Techno-economic comparison of a biological hydrogen process and a 2nd generation ethanol process using barley straw as feedstock

A process combining dark fermentation and photofermentation for production of hydrogen is interesting due to its potential of producing hydrogen at a high yields. In this study, the hydrogen process is compared to a 2nd generation ethanol process with respect to cost and with the aim of increasing our understanding of the pros and cons and giving a clear picture of the present status of the two processes. The hydrogen production cost was found to be about 20 times higher than the ethanol production cost, 421.7 €/GJ compared to 19.5 €/GJ. The main drawbacks of the hydrogen process are its low productivity, low energy efficiency, and the high cost of buffer and base required to control the pH.     

Ethanol production by coupled saccharification and fermenation of sugar cane bagasse

Summary As initial studies showed that enzymatic saccharification of sugar cane bagasse in columns with recycling of eluate was slightly more efficient than in agitated flasks, ethanol production by fermentation of the eluates with fast-decanting yeast and recycling of the fermentate through the bagasse columns was studied. The alcohol yield from these coupled columns after 24 or 48 h was more than 10% more than that in a simultaneous saccharification and fermentation in agitated flasks at 40°.     

Structural evaluation of sugar cane bagasse steam pretreated in the presence of CO2 and SO2

Background

Previous studies on the use of SO₂ and CO₂ as impregnating agent for sugar cane bagasse steam treatment showed comparative and promising results concerning the cellulose enzymatic hydrolysis and the low formation of the inhibitors furfural and hydroxymethylfurfural for the use of CO₂ at 205°C/15 min or SO₂ at 190°C/5 min. In the present study sugar cane bagasse materials pretreated as aforementioned were analyzed by scanning and transmission electron microscopy (SEM and TEM), X-Ray Diffraction (XRD) and Infrared (FTIR spectroscopy) aiming a better understanding of the structural and chemical changes undergone by the pretreated materials.

Results

SEM and TEM data showed that the structural modifications undergone by the pretreatment with CO₂ were less pronounced in comparison to that using SO_2, which can be directly related to the combined severity of each pretreatment. According to XRD data, untreated bagasse showed, as expected, a lower crystallinity index (CI = 48.0%) when compared to pretreated samples with SO₂ (CI = 65.5%) or CO₂ (CI = 56.4%), due to the hemicellulose removal of 68.3% and 40.5%, respectively. FTIR spectroscopy supported SEM, TEM and XRD results, revealing a more extensive action of SO₂.

Conclusions

The SEM, TEM, XRD and FTIR spectroscopy techniques used in this work contributed to structural and chemical analysis of the untreated and pretreated bagasse. The images from SEM and TEM can be related to the severity of SO₂ pretreatment, which is almost twice higher. The crystallinity index values obtained from XRD showed that pretreated materials have higher values when compared with untreated material, due to the partial removal of hemicellulose after pretreatment. FTIR spectroscopy supported SEM, TEM and XRD results. CO₂ can actually be used as impregnating agent for steam pretreatment, although the present study confirmed a more extensive action of SO₂.     

Preliminary evaluation of the ethanol production from enzymatically hydrolyzed sugarcane bagasse

Ethanol production from sugarcane bagasse using immobilizedSaccharomyces cerevisiae was increased when coupled to a saccharification process involving the cellulase fromTrichoderma viride. However, the fixed costs of production, estimated to be about $US 0.4/tonne 95% ethanol, were high. Some key areas that influence these costs were identified.     

Integrated versus stand-alone second generation ethanol production from sugarcane bagasse and trash

Ethanol production from lignocellulosic materials is often conceived considering independent, stand-alone production plants; in the Brazilian scenario, where part of the potential feedstock (sugarcane bagasse) for second generation ethanol production is already available at conventional first generation production plants, an integrated first and second generation production process seems to be the most obvious option. In this study stand-alone second generation ethanol production from surplus sugarcane bagasse and trash is compared with conventional first generation ethanol production from sugarcane and with integrated first and second generation; simulations were developed to represent the different technological scenarios, which provided data for economic and environmental analysis. Results show that the integrated first and second generation ethanol production process from sugarcane leads to better economic results when compared with the stand-alone plant, especially when advanced hydrolysis technologies and pentoses fermentation are included.     

