Technology and economics of ethanol production from fodder beets via solid-phase fermentation

Summary Operating conditions for our semi-continuous, solid-phase fermentation system were optimized for conversion of fodder beets to fuel ethanol and distiller's wet feed (DWF). This information was then used to estimate operating parameters achievable in a commercial plant, and likely baseline production costs of such a plant. Initial acidification of pulp to pH 2.9–3.2 was effective in controlling bacterial contamination. The maximum operating capacity of the fermentor was approximately 92%, with 75% used for commercial application. A fermentation time of 24 h was sufficient to completely ferment the beet pulp to 8–9% (v/v) ethanol. Based on these parameters, a fodder beet cost of $19.25/metric ton ($17.50/ton), other operating and capital costs, and a PF credit of $0.14/L ($0.53/gal), ethanol production costs were estimated to be $0.49/L ($1.87/gal).     

Conditions for Ethanol Production during Bioconversion of Cellulose-Containing Raw Material

Several natural associations composed of thermophilic anaerobic bacteria capable of utilizing various cellulose materials at 60 ± 2°C and pH 6.0–7.0 were isolated from the sludge of Kamchatka geothermal springs. The rate of ethanol production (up to 1.7 g/l per day) and the concentration of ethanol in the medium (up to 1.2%), as well as the fermentation period (10–15 days), were determined under anaerobic conditions in the presence of cellulose, coniferous sawdust, newsprint, or paper pulp as a carbon source. Microorganisms were found that inhibited the production of ethanol. The initial pH value was found to influence both the ethanol production rate and ethanol/acetate ratio. A pH decrease from 7.0 to 5.0 led to a 6.7-fold increase in ethanol production and caused a 23.8-fold increase in the ethanol/acetate ratio.     

Production of ethanol from guava pulp by yeast strains

Guava pulp used for ethanol production by three yeast strains contained 10% (w/v) total sugars and was pH 4.1. Ethanol production at the optimum sugar concentration of 10%, at pH 4.1 and 30°C was 1.5%, 3.6% and 3.9% (w/v) by Saccharomyces cerevisiae MTCC 1972, Isolate-1 and Isolate-2, respectively, at 60 h fermentation. Higher sugar concentrations at 15 and 20% were inhibitory for ethanol production by all test cultures. The maximum production of ethanol at optimum natural sugar concentration (10%) of guava pulp, was 5.8% (w/v) at pH 5.0 by Isolate-2 over 36 h fermentation, which was only slightly more than the quantity of ethanol produced by Saccharomyces cerevisiae (5.0%) and Isolate-1 (5.3%) over 36 and 60h fermentation, respectively.     

Batch and continuous solid-phase fermentation of Jerusalem artichoke tubers

Two strains of Kluyveromyces marxianus were evaluated for their ability to ferment Jerusalem artichoke tuber pulp to ethanol under pH levels ranging from 2.0–6.3. Bacterial contamination was prevented in batch, solid-phase fermentation when pulp was initially adjusted to pH 3.5 or less, and maximal yeast populations occurred at pH 3.0–3.5. Fermentation times were also shortest for both yeast (13–18 h) and ethanol (48–64 h) production when pulp pH was in this range. However, ethanol yields (41–53% of theoretical) and fermentation efficiencies (68–78%) were somewhat lower than expected, with only 6.6–7.2% (v/v) ethanol produced by strain Y-1598 and 5.7–6.9% produced by strain Y-1550. Based on these parameters, the continuous solid-phase fermentor was operated for 396 h using strain Y-1598. The pH of pulp entering the fermentor was adjusted to 2.5 to compensate for partial neutralization by the mild steel of the fermentor. This resulted in fermenting pulp with a pH of 3.0–3.5, and therefore no contamination. Pulp exiting the fermentor after 72 h contained 6.9 × 10⁸ yeast cells/ml and 7.3% ethanol, which represented 55.9% of the theoretical yield and a fermentation efficiency of 73.3%. Further modifications (partial acid hydrolysis, finer grinding, etc.) should permit higher yields.     

Scale-up of ethanol production from sugarcane usingZymomonas mobilis

Summary TheZymomonas fermentation for industrial ethanol production has been successfully scaled up. Pilot plant experiments at 100 and 1,000 litre fermentation capacity gave 91–95% conversion efficiencies and up to 10% (v/v) ethanol yields within 17–20 hours using sugar cane syrup, A-, B-, and C-molasses with the addition of sucrose or syrup to a final 15% total sugar concentration.     

