers for cell immobilization) at 50% of the working volume of the CR were suitable for use in a batch ethanol fermentation. The average ethanol concentration (PE) and ethanol productivity (QP) of repeated-batch fermentation in the CR for eight successive cycles were 109.85 g/L and 1.88 g/L⋅h, respectively. Then an STR coupled with a CR was applied for repeated-batch ethanol fermentation in two systems. System I was an STR (1.8 L working volume), and System II was an STR (1 L) coupled with a CR, referred to as a CR-F (0.8 L). Both systems were connected to a new CR, called CR-I, containing sterile dried rattan pieces at 50% of its working volume. Active yeast cells were inoculated only into the STR, and the medium circulation rate between bioreactors was 5.2 mL/min. The results showed that at least eight successive cycles could be operated with an average PE of 108.51 g/L for System I and 109.44 g/L for System II. The average QP and SC values of both systems were also similar, with values of 1.87 to 1.88 g/L⋅h and 93 to 94%, respectively. The morphology of the carriers with and without immobilized cells before and after the fermentation was investigated. The obtained results demonstrated that a repeated-batch fermentation by immobilized cells on rattan pieces, using an STR coupled with a CR, was successfully used to produce high levels of ethanol from SSJ under a VHG condition.

Determining global trends in syngas fermentation research through a bibliometric analysis

Syngas fermentation, in which microorganisms convert H₂, CO, and CO₂ to acids and alcohols, is a promising alternative for carbon cycling and valorization. The intellectual landscape of the topic was characterized through a bibliometric analysis using a search query (SQ) that included all relevant documents on syngas fermentation available through the Web of Science database up to December 31st, 2021. The SQ was validated with a preliminary analysis in bibliometrix and a review of titles and abstracts of all sources. Although syngas fermentation began in the early 1980s, it grew rapidly beginning in 2008, with 92.5% of total publications and 87.3% of total citations from 2008 to 2021. The field has been steadily moving from fundamentals towards applications, suggesting that the field is maturing scientifically. The greatest number of publications and citations are from the USA, and researchers in China, Germany, and Spain also are highly active. Although collaborations have increased in the past few years, author-cluster analysis shows specialized research domains with little collaboration between groups. Based on topic trends, the main challenges to be address are related to mass-transfer limitations, and researchers are starting to explore mixed cultures, genetic engineering, microbial chain elongation, and biorefineries.

Biological conversion of carbon monoxide and hydrogen by anaerobic culture: Prospect of anaerobic digestion and thermochemical processes combination

Waste biomass is considered a promising renewable energy feedstock that can be converted by anaerobic digestion. However, anaerobic digestion application can be challenging due to the structural complexity of several waste biomass kinds. Therefore, coupling anaerobic digestion with thermochemical processes can offset the limitations and convert the hardly biodegradable waste biomass, including digestate residue, into value-added products: syngas and pyrogas (gaseous mixtures consisting mainly of H₂, CO, CO₂), bio-oil, and biochar for further valorisation. In this review, the utilisation boundaries and benefits of the aforementioned products by anaerobic culture are discussed. First, thermochemical process parameters for an enhanced yield of desired products are summarised. Particularly, the microbiology of CO and H₂ mixture biomethanation and fermentation in anaerobic digestion is presented. Finally, the state-of-the-art biological conversion of syngas and pyrogas to CH₄ mediated by anaerobic culture is adequately described. Extensive research shows the successful selective biological conversion of CO and H₂ to CH₄, acetic acid, and alcohols. The main bottleneck is the gas-liquid mass transfer which can be enhanced appropriately by bioreactors' configurations. A few research groups focus on bio-oil and biochar addition into anaerobic digesters. However, according to the literature review, there has been no research for utilising all value-added products at once in anaerobic digestion published so far. Although synergic effects of such can be expected. In summary, the combination of anaerobic digestion and thermochemical processes is a promising alternative for wide-scale waste biomass utilisation in practice.

