Biorefinery: Toward an industrial metabolism

Fossil fuel reserves are running out, global warming is becoming a reality, waste recycling is becoming ever more costly and problematic, and unrelenting population growth will require more and more energy and consumer products. There is now an alternative to the 100% oil economy; it is a renewable resource based on agroresources by using the whole plant. Production and development of these new products are based on biorefinery concept. Each constituent of the plant can be extracted and functionalized in order to produce non-food and food fractions, intermediate agro-industrial products and synthons. Three major industrial domains can be concerned: molecules, materials and energy. Molecules can be used as solvent surfactants or chemical intermediates in substitution of petrol derivatives. Fibers can be valorized in materials like composites. Sugars and oils are currently used to produce biofuels like bioethanol or biodiesel, but second-generation biofuels will use lignocellulosic biomass as raw material. Lipids can be used to produce a large diversity of products like solvent, lubricants, pastes or surfactants. Industrial biorefinery will be linked to the creation of new processes based on the twelve principles of green chemistry (clean processes, atom economy, renewable feedstocks…). Biotechnology, especially white biotechnology, will take a major part into these new processes with biotransformations (enzymology, micro-organisms…) and fermentation. The substitution of oil products by biobased products will develop a new bioeconomy and new industrial processes respecting the sustainable development concept. Industrial biorefinery can be developed on the principle that any residues of one can then be exploited as raw material by others in an industrial metabolism.     

Transformation of vegetable waste into value added products: (A) the upgrading concept; (B) practical implementations

Waste can contain many reusable substances of high value. Depending on there being an adequate technology this residual matter can be converted into commercial products either as raw material for secondary processes, as operating supplies or as ingredients of new products. Numerous valuable substances in food production are suitable for separation and recycling at the end of their life cycle, even though present separation and recycling processes are not absolutely cost efficient. In Part A a need statement is visualised--based on a holistic concept of food production--for the vegetable industry, recording occurrence, quantities and utilisation of the residual products. A literature survey, covering more than 160 articles from all over the world, plus our own investigations summarises the latest knowledge in the above-mentioned field and outline prospects for future economic treatment of vegetable 'co-products'. The main goal of a clean production process is demonstrated by three practical implementations in Part B: 1. Upgrading of vegetable residues for the production of novel types of products: multifunctional food ingredients in fruit juice and bakery goods. 2. Bioconversion via solid-state fermentation: vegetable residues as an exclusive substrate for the generation of fruity food flavours. 3. Conversion of vegetable residues into operating supplies: bioadsorbents for waste water treatment. The investigations are promising with regard to future application in the mentioned industrial branch. The outlined concept can be naturally transferred to several areas of industrial food production. The intentions of this research area are located at the development of techniques, which fulfil the conditions of environmental protection with costs to a minimum. The prospect of several new niche markets is worthwhile indeed.     

Industrial and biotechnological applications of laccases: a review

Laccases have received much attention from researchers in last decades due to their ability to oxidise both phenolic and non-phenolic lignin related compounds as well as highly recalcitrant environmental pollutants, which makes them very useful for their application to several biotechnological processes. Such applications include the detoxification of industrial effluents, mostly from the paper and pulp, textile and petrochemical industries, use as a tool for medical diagnostics and as a bioremediation agent to clean up herbicides, pesticides and certain explosives in soil. Laccases are also used as cleaning agents for certain water purification systems, as catalysts for the manufacture of anti-cancer drugs and even as ingredients in cosmetics. In addition, their capacity to remove xenobiotic substances and produce polymeric products makes them a useful tool for bioremediation purposes. This paper reviews the applications of laccases within different industrial fields as well as their potential extension to the nanobiotechnology area.     

Using an Industrial Waste Account to Facilitate National Level Industrial Symbioses by Uncovering the Waste Exchange Potential

The identification of potential by‐product exchanges is important for fostering industrial symbiosis. To discover these potential exchanges, this article extends the analysis of local industrial symbiosis to a national scale. A waste input‐output table, which is a material flow accounting tool, was compiled and used as a database to examine the existing exchanges of by‐products. The supplies and demands of industrial wastes or by‐products were compared to highlight their potential use for promoting higher exchange flows. The analysis of the linkages indicated that the majority of each of the by‐products were reused by the few industries that had the technology and operational capacity for reuse. This finding is useful for determining which industries are good candidates for promoting further industrial symbiosis (IS). Based on a nation‐wide analysis that considered the industrial characteristics of Taiwan comprehensively, 23 types of major by‐products with greater reuse flows and 216 potential exchange patterns were identified between the industries. In addition, three types of eco‐industrial networks were characterized as follows according to their dominant types: (1) fossil fuel, metal, and mineral‐dominated; (2) agricultural and synthetic material‐dominated; and (3) information and communications technology (ICT) and chemical industry‐dominated eco‐industrial networks. This analysis highlights the resource exchange potentials and provides information to new firms for networking with existing businesses.     