Inhibition of yeast by lactic acid bacteria in continuous culture: nutrient depletion and/or acid toxicity?

Lactic acid was added to batch very high gravity (VHG) fermentations and to continuous VHG fermentations equilibrated to steady state with Saccharomyces cerevisiae. A 53% reduction in colony-forming units (CFU) ml^–1 of S. cerevisiae was observed in continuous fermentation at an undissociated lactic acid concentration of 3.44% w/v; and greater than 99.9% reduction was evident at 5.35% w/v lactic acid. The differences in yeast cell number in these fermentations were not due to pH, since batch fermentations over a pH range of 2.5–5.0 did not lead to changes in growth rate. Similar fermentations performed in batch showed that growth inhibition with added lactic acid was nearly identical. This indicates that the apparent high resistance of S. cerevisiae to lactic acid in continuous VHG fermentations is not a function of culture mode. Although the total amount of ethanol decreased from 48.7 g l^–1 to 14.5 g l^–1 when 4.74% w/v undissociated lactic acid was added, the specific ethanol productivity increased ca. 3.2-fold (from 7.42×10^–7 g to 24.0×10^–7 g ethanol CFU^–1 h^–1), which indicated that lactic acid stress improved the ethanol production of each surviving cell. In multistage continuous fermentations, lactic acid was not responsible for the 83% (CFU ml^–1) reduction in viable S. cerevisiae yeasts when Lactobacillus paracasei was introduced to the system at a controlled pH of 6.0. The competition for trace nutrients in those fermentations and not lactic acid produced by L. paracasei likely caused the yeast inhibition.     

Effect of fodder beet cube size on ethanol production via diffusion fermentation

Summary The size of fodder beet cubes used to produce fuel ethanol via diffusion fermentation was varied to see how this affected various fermentation parameters. The highest yeast populations, shortest fermentation times, and highest ethanol yields and fermentation efficiencies were observed when 2.54 cm square cubes (or smaller) were utilized. Ethanol concentrations here averaged 4.21% (v/v) while the highest concentration reached was 4.83%. To minimize energy for slicing beets and still optimize yields, cubes of 1.91–2.54 cm should be used.     

Solid-state fermentation of carob pods for ethanol production

The production of ethanol from carob pods by Saccharomyces cerevisiae in solid-state fermentation was investigated. The maximal ethanol concentration (160±3 g/kg dry pods), ethanol productivity (6.7 ± 0.2 g/kg per hour), ethanol yield (40 ± 1.8%), biomass concentration (7.5 ± 0.4 x 10⁸ cells/g carob pulp) and fermentation efficiency (80 ± 2%) were obtained at an inoculum amount of 3%, a particle size of 0.5 mm, a moisture level of 70%, a pH of 4.5 and a temperature of 30°C. Under the same fermentation conditions both sterilized and non-sterilized carob pods pulp gave the same maximum ethanol concentration.     

Industrial scale ethanol production using the thermotolerant yeast Kluyveromyces marxianus IMB3 in an Indian distillery

The thermotolerant ethanol producing Kluyveromyces marxianus IMB3 yeast was used in eight 60m3 fermenters for industrial ethanol production in India using sugarcane molasses. Ethanol ranged between 6.0–7.2% (w/v) with added advantages of elimination of cooling during fermentation and shorter fermentation periods of 20h. © Rapid Science Ltd. 1998     

Solid phase fermentation of foder beets for ethanol production: Effect of grind size

Solid phase fermentation of pulped fodder beets was studied to see what effect beet particle size had on various fermentation parameters. All trials were run in 4-l stainless stell containers and hammermilled pulp was initially adjusted to pH 3.0 to control bacterial contaminants. The maximum yeast population that built up in the pulp was independent of the hammermill screen size (0.476–1.905 cm) and averaged 2.0−2.3 × 10⁸ cells/ml. Pulp from finer screens (0.476–0.953 cm) took 19–22 h to reach a peak yeast population while pulp from coarser screens (1.270–1.905 cm) took a slightly longer 24–28 h. The time to reach maxium ethanol concentration was not affected by screeen size and averaged 28–30 h. Ethanol yields dropped slightly form 85–87% of theoretical with the finest screens to 83–84% with the coarset screens. The maximum ethanol concentration observed was 7.96% (v/v) and the average of all runs was 7.63% (v/v). Fermentation efficiency averaged 98–99% thoughout. The lack of a response to grinding fodder beets with different screens was due to their wet fibrous nature which hindered free flow of pulp though the screens. Pulp was, instead, extruded though the screens, forming particles of generally similar size. Our results indicate that the primary consideration for grind size is energy consumption for grinding. Therefore, if a hammermill is used, a large screen (1.270–1.905 cm) which requires less energy should be employed so as to minimize energy consumption. This strategy does not result in longer fermentation times or reduced ethanol yields.     