Biomethanation of Carbon Monoxide by Hyperthermophilic Artificial Archaeal Co-Cultures

Climate neutral and sustainable energy sources will play a key role in future energy production. Biomethanation by gas to gas conversion of flue gases is one option with regard to renewable energy production. Here, we performed the conversion of synthetic carbon monoxide (CO)-containing flue gases to methane (CH4) by artificial hyperthermophilic archaeal co-cultures, consisting of Thermococcus onnurineus and Methanocaldococcus jannaschii, Methanocaldococcus vulcanius, or Methanocaldococcus villosus. Experiments using both chemically defined and complex media were performed in closed batch setups. Up to 10 mol% CH4 was produced by converting pure CO or synthetic CO-containing industrial waste gases at a high rate using a co-culture of T. onnurineus and M. villosus. These findings are a proof of principle and advance the fields of Archaea Biotechnology, artificial microbial ecosystem design and engineering, industrial waste-gas recycling, and biomethanation.

Reactor Designs and Configurations for Biological and Bioelectrochemical C1 Gas Conversion: A Review

Microbial C1 gas conversion technologies have developed into a potentially promising technology for converting waste gases (CO₂, CO) into chemicals, fuels, and other materials. However, the mass transfer constraint of these poorly soluble substrates to microorganisms is an important challenge to maximize the efficiencies of the processes. These technologies have attracted significant scientific interest in recent years, and many reactor designs have been explored. Syngas fermentation and hydrogenotrophic methanation use molecular hydrogen as an electron donor. Furthermore, the sequestration of CO₂ and the generation of valuable chemicals through the application of a biocathode in bioelectrochemical cells have been evaluated for their great potential to contribute to sustainability. Through a process termed microbial chain elongation, the product portfolio from C1 gas conversion may be expanded further by carefully driving microorganisms to perform acetogenesis, solventogenesis, and reverse β-oxidation. The purpose of this review is to provide an overview of the various kinds of bioreactors that are employed in these microbial C1 conversion processes.

Residual Gas for Ethanol Production by Clostridium carboxidivorans in a Dual Impeller Stirred Tank Bioreactor (STBR)

Recycling residual industrial gases and residual biomass as substrates to biofuel production by fermentation is an important alternative to reduce organic wastes and greenhouse gases emission. Clostridium carboxidivorans can metabolize gaseous substrates as CO and CO2 to produce ethanol and higher alcohols through the Wood-Ljungdahl pathway. However, the syngas fermentation is limited by low mass transfer rates. In this work, a syngas fermentation was carried out in serum glass bottles adding different concentrations of Tween® 80 in ATCC® 2713 culture medium to improve gas-liquid mass transfer. We observed a 200% increase in ethanol production by adding 0.15% (v/v) of the surfactant in the culture medium and a 15% increase in biomass production by adding 0.3% (v/v) of the surfactant in the culture medium. The process was reproduced in stirred tank bioreactor with continuous syngas low flow, and a maximum ethanol productivity of 0.050 g/L.h was achieved.

Syngas Derived from Lignocellulosic Biomass Gasification as an Alternative Resource for Innovative Bioprocesses

A hybrid system based on lignocellulosic biomass gasification and syngas fermentation represents a second-generation biorefinery approach that is currently in the development phase. Lignocellulosic biomass can be gasified to produce syngas, which is a gas mixture consisting mainly of H2, CO, and CO2. The major challenge of biomass gasification is the syngas’s final quality. Consequently, the development of effective syngas clean-up technologies has gained increased interest in recent years. Furthermore, the bioconversion of syngas components has been intensively studied using acetogenic bacteria and their Wood–Ljungdahl pathway to produce, among others, acetate, ethanol, butyrate, butanol, caproate, hexanol, 2,3-butanediol, and lactate. Nowadays, syngas fermentation appears to be a promising alternative for producing commodity chemicals in comparison to fossil-based processes. Research studies on syngas fermentation have been focused on process design and optimization, investigating the medium composition, operating parameters, and bioreactor design. Moreover, metabolic engineering efforts have been made to develop genetically modified strains with improved production. In 2018, for the first time, a syngas fermentation pilot plant from biomass gasification was built by LanzaTech Inc. in cooperation with Aemetis, Inc. Future research will focus on coupling syngas fermentation with additional bioprocesses and/or on identifying new non-acetogenic microorganisms to produce high-value chemicals beyond acetate and ethanol.