Engineering Tobacco Mosaic Virus and Its Virus-Like-Particles for Synthesis of Biotemplated Nanomaterials

Biomolecules are increasingly attractive templates for the synthesis of functional nanomaterials. Chief among them is the plant tobacco mosaic virus (TMV) due to its high aspect ratio, narrow size distribution, diverse biochemical functionalities presented on the surface, and compatibility with a number of chemical conjugations. These properties are also easily manipulated by genetic modification to enable the synthesis of a range of metallic and non-metallic nanomaterials for diverse applications. This article reviews the characteristics of TMV and related viruses, and their virus-like particle (VLP) derivatives, and how these may be manipulated to extend their use and function. A focus of recent efforts has been on greater understanding and control of the self-assembly processes that drive biotemplate formation. How these features have been exploited in engineering applications such as, sensing, catalysis, and energy storage are briefly outlined. While control of VLP surface features is well-established, fewer tools exist to control VLP self-assembly, which limits efforts to control template uniformity and synthesis of certain templated nanomaterials. However, emerging advances in synthetic biology, machine learning, and other fields promise to accelerate efforts to control template uniformity and nanomaterial synthesis enabling more widescale industrial use of VLP-based biotemplates.     

Application of whole cell rhodococcal biocatalysts in acrylic polymer manufacture

Rhodococci are ubiquitous in nature and their ability to metabolise a wide range of chemicals, many of which are toxic, has given rise to an increasing number of studies into their diverse use as biocatalysts. Indeed rhodococci have been shown to be especially good at degrading aromatic and aliphatic nitriles and amides and thus they are very useful for waste clean up where these toxic chemicals are present.The use of biocatalysts in the chemical industry has in the main been for the manufacture of high-value fine chemicals, such as pharmaceutical intermediates, though investigations into the use of nitrile hydratase, amidase and nitrilase to convert acrylonitrile into the higher value products acrylamide and acrylic acid have been carried out for a number of years. Acrylamide and acrylic acid are manufactured by chemical processes in vast tonnages annually and they are used to produce polymers for applications such as superabsorbents, dispersants and flocculants. Rhodococci are chosen for use as biocatalysts on an industrial scale for the production of acrylamide and acrylic acid due to their ease of growth to high biomass yields, high specific enzyme activities obtainable, their EFB class 1 status and robustness of the whole cells within chemical reaction systems.Several isolates belonging to the genus Rhodococcus have been shown in our studies to be among the best candidates for acrylic acid preparation from acrylonitrile due to their stability and tolerance to high concentrations of this reactive and disruptive substrate. A critical part of the selection procedure for the best candidates during the screening programme was high purity product with very low residual substrate concentrations, even in the presence of high product concentrations. Additionally the nitrile and amide substrate scavenging ability which enables rhodococci to survive very successfully in the environment leads to the formation of biocatalysts which are suitable for the removal of low concentrations of acrylonitrile and acrylamide in waste streams and for the removal of impurities in manufacturing processes.     

Oxidative catalysts for the transformation of phenolic pollutants: a brief review

Phenolics are often produced as wastes by several industrial and agricultural activities. Many of these compounds and their derivatives are extremely dangerous to living organisms, because they are highly toxic and thus represent a serious environmental concern.

Conventional remediation methods of phenol-polluted systems have some disadvantages due to high cost, time-consuming procedures and formation of toxic residues. Conversely, the use of oxidative catalysts, both enzymatic or inorganic, is a promising alternative technology to address the clean up of such wastes. Oxidative enzymes and inorganic compounds, both naturally occurring in soil, behave as biotic and abiotic catalysts and support the transformation of phenolic compounds. The complete mineralization of phenolic pollutants as well as the formation of polymeric products, often less toxic than their precursors, may occur.

The present paper gives a brief review of many aspects concerning the properties of biotic and abiotic catalytic agents effective in the transformation of phenolic compounds. The main mechanisms of the processes as well as their feasibility for catalytic practical applications will be addressed. Examples of their potentiality in the detoxification of phenol-polluted systems will be provided, as well.     