High ethanol yields using Aspergillus oryzae koji and corn media

Summary High ethanol and stillage solids have been achieved using whole corn mashes. Ethanol yields of 14% (v/v) (89.5% of theory) and stillage levels of approximately 23% (w/v) were obtained in 74–90 hours using mild acid pretreatment with Aspergillus oryzae wheat bran koji saccharification. High ethanol yields were also obtained with bacterial amylase, instead of the acid treatment, when the sterilization step was omitted. The implications of ethanol fermentation process modifications are explored.     

Optimization of fermentation conditions for the production of ethanol from sago starch using response surface methodology

The quantitative effects of temperature, pH and time of fermentation were investigated on simultaneous saccharification and fermentation (SSF) of ethanol from sago starch with glucoamylase (AMG) and Zymomonas mobilis ZM4 using a Box–Wilson central composite design protocol. The SSF process was studied using free enzyme and free cells and it was found that with sago starch, maximum ethanol concentration of 70.68 g/l was obtained using a starch concentration of 140 g/l, which represents an ethanol yield of 97.08%. The optimum conditions for the above yield were found to be a temperature of 36.74 °C, pH of 5.02 and time of fermentation of 17 h. Thus by using the central composite design, it is possible to determine the accurate values of the fermentation parameters where maximum production of ethanol occurs.     

Xanthan gum and ethanol production by Xanthomonas campestris and Zymomonas mobilis from peach pulp

The wild type of Xanthomonas campestris and a mutant strain of Zymomonas mobilis CP4, tolerant to sucrose up to 40% (w/v), were used to produce either xanthan gum or ethanol, respectively, from peach pulp supplemented with different salts. Both bacteria grew well (2.7 mg/ml for X. campestris and 1.45 mg/ml for Z. mobilis) in fine peach pulp and the production of xanthan gum or ethanol was 0.1–0.2 g/l or 110 g/l, respectively.     

Very high gravity wort fermentation by immobilised yeast

Using calcium alginate-entrapped yeast, 24% (w/w) wort was successfully fermented within 8 days. This is half the time needed for fermentation by free yeast. The highest ethanol concentration obtained was 10.5% (v/v). When the original wort gravity was increased, the specific rate of ethanol production remained constant 0.16 g gh^–1 and the viability did not fall bellow 95% of living cells. Protection of cell against osmotic stress by gel matrix was also confirmed by trehalose measurement. The maximum intracellular trehalose content in calcium alginate-entrapped yeast was 3 times lower compared to free yeast at 30% (w/w) wort fermentation.     

Optimization of pyrite bioleaching using Sulfolobus acidocaldarius

Optimization of batch pyrite bioleaching with Sulfolobus acidocaldarius was performed using statistical modelling and experimental design. First a screening design was made followed by response surface modelling. The dominating factors identified were pH, pulp density and particle size. The highest batch leaching rate after optimization was 270 mg iron·l^–1·h^–1 for 6% (w/v) pulp density, pH = 1.5 and particle size <20 m. This represents a 3.5-fold increase from the leaching rate of 80 mg iron·l^–1·h^–1 obtained under our standard laboratory conditions. Correspondence to: E. B. Lindström     

The combined enzymatic hydrolysis and fermentation of hemicellulose to 2,3-butanediol

Summary Hemicellulose-rich fractions from several agricultural residues were converted to 2,3-butanediol by a combined enzymatic hydrolysis and fermentation process. Culture filtrates from Trichoderma harzianum E58 were used to hydrolyze the substrates while Klebsiella pneumoniae fermented the liberated sugars to 2,3-butanediol. Approximately 50–60% of a 5% (w/v) xylan preparation could be hydrolyzed and quantitatively converted to 2,3-butanediol using this procedure. Although enzymatic hydrolysis was optimal at pH 5.0 and 50° C, the combined hydrolysis and fermentation was most efficient at pH 6.5 and 30° C. Combined hydrolysis and fermentation resulted in butanediol levels that were 20–40% higher than could be obtained with a separate hydrolysis and fermentation process. The hemicellulose-rich water-soluble fractions obtained from a variety of steam-exploded agricultural residues could be readily used by the combined hydrolysis and fermentation approach resulting in butanediol yields of 0.4–0.5 g/g of reducing sugar utilized.     