Improving biogas upgrading and liquid chemicals production simultaneously by a membrane biofilm reactor

In this study, a novel membrane biofilm reactor (MBfR) was developed for simultaneously biogas upgrading and liquid chemicals production. With external hydrogen supplied from inside of the gas permeable hollow fiber of the MBfR, CO₂ in biogas could be captured via a biological process as liquid chemicals and simultaneously producing high-purity methane. Continuous operation of MBfR further confirmed that higher solubilized hydrogen was favorably affecting acetate and ethanol titer and rate, and methane purity. Moreover, by retaining biomass on the outer surface of hollow fiber, the highest biogas purity (96.7%) and acetate and ethanol production rates (37.8 and 13.5 mmol L^-1d^-1) were achieved at a hydraulic retention time of 2.0 d. Meanwhile, the CO₂ and hydrogen conversion efficiency reached to the maximum of 93.8% and 98.1%, respectively. The findings obtained can pave a new way for efficient liquid chemical production and biogas upgrading with both economic and environmental benefits.

Towards continuous industrial bioprocessing with solventogenic and acetogenic clostridia: challenges, progress and perspectives

The sustainable production of solvents from above ground carbon is highly desired. Several clostridia naturally produce solvents and use a variety of renewable and waste-derived substrates such as lignocellulosic biomass and gas mixtures containing H2/CO2 or CO. To enable economically viable production of solvents and biofuels such as ethanol and butanol, the high productivity of continuous bioprocesses is needed. While the first industrial-scale gas fermentation facility operates continuously, the acetone-butanol-ethanol (ABE) fermentation is traditionally operated in batch mode. This review highlights the benefits of continuous bioprocessing for solvent production and underlines the progress made towards its establishment. Based on metabolic capabilities of solvent producing clostridia, we discuss recent advances in systems-level understanding and genome engineering. On the process side, we focus on innovative fermentation methods and integrated product recovery to overcome the limitations of the classical one-stage chemostat and give an overview of the current industrial bioproduction of solvents.

Technology of large volume alcohols, carboxylic acidsand esters

Paper describes industrial synthesis of the most important alcohols (methanol and ethanol), organic acids (acetic and lactic), and fatty acid methyl esters (biodiesel). Also, current industrial solutions and global trends in manufacturing of these chemicals are presented. Moreover, several alternative production technologies of these chemical compounds are discussed, which might successfully replace current commercial methods in the future.

Mutual and Thermal Diffusivities as well as Fluid-Phase Equilibria of Mixtures of 1-Hexanol and Carbon Dioxide

This work contributes to an improved understanding of the fluid-phase behavior and diffusion processes in mixtures of 1-hexanol and carbon dioxide (CO₂) at temperatures around the upper critical end point (UCEP) of the system. Raman spectroscopy and dynamic light scattering were used to determine the composition at saturation conditions as well as Fick and thermal diffusivities. An acceleration of the Fick diffusive process up to CO₂ mole fractions of about 0.2 was found, followed by a strong slowing-down approaching vapor-liquid-liquid equilibrium or critical conditions. The acceleration of the Fick diffusive process vanished at temperatures much higher than the UCEP. Experimental Fick diffusivity data were compared with predictions from equilibrium molecular dynamics simulations and excess Gibbs energy calculations using interaction parameters from the literature. Both theoretical methods were not able to predict that the thermodynamic factor is equal to zero at the spinodal composition, stressing the need for new methodologies under such conditions. Thus, new sets of temperature-dependent interaction parameters were developed for the nonrandom two-liquid model, which improve the prediction of the Fick diffusion coefficient considerably. The link between the Fick diffusion coefficient and the nonrandomness of the liquid phases is also discussed.

Continuous conversion of CO2/H2 with Clostridium aceticum in biofilm reactors

A lab-scale stirred-tank bioreactor was reversibly retrofitted to a packed-bed and a trickle-bed biofilm reactor to study and compare the conversion of CO₂/H₂ with immobilised Clostridiumaceticum. The biofilm reactors were characterised and their functionality confirmed. Up to 8.6 g of C. aceticum were immobilised onto 300 g sintered ceramic carrier material, proving biofilm formation to be a robust means for cell retention of C. aceticum. Continuous CO₂/H₂-fermentation studies were performed with both biofilm reactor configurations as function of dilution rates, partial gas pressures and gas flow rates. The experiments showed that in the packed-bed biofilm reactor, the acetate space-time yield was independent of the dilution rate, because of low H₂ gas-liquid mass transfer rates (≤17 mmol H₂ L^-1 h^-1). The continuous operation of the trickle-bed biofilm reactor increased the gas-liquid mass transfer rates to up to 56 mmol H₂ L^-1 h^-1. Consequently, the acetate space-time yield of up to 14 mmol acetate L^-1 h^-1 was improved 3-fold at hydrogen conversions of up to 96%.