Impact of fungal molecular genetics on biotechnology

Summary The application of biotechnology has a very long history and life has benefited a lot from the application of fungal products. The industrial successful application of the use of fungi has been due to pioneering activities in both universities and industry. The most recent example of the application of a new technique was demonstrated with recombinant DNA techniques. Until now these techniques were mainly applied to rather simple processes. But we might also expect in the near future the application of these techniques to more complex systems. A very interesting area in this respect might be the production of plant secondary metabolites by fungi. As far as the economic benefits are concerned, a good balance has to be found between the economics of the processes and constrains posed on these processes by governmental regulations.     

Phospholipases and their industrial applications

Phospholipids are present in all living organisms. They are a major component of all biological membranes, along with glycolipids and cholesterol. Enzymes aimed at modifying phospholipids, namely, phospholipases, are consequently widespread in nature, playing very diverse roles from aggression in snake venom to signal transduction and digestion in humans. In this review, we give a general overview of phospholipases A₁, A₂, C and D from a sequence and structural perspective and their industrial application. The use of phospholipases in industrial processes has grown hand-in-hand with our ability to clone and express the genes in microbial hosts with commercially attractive amounts. Further, the use in industrial processes is increasing by optimizing the enzymes by protein engineering. Here, we give a perspective on the work done to date to express phospholipases in heterologous hosts and the efforts to optimize them by protein engineering. We will draw attention to the industrial processes where phospholipases play a key role and show how the use of a phospholipase for oil degumming leads to substantial environmental benefits. This illustrates a very general trend: the use of enzymes as an alternative to chemical processes to make products often provides a cleaner solution for the industrial processes. In a world with great demands on non-polluting, energy saving technical solutions—white biotechnology is a strong alternative. An erratum to this article can be found at     

Next‐Generation Industrial Biotechnology‐Transforming the Current Industrial Biotechnology into Competitive Processes

The chemical industry has made a contribution to modern society by providing cost‐competitive products for our daily use. However, it now faces a serious challenge regarding environmental pollutions and greenhouse gas emission. With the rapid development of molecular biology, biochemistry, and synthetic biology, industrial biotechnology has evolved to become more efficient for production of chemicals and materials. However, in contrast to chemical industries, current industrial biotechnology (CIB) is still not competitive for production of chemicals, materials, and biofuels due to their low efficiency and complicated sterilization processes as well as high‐energy consumption. It must be further developed into “next‐generation industrial biotechnology” (NGIB), which is low‐cost mixed substrates based on less freshwater consumption, energy‐saving, and long‐lasting open continuous intelligent processing, overcoming the shortcomings of CIB and transforming the CIB into competitive processes. Contamination‐resistant microorganism as chassis is the key to a successful NGIB, which requires resistance to microbial or phage contaminations, and available tools and methods for metabolic or synthetic biology engineering. This review proposes a list of contamination‐resistant bacteria and takes Halomonas spp. as an example for the production of a variety of products, including polyhydroxyalkanoates under open‐ and continuous‐processing conditions proposed for NGIB.     

Industrial symbiosis in the forestry sector: A case study in southern Brazil

Industrial symbiosis (IS) is an important concept in the field of industrial ecology that has disseminated worldwide as a practice to decrease the ecological impact of industrial processes through the exchange of by‐products and waste between units in a system. The forestry industry is the main economic activity in the region of Lages in southern Brazil. IS relationships have expanded with the use of waste material from wood processing and strengthened cooperation between companies in different sectors. The aims of this article were to: a) quantify the level of IS in the system, b) identify the benefits of IS for participants, and c) explain why the network further developed IS to the formation of an industrial ecosystem. A questionnaire was administered during visits to 24 forestry companies in order to analyze their products and processes, commercial relations, positive impacts, and local insertion. The industrial symbiosis indicator (ISI) was determined using waste stream data from the system to represent the level of symbiosis among the companies in this region. The results show that the companies participate in a symbiotic network, mainly involving the exchange of chips, bark, sawdust and shavings. In most cases, these exchanges occur between nearby companies, constituting an extensive industrial ecosystem.     