Effects of acetic acid on the temperature range of ethanol tolerance inCandida shehate growing on D-xylose

Summary The yeastCandida shehatæ, growing on a mineral medium with vitamins and D-xylose as sole carbon and energy source, tolerated acetic acid up to 0.4% (v/v), at pH 4.5, the temperature range of growth narrowing from 5–34°C to 21–27°C, and the growth yield on D-xylose decreasing to 64%; tolerance to added ethanol dropped from 5% (v/v) to 2% (v/v). Acetic acid concertedly shifted the Arrhenius plots of thermal death and growth to lower temperatures, but left unchanged the former dissociative relations in the temperature profile. The entropy coefficient of acetic acid-enhanced thermal death was 183.3 entropy units. M^–1.     

Determination of retinol and retinyl esters in human plasma by high-performance liquid chromatography with automated column switching and ultraviolet detection

A HPLC method with automated column switching and UV detection is described for the simultaneous determination of retinol and major retinyl esters (retinyl palmitate, retinyl stearate, retinyl oleate and retinyl linoleate) in human plasma. Plasma (0.2 ml) was deproteinized by adding ethanol (1.5 ml) containing the internal standard retinyl propionate. Following centrifugation the supernatant was directly injected onto the pre-column packed with LiChrospher 100 RP-18 using 1.2% ammonium acetate–acetic acid–ethanol (80:1:20, v/v) as mobile phase. The elution strength of the ethanol containing sample solution was reduced by on-line supply of 1% ammonium acetate–acetic acid–ethanol (100:2:4, v/v). The retained retinol and retinyl esters were then transferred to the analytical column (Superspher 100 RP-18, endcapped) in the backflush mode and chromatographed under isocratic conditions using acetonitrile–methanol–ethanol–2-propanol (1:1:1:1, v/v) as mobile phase. Compounds of interest were detected at 325 nm. The method was linear in the range 2.5–2000 ng/ml with a limit of quantification for retinol and retinyl esters of 2.5 ng/ml. Mean recoveries from plasma were 93.4–96.5% for retinol (range 100–1000 ng/ml) and 92.7–96.0% for retinyl palmitate (range 5–1000 ng/ml). Inter-assay precision was ≤5.1% and ≤6.3% for retinol and retinyl palmitate, respectively. The method was successfully applied to more than 2000 human plasma samples from clinical studies. Endogenous levels of retinol and retinyl esters determined in female volunteers were in good accordance with published data.     

Ethanol production in a continuous fermentation/membrane pervaporation system

The productivity of ethanol fermentation processes, predominantly based on batch operation in the U.S. fuel ethanol industry, could be improved by adoption of continuous processing technology. In this study, a conventional yeast fermentation was coupled to a flat-plate membrane pervaporation unit to recover continuously an enriched ethanol stream from the fermentation broth. The process employed a concentrated dextrose feed stream controlled by the flow rate of permeate from the pervaporation unit via liquid-level control in the fermentor. The pervaporation module contained 0.1 m² commercially available polydimethylsiloxane membrane and consistently produced a permeate of 20%–23% (w/w) ethanol while maintaining a level of 4%–6% ethanol in a stirred-tank fermentor. The system exhibited excellent operational stability. During continuous operation with cell densities of 15–23 g/l, ethanol productivities of 4.9–7.8 gl^–1 h^–1 were achieved utilizing feed streams of 269–619 g/l glucose. Pervaporation flux and ethanol selectivities were 0.31–0.79 lm^–2 h^–1 and 1.8–6.5 respectively.     

Improvement of the ethanol productivity in a high gravity brewing at pilot plant scale

A 2³ full factorial design was used to study the influence of different experimental variables, namely wort gravity, fermentation temperature and nutrient supplementation, on ethanol productivity from high gravity wort fermentation by Saccharomyces cerevisiae (lager strain), under pilot plant conditions. The highest ethanol productivity (0.69 g l^–1 h^–1) was obtained at 20°P [°P is the weight of extract (sugar) equivalent to the weight of sucrose in a 100 g solution at 20°C], 15°C, with the addition of 0.8% (w/v) yeast extract, 24 mg l^–1 ergosterol and 0.24% (v/v) Tween 80.