Fed-batch culture of Candida guilliermondii FTI 20037 for xylitol production from sugar cane bagasse hydrolysate

A fed-batch culture system was used to study xylitol production by Candida guilliermondii FTI 20037 in a synthetic and a sugar cane bagasse hydrolysate medium. The values achieved for xylitol yield and volumetric productivity were, respectively, 0 · 84 g g⁻¹ and 0 · 64 g l⁻¹ h⁻¹ using the synthetic medium and 0 · 78 g g⁻¹ and 0 · 62 g l⁻¹ h⁻¹ using the hydrolysate medium.     

Fermentation of sugar cane bagasse hemicellulosic hydrolysate and sugar mixtures to ethanol by recombinant Escherichia coli KO11

Escherichia coli KO11, carrying the ethanol pathway genes pdc (pyruvate decarboxylase) and adh (alcohol dehydrogenase) from Zymomonas mobilis integrated into its chromosome, has the ability to metabolize pentoses and hexoses to ethanol, both in synthetic medium and in hemicellulosic hydrolysates. In the fermentation of sugar mixtures simulating hemicellulose hydrolysate sugar composition (10.0 g of glucose/l and 40.0 g of xylose/l) and supplemented with tryptone and yeast extract, recombinant bacteria produced 24.58 g of ethanol/l, equivalent to 96.4% of the maximum theoretical yield. Corn steep powder (CSP), a byproduct of the corn starch-processing industry, was used to replace tryptone and yeast extract. At a concentration of 12.5 g/l, it was able to support the fermentation of glucose (80.0 g/l) to ethanol, with both ethanol yield and volumetric productivity comparable to those obtained with fermentation media containing tryptone and yeast extract. Hemicellulose hydrolysate of sugar cane bagasse supplemented with tryptone and yeast extract was also readily fermented to ethanol within 48 h, and ethanol yield achieved 91.5% of the theoretical maximum conversion efficiency. However, fermentation of bagasse hydrolysate supplemented with 12.5 g of CSP/l took twice as long to complete. This revised version was published online in November 2006 with corrections to the Cover Date.     

Composition of sugar cane,energy cane,and sweet sorghum suitable for ethanol production at Louisiana sugar mills

A challenge facing the biofuel industry is to develop an economically viable and sustainable biorefinery. The existing potential biorefineries in Louisiana, raw sugar mills, operate only 3 months of the year. For year-round operation, they must adopt other feedstocks, besides sugar cane, as supplemental feedstocks. Energy cane and sweet sorghum have different harvest times, but can be processed for bio-ethanol using the same equipment. Juice of energy cane contains 9.8% fermentable sugars and that of sweet sorghum, 11.8%. Chemical composition of sugar cane bagasse was determined to be 42% cellulose, 25% hemicellulose, and 20% lignin, and that of energy cane was 43% cellulose, 24% hemicellulose, and 22% lignin. Sweet sorghum was 45% cellulose, 27% hemicellulose, and 21% lignin. Theoretical ethanol yields would be 3,609 kg per ha from sugar cane, 12,938 kg per ha from energy cane, and 5,804 kg per ha from sweet sorghum.     

Dynamic model-based evaluation of process configurations for integrated operation of hydrolysis and co-fermentation for bioethanol production from lignocellulose

In this study a number of different process flowsheets were generated and their feasibility evaluated using simulations of dynamic models. A dynamic modeling framework was used for the assessment of operational scenarios such as, fed-batch, continuous and continuous with recycle configurations. Each configuration was evaluated against the following benchmark criteria, yield (kg ethanol/kg dry-biomass), final product concentration and number of unit operations required in the different process configurations. The results show that simultaneous saccharification and co-fermentation (SSCF) operating in continuous mode with a recycle of the SSCF reactor effluent, results in the best productivity of bioethanol among the proposed process configurations, with a yield of 0.18 kg ethanol/kgdry-biomass.     