Recombinant organisms for production of industrial products

A revolution in industrial microbiology was sparked by the discoveries of ther double-stranded structure of DNA and the development of recombinant DNA technology. Traditional industrial microbiology was merged with molecular biology to yield improved recombinant processes for the industrial production of primary and secondary metabolites, protein biopharmaceuticals and industrial enzymes. Novel genetic techniques such as metabolic engineering, combinatorial biosynthesis and molecular breeding techniques and their modifications are contributing greatly to the development of improved industrial processes. In addition, functional genomics, proteomics and metabolomics are being exploited for the discovery of novel valuable small molecules for medicine as well as enzymes for catalysis. The sequencing of industrial microbal genomes is being carried out which bodes well for future process improvement and discovery of new industrial products.     

Modelling Representative Life Cycle Inventories for Swiss Arable Crops (9 pp)

Goal, Scope and Background Life cycle inventories (LCIs) of agricultural products, infrastructure, inputs and processes are required to optimise food supply chains. In the past, the use of LCA was hindered by the limited availability of databases with LCIs for such agricultural inputs, processes and products in combination with LCIs of other major economic sectors. The ecoinvent database covers this need for the Swiss, and to an extent, the European context. A suitable approach had to be outlined for defining representative datasets for products from arable crops, since there was no comprehensive survey of agricultural production.Methods No single data source was available for defining representative datasets for arable crops. It was therefore decided to define model crops on the basis of a variety of sources in collaboration with experts on the crops in question. The datasets were validated by experts and by comparison with literature. Field emissions were calculated using a set of models taking into account situation-specific parameters. Data defined by this procedure are more generally usable, but their definition is also more laborious. Results and Discussion Selected results (inventories and impact assessment) are presented for infrastructure (buildings, machinery), work processes, fertilisers, pesticides, seed and arable crop products. Infrastructure has a higher share of environmental impacts than in typical industrial processes, often due to low utilisation rates. Energy use is dominated by mechanisation, the use of mineral fertilisers (particularly nitrogen) and grain drying. Eutrophication is caused mainly by nitrogen compounds. In general, field emissions are of decisive importance for many environmental impacts. Conclusion and Outlook The ecoinvent database provides representative agricultural data for the Swiss, and to an extent, the European context. It also provides the meta-information necessary for deciding whether a dataset is suitable for the purpose of a particular LCA study. To further improve the representativeness of the datasets, an environmental farm monitoring network is required.     

Capacity planning for batch and perfusion bioprocesses across multiple biopharmaceutical facilities

Production planning for biopharmaceutical portfolios becomes more complex when products switch between fed‐batch and continuous perfusion culture processes. This article describes the development of a discrete‐time mixed integer linear programming (MILP) model to optimize capacity plans for multiple biopharmaceutical products, with either batch or perfusion bioprocesses, across multiple facilities to meet quarterly demands. The model comprised specific features to account for products with fed‐batch or perfusion culture processes such as sequence‐dependent changeover times, continuous culture constraints, and decoupled upstream and downstream operations that permit independent scheduling of each. Strategic inventory levels were accounted for by applying cost penalties when they were not met. A rolling time horizon methodology was utilized in conjunction with the MILP model and was shown to obtain solutions with greater optimality in less computational time than the full‐scale model. The model was applied to an industrial case study to illustrate how the framework aids decisions regarding outsourcing capacity to third party manufacturers or building new facilities. The impact of variations on key parameters such as demand or titres on the optimal production plans and costs was captured. The analysis identified the critical ratio of in‐house to contract manufacturing organization (CMO) manufacturing costs that led the optimization results to favor building a future facility over using a CMO. The tool predicted that if titres were higher than expected then the optimal solution would allocate more production to in‐house facilities, where manufacturing costs were lower. Utilization graphs indicated when capacity expansion should be considered. © 2013 The Authors Biotechnology Progress published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers Biotechnol. Prog., 30:594–606, 2014     

Fast sterility assessment by germinable-endospore biodosimetry

The increased demand for sterile products has created the need for rapid technologies capable of validating the hygiene of industrial production processes. Bacillus endospores are in standard use as biological indicators for evaluating the effectiveness of sterilization processes. Currently, culture-based methods, requiring more than 2 days before results become available, are employed to verify endospore inactivation. We describe a rapid, microscopy-based endospore viability assay (microEVA) capable of enumerating germinable endospores in less than 15 min. MicroEVA employs time-gated luminescence microscopy to enumerate single germinable endospores via terbium-dipicolinate (Tb-DPA) luminescence, which is triggered under UV excitation as 10(8) DPA molecules are released during germination on agarose containing Tb(3+) and a germinant (e.g., L-alanine). Inactivation of endospore populations to sterility was monitored with microEVA as a function of thermal and UV dosage. A comparison of culturing results yielded nearly identical decimal reduction values, thus validating microEVA as a rapid biodosimetry method for monitoring sterilization processes. The simple Tb-DPA chemical test for germinability is envisioned to enable fully automated instrumentation for in-line monitoring of hygiene in industrial production processes.     