Diffusivities in 1-Alcohols Containing Dissolved H2, He, N2, CO, or CO2 Close to Infinite Dilution

The influence of the strength of intermolecular interactions on mass diffusive processes remains poorly understood for mixtures of associative liquids with dissolved gases. For contributing to a fundamental understanding of the interplay between liquid structures and mass diffusivities in such systems, dynamic light scattering, Raman spectroscopy, and molecular dynamics simulations were used in this work. As model systems, binary mixtures consisting of the gases hydrogen, helium, nitrogen, carbon monoxide, or carbon dioxide dissolved in ethanol, 1-hexanol, or 1-decanol were selected. Experiments and simulations were performed at macroscopic thermodynamic equilibrium close to infinite dilution of solute for temperatures between 303 and 423 K. The Fick diffusion coefficients and self-diffusivities of the gas solutes increase with increasing temperature, decreasing alkyl chain length of the 1-alcohols, and decreasing molar mass of the solutes except for helium and hydrogen showing the opposite behavior. The analysis of the liquid structure of the mixtures showed that the fraction of hydrogen-bonded alcohol molecules decreases with increasing alkyl chain length and temperature. From the obtained structure-property relationships, a new correlation was developed to predict mass diffusivities in binary mixtures consisting of n-alkanes or 1-alcohols with dissolved gases close to infinite dilution within 10% on average.

Review on the Use of Diesel–Biodiesel–Alcohol Blends in Compression Ignition Engines

The use of alternative fuels contributes to the lowering of the carbon footprint of the internal combustion engine. Biofuels are the most important kinds of alternative fuels. Currently, thanks to the new manufacturing processes of biofuels, there is potential to decrease greenhouse gas (GHG) emissions, compared to fossil fuels, on a well-to-wheel basis. Amongst the most prominent alternative fuels to be used in mixtures/blends with fossil fuels in internal combustion (IC) engines are biodiesel, bioethanol, and biomethanol. With this perspective, considerable attention has been given to biodiesel and petroleum diesel fuel blends in compression ignition (CI) engines. Many studies have been conducted to assess the impacts of biodiesel use on engine operation. The addition of alcohols such as methanol and ethanol is also practised in biodiesel–diesel blends, due to their miscibility with the pure biodiesel. Alcohols improve the physico-chemical properties of biodiesel–diesel blends, which lead to improved CI engine operation. This review paper discusses some results of recent studies on biodiesel, bioethanol, and biomethanol production, their physicochemical properties, and also, on the influence of the use of diesel–biodiesel–alcohols blends in CI engines: combustion characteristics, performance, and emissions.

Gene cloning, expression, and reducing property enhancement of nitrous oxide reductase from Alcaligenes denitrificans strain TB

Nitrous oxide (N₂O) is a potent greenhouse gas and tends to accumulate as an intermediate in the process of bacteria denitrification. To achieve complete reduction of nitrogen oxide (NO_x) in bacteria denitrification, the structural gene nosZ encoding nitrous oxide reductase (N₂OR) was cloned from Alcaligenes denitrificans strain TB (GenBank JQ044686). The recombinant plasmid containing the nosZ gene was built, and the expression of nosZ gene in Escherichia coli was determined. Results show that the nosZ gene consisting of 1917 nucleotides achieves heterologous expression successfully by codon optimization strategy under optimal conditions (pre-induction inoculum OD₆₀₀ of 0.67, final IPTG concentration of 0.5 mM, inducing time of 6 h, and inducing temperature of 28 °C). Determination result of gas chromatography confirms that N₂O degradation efficiency of recombinant E. coli is strengthened by at least 1.92 times compared with that of original strain TB when treated with N₂O as substrate. Moreover, N₂OR activity in recombinant strain is 2.09 times higher than that in wild strain TB, which validates the aforementioned result and implies that the recombinant E. coli BL21 (DE3)-pET28b-nosZ is a potential candidate to control N₂O accumulation and alleviate greenhouse effect. In addition, the N₂OR structure and the possible N₂O binding site in Alcaligenes sp. TB are predicted, which open an avenue for further research on the relationship between N₂OR activity and its structure.