Optimization of process parameters for ethanol production from sugar cane molasses by Zymomonas mobilis using response surface methodology and genetic algorithm

Ethanol is a potential energy source and its production from renewable biomass has gained lot of popularity. There has been worldwide research to produce ethanol from regional inexpensive substrates. The present study deals with the optimization of process parameters (viz. temperature, pH, initial total reducing sugar (TRS) concentration in sugar cane molasses and fermentation time) for ethanol production from sugar cane molasses by Zymomonas mobilis using Box–Behnken experimental design and genetic algorithm (GA). An empirical model was developed through response surface methodology to analyze the effects of the process parameters on ethanol production. The data obtained after performing the experiments based on statistical design was utilized for regression analysis and analysis of variance studies. The regression equation obtained after regression analysis was used as a fitness function for the genetic algorithm. The GA optimization technique predicted a maximum ethanol yield of 59.59 g/L at temperature 31 °C, pH 5.13, initial TRS concentration 216 g/L and fermentation time 44 h. The maximum experimental ethanol yield obtained after applying GA was 58.4 g/L, which was in close agreement with the predicted value.     

A comparison of liquid hot water and steam pretreatments of sugar cane bagasse for bioconversion to ethanol.

Sugar cane bagasse was pretreated with either liquid hot water (LHW) or steam using the same 25 l reactor. Solids concentration ranged from 1% to 8% for LHW pretreatment and was > or = 50% for steam pretreatment. Reaction temperature and time ranged from 170 to 230 degrees C and 1 to 46 min, respectively. Key performance metrics included fiber reactivity, xylan recovery, and the extent to which pretreatment hydrolyzate inhibited glucose fermentation. In four cases, LHW pretreatment achieved > or = 80% conversion by simultaneous saccharification and fermentation (SSF). > or = 80% xylan recovery, and no hydrolyzate inhibition of glucose fermentation yield. Combined effectiveness was not as good for steam pretreatment due to low xylan recovery. SSF conversion increased and xylan recovery decreased as xylan dissolution increased for both modes. SSF conversion, xylan dissolution. hydrolyzate furfural concentration, and hydrolyzate inhibition increased, while xylan recovery and hydrolyzate pH decreased, as a function of increasing LHW pretreatment solids concentration (1-8%). These results are consistent with the notion that autohydrolysis plays an important. if not exclusive, role in batch hydrothermal pretreatment. Achieving concurrently high (greater than 90%) SSF conversion and xylan recovery will likely require a modified reactor configuration (e.g. continuous percolation or base addition) that better preserves dissolved xylan.     

Influence of the burning of sugar cane prior to its harvesting upon the production of single-cell protein from bagasse pith

Summary A culture of Cellulomonas sp. and Bacillus subtilis was grown using sugar cane bagasse pith from unburnt sugar cane (UCP) as the source of carbohydrates. The yield and production values were proved to be higher than those obtained with burnt sugar cane (BCP).For UCP the maximum protein production was 7.8 g/l, the cellulolytic activity being 70 %, with a protein/hydrolyzed pith yield of 22 %. For BCP, the maximum protein value was 4.6 g/l, with a cellulolytic activity of 55 % and a protein/hydrolyzed pith of 17 %.The possibility of a chemical inhibitor being present in BCP is discarded because of the alkaline pretreatment and the results obtained on treating the pith from burnt cane with a benzene-ethanol (2:1) mixture. These results were the same as the ones obtained without the benzene-ethyl alcohol mixture extraction.     

Enzymatic saccharification of sugar cane bagasse by continuous xylanase and cellulase production from cellulomonas flavigena PR‐22