Biomachining: Preservation of Acidithiobacillus ferrooxidans and treatment of the liquid residue

Biomachining has become a promising alternative to micromachining metal pieces, as it is considered more environmentally friendly than their physical and chemical machining counterparts. In this research work, two strategies that contribute to the development of this innovative technology and could promote its industrial implementation were investigated: preservation of biomachining microorganisms (Acidithiobacillus ferrooxidans) for their further use, and making valuable use of the liquid residue obtained following the biomachining process. Regarding the preservation method, freeze‐drying, freezing, and drying were tested to preserve biomachining bacteria, and the effect of different cryoprotectants, storage times, and temperatures was studied. Freezing at –80°C in Eppendorf cryovials using betaine as a cryoprotective agent reported the highest bacteria survival rate (40% of cell recovery) among the studied processes. The treatment of the liquid residue in two successive stages led to the precipitation of most of the total dissolved iron and divalent copper (99.9%). The by‐products obtained (iron and copper hydroxide) could be reused in several industrial applications, thereby enhancing the environmentally friendly nature of the biomachining process.     

Microalgae and wastewater treatment

Organic and inorganic substances which were released into the environment as a result of domestic, agricultural and industrial water activities lead to organic and inorganic pollution. The normal primary and secondary treatment processes of these wastewaters have been introduced in a growing number of places, in order to eliminate the easily settled materials and to oxidize the organic material present in wastewater. The final result is a clear, apparently clean effluent which is discharged into natural water bodies. This secondary effluent is, however, loaded with inorganic nitrogen and phosphorus and causes eutrophication and more long-term problems because of refractory organics and heavy metals that are discharged. Microalgae culture offers an interesting step for wastewater treatments, because they provide a tertiary biotreatment coupled with the production of potentially valuable biomass, which can be used for several purposes. Microalgae cultures offer an elegant solution to tertiary and quandary treatments due to the ability of microalgae to use inorganic nitrogen and phosphorus for their growth. And also, for their capacity to remove heavy metals, as well as some toxic organic compounds, therefore, it does not lead to secondary pollution. In the current review we will highlight on the role of micro-algae in the treatment of wastewater.     

Rapid detection of viable Bacillus pumilus SAFR-032 encapsulated spores using novel propidium monoazide-linked fluorescence in situ hybridization

The survival of Bacillus pumilus SAFR-032 spores to standard industrial clean room sterilization practices necessitates the development of rapid molecular diagnostic tool(s) for detection and enumeration of viable bacterial spores in industrial clean room environments. This is of importance to maintaining the sterility of clean room processing products. This paper describes the effect of propidium monoazide (PMA) on fluorescence in situ hybridization (FISH) for detecting and enumerating B. pumilus SAFR-032 viable spores having been artificially encapsulated within poly(methylmethacrylate) (Lucite, Plexiglas) and released via an organic solvent (PolyGone-500). The results of the PMA-FISH experiments discussed herein indicate that PMA was able to permeate only the compromised coat layers of non-viable spores, identifying PMA treatment of bacterial spores prior to FISH analysis as a novel method for selecting out the fraction of the spore population that is non-viable from fluorescence detection. The ability of novel PMA-FISH to selectively distinguish and enumerate only the living spores present in a sample is of potential significance for development of improved strategies to minimize spore-specific microbial burden in a given environment.     

Water Management Tool of Industrial Products: A case study of screen printing fabric and digital printing fabric

Water scarcity and pollution have become increasingly serious because of industrial production. Thus, a tool should be developed to evaluate the level of water use of industrial production. Several calculation methods for water use relative to water footprint have been developed by many scholars. However, most of these methods still have defects in terms of indicators, parameters, and calculation methods. In this paper, we established an evaluation tool that is suitable for the current production situation of industrial products, i.e., a water management tool of industrial products that includes two parts: direct water use caused by the production process of industrial products and indirect water use caused by the energy and material used during production. Each part contains three indicators: water withdrawal, water consumption, and water assimilation. We applied the tool in the textile and apparel industry to calculate the water use of screen and digital printing fabrics, as well as the production processes for both printing fabrics. Results show that the tool can highlight the water intensive product and production process, which can help enterprises take effective and specific measures to save water and reduce pollution.