Production of acids and alcohols from syngas in a two-stage continuous fermentation process

A two-stage continuous system with two stirred tank reactors in series was utilized to perform syngas fermentation using Clostridium carboxidivorans. The first bioreactor (bioreactor 1) was maintained at pH 6 to promote acidogenesis and the second one (bioreactor 2) at pH 5 to stimulate solventogenesis. Both reactors were operated in continuous mode by feeding syngas (CO:CO₂:H₂:N₂; 30:10:20:40; vol%) at a constant flow rate while supplying a nutrient medium at different flow rates of 8.1, 15, 22 and 30 ml/h. A cell recycling unit was added to bioreactor 2 in order to recycle the cells back to the reactor, maintaining the OD₆₀₀ around 1 in bioreactor 2 throughout the experimental run. When comparing the flow rates, the best results in terms of solvent production were obtained with a flow rate of 22 ml/h, reaching the highest average outlet concentration for alcohols (1.51 g/L) and the most favorable alcohol/acid ratio of 0.32.

Bacterial Anaerobic Synthesis Gas (Syngas) and CO2+H2 Fermentation

Anaerobic bacterial gas fermentation gains broad interest in various scientific, social, and industrial fields. This microbial process is carried out by a specific group of bacterial strains called acetogens. All these strains employ the Wood-Ljungdahl pathway but they belong to different taxonomic groups. Here we provide an overview of the metabolism of acetogens and naturally occurring products. Characteristics of 61 strains were summarized and selected acetogens described in detail. Acetobacterium woodii, Clostridium ljungdahlii, and Moorella thermoacetica serve as model organisms. Results of approaches such as genome-scale modeling, proteomics, and transcriptomics are discussed. Metabolic engineering of acetogens can be used to expand the product portfolio to platform chemicals and to study different aspects of cell physiology. Moreover, the fermentation of gases requires specific reactor configurations and the development of the respective technology, which can be used for an industrial application. Even though the overall process will have a positive effect on climate, since waste and greenhouse gases could be converted into commodity chemicals, some legislative barriers exist, which hamper successful exploitation of this technology.

Process simulation of ethanol production from biomass gasification and syngas fermentation

The hybrid gasification-syngas fermentation platform can produce more bioethanol utilizing all biomass components compared to the biochemical conversion technology. Syngas fermentation operates at mild temperatures and pressures and avoids using expensive pretreatment processes and enzymes. This study presents a new process simulation model developed with Aspen Plus® of a biorefinery based on a hybrid conversion technology for the production of anhydrous ethanol using 1200tons per day (wb) of switchgrass. The simulation model consists of three modules: gasification, fermentation, and product recovery. The results revealed a potential production of about 36.5million gallons of anhydrous ethanol per year. Sensitivity analyses were also performed to investigate the effects of gasification and fermentation parameters that are keys for the development of an efficient process in terms of energy conservation and ethanol production.

Syngas Fermentation: A Microbial Conversion Process of Gaseous Substrates to Various Products

Biomass and other carbonaceous materials can be gasified to produce syngas with high concentrations of CO and H2. Feedstock materials include wood, dedicated energy crops, grain wastes, manufacturing or municipal wastes, natural gas, petroleum and chemical wastes, lignin, coal and tires. Syngas fermentation converts CO and H2 to alcohols and organic acids and uses concepts applicable in fermentation of gas phase substrates. The growth of chemoautotrophic microbes produces a wide range of chemicals from the enzyme platform of native organisms. In this review paper, the Wood–Ljungdahl biochemical pathway used by chemoautotrophs is described including balanced reactions, reaction sites physically located within the cell and cell mechanisms for energy conservation that govern production. Important concepts discussed include gas solubility, mass transfer, thermodynamics of enzyme-catalyzed reactions, electrochemistry and cellular electron carriers and fermentation kinetics. Potential applications of these concepts include acid and alcohol production, hydrogen generation and conversion of methane to liquids or hydrogen.