Cellulase (CMCase) and xylanase enzyme production and saccharification of sugar cane bagasse were coupled into two stages and named enzyme production and sugar cane bagasse saccharification. The performance of Cellulomonas flavigena (Cf) PR‐22 cultured in a bubble column reactor (BCR) was compared to that in a stirred tank reactor (STR). Cells cultured in the BCR presented higher yields and productivity of both CMCase and xylanase activities than those grown in the STR configuration. A continuous culture with Cf PR‐22 was run in the BCR using 1% alkali‐pretreated sugar cane bagasse and mineral media, at dilution rates ranging from 0.04 to 0.22 1/h. The highest enzymatic productivity values were found at 0.08 1/h with 1846.4 ± 126.4 and 101.6 ± 5.6 U/L·h for xylanase and CMCase, respectively. Effluent from the BCR in steady state was transferred to an enzymatic reactor operated in fed‐batch mode with an initial load of 75 g of pretreated sugar cane bagasse; saccharification was then performed in an STR at 55°C and 300 rpm for 90 h. The constant addition of fresh enzyme as well as the increase in time of contact with the substrate increased the total soluble sugar concentration 83% compared to the value obtained in a batch enzymatic reactor. This advantageous strategy may be used for industrial enzyme pretreatment and saccharification of lignocellulosic wastes to be used in bioethanol and chemicals production from lignocellulose. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:321–326, 2016     

Cultivation of Candida langeronii in sugar cane bagasse hemicellulosic hydrolyzate for the production of single cell protein

Sugar cane bagasse hemicellulosic fraction was hydrolysed by treatment with 70 mg of sulphuric acid per gram of dry mass at 125 °C for 2 h. The hydrolysate was used as the substrate to grow Candida langeronii RLJ Y-019 at 42 °C; initial pH 6.0; stirring at 700 rev/min and aeration at 1.0 and 2.0 v/v/min. The utilization of D-xylose, L-arabinose, and acetic acid were delayed due to the presence of D-glucose, but after D-glucose depletion the other carbon sources were utilized. The kinetic parameters calculated for both cultivations at 1.0 and 2.0 v/v/min included: maximum specific growth rate (_max) of 0.29 ± 0.01 h^–1 and 0.43 ± 0.016 h^–1, yields (Y _x/s) of 0.36 ± 0.012 and 0.40 ± 0.012 g_x/g_s and productivity (Q _x) of 0.81 ± 0.016 and 0.97 ± 0.012 g_x/l/h, respectively, and compared favourably with published results obtained with Candida utilis and Geotrichum candidum. Candida langeronii appeared superior to C. utilis for biomass production from hemicellulose hydrolysate, in that it utilized L-arabinose and was capable of growth at higher temperatures. The biomass contained 48.2, 1.4, 5.8 and 23.4% of total protein, DNA, RNA and carbohydrate, respectively and contained essential amino acids for animal feed.     

Bio-production of compost with low pH and high soluble phosphorus from sugar cane bagasse enriched with rock phosphate

Summary Aspergillus niger and Trichoderma viride strains were used together as a fungal activator in the presence or absence of farmyard manure (FM) for composting of bagasse enriched with rock phosphate. Quality of the composts produced was compared with that obtained from non-inoculated bagasse. The composts were evaluated as organic phosphatic fertilizers, for broad bean plants. The results showed that composting of bagasse without microbial inoculation or FM addition was not complete after 105 days of fermentation. An excellent decomposition in a relatively short time however was obtained with the use of A. niger and T. viride as inoculant agents with or without FM. The inoculation with A. niger + T. viridewith or without FM, also represented the most suitable conditions for phosphate solubilization. Acidic conditions (pH 4–5) at the end of the experiment were obtained in all piles receiving Aspergillus niger and there was a correlation between the amounts of soluble phosphorus and the reduction in pH values in the compost piles. There were no phosphate-dissolving fungi present in any composted piles except those treated with Aspergillus niger and Trichoderma viride. The number of phosphate-dissolving bacteria increased only in the treatments that were treated with FM. The non-fertilized sandy soil and the non-inoculated bagasse compost did not provide broad bean plants with phosphorus while the composts produced by inoculation with A. niger + T. viride provided the plants with the highest amounts of phosphorus.     

An improved CARV process for bioethanol production from a mixture of sugar beet mash and potato mash

A mixed mash of sugar beet roots and potato tubers with a sugar concentration of 23.7% w/v was used as a feedstock for bioethanol production. Enzymatic digestion successfully reduced the viscosity of the mixture, enabling subsequent heat pretreatment for liquefaction/sterilization. An energy-consuming thick juice preparation from sugar beet for concentration and sterilization was omitted in this new process.     

Simulation of integrated first and second generation bioethanol production from sugarcane: comparison between different biomass pretreatment methods

Sugarcane bagasse is used as a fuel in conventional bioethanol production, providing heat and power for the plant; therefore, the amount of surplus bagasse available for use as raw material for second generation bioethanol production is related to the energy consumption of the bioethanol production process. Pentoses and lignin, byproducts of the second generation bioethanol production process, may be used as fuels, increasing the amount of surplus bagasse. In this work, simulations of the integrated bioethanol production process from sugarcane, surplus bagasse and trash were carried out. Selected pre-treatment methods followed, or not, by a delignification step were evaluated. The amount of lignocellulosic materials available for hydrolysis in each configuration was calculated assuming that 50% of sugarcane trash is recovered from the field. An economic risk analysis was carried out; the best results for the integrated first and second generation ethanol production process were obtained for steam explosion pretreatment, high solids loading for hydrolysis and 24–48 h hydrolysis. The second generation ethanol production process must be improved (e.g., decreasing required investment, improving yields and developing pentose fermentation to ethanol) in order for the integrated process to be more economically competitive.     

Combined ensiling and hydrothermal processing as efficient pretreatment of sugarcane bagasse for 2G bioethanol production

Background

Ensiling cannot be utilized as a stand-alone pretreatment for sugar-based biorefinery processes but, in combination with hydrothermal processing, it can enhance pretreatment while ensuring a stable long-term storage option for abundant but moist biomass. The effectiveness of combining ensiling with hydrothermal pretreatment depends on biomass nature, pretreatment, and silage conditions.

Results

In the present study, the efficiency of the combined pretreatment was assessed by enzymatic hydrolysis and ethanol fermentation, and it was demonstrated that ensiling of sugarcane bagasse produces organic acids that can partly degrade biomass structure when in combination with hydrothermal treatment, with the consequent improvement of the enzymatic hydrolysis of cellulose and of the overall 2G bioethanol process efficiency. The optimal pretreatment conditions found in this study were those using ensiling and/or hydrothermal pretreatment at 190 °C for 10 min as this yielded the highest overall glucose recovery yield and ethanol yield from the raw material (0.28–0.30 g/g and 0.14 g/g, respectively).

Conclusion

Ensiling prior to hydrothermal pretreatment offers a controlled solution for wet storage and long-term preservation for sugarcane bagasse, thus avoiding the need for drying. This preservation method combined with long-term storage practice can be an attractive option for integrated 1G/2G bioethanol plants, as it does not require large capital investments or energy inputs and leads to comparable or higher overall sugar recovery and ethanol yields.

     

Strategies for the development of a side stream process for polyhydroxyalkanoate (PHA) production from sugar cane molasses

A three-stage process was developed to produce polyhydroxyalkanoates (PHAs) from sugar cane molasses. The process includes (1) molasses acidogenic fermentation, (2) selection of PHA-accumulating cultures, (3) PHA batch accumulation using the enriched sludge and fermented molasses. In the fermentation step, the effect of pH (5–7) on the organic acids profile and productivity was evaluated. At higher pH, acetic and propionic acids were the main products, while lower pH favoured the production of butyric and valeric acids. PHA accumulation using fermented molasses was evaluated with two cultures selected either with acetate or fermented molasses. The effect of organic acids distribution on polymer composition and yield was evaluated with the acetate selected culture. Storage yields varied from 0.37 to 0.50 Cmmol HA/Cmmol VFA. A direct relationship between the type of organic acids used and the polymers composition was observed. Low ammonia concentration (0.1 Nmmol/l) in the fermented molasses stimulated PHA storage (0.62 Cmmol HA/Cmmol VFA). In addition, strategies of reactor operation to select a PHA-accumulating culture on fermented molasses were developed. The combination of low organic loading with high ammonia concentration selected a culture with a stable storage capacity and with a storage yield (0.59 Cmmol HA/Cmmol VFA) similar to that of the acetate-selected culture.