Visualization of Polyhydroxyalkanoate Accumulated in Waste Activated Sludge.

Polyhydroxyalkanoates (PHAs) can be produced with municipal waste activated sludge from biological wastewater treatment processes. Methods of selective fluorescent staining with confocal laser scanning microscopy (CLSM) were developed and optimized to evaluate the distribution of PHA storage activity in this mixed culture activated sludge microbial communities. Selective staining methods were applied to a municipal activated sludge during pilot scale PHA accumulation in replicate experiments. Visualization of stained flocs revealed that a significant but limited fraction of the biomass was engaged with PHA accumulation. Accumulated PHA granules were furthermore heterogeneously distributed within and between flocs. These observations suggested that the PHA content for the bacteria storing PHAs was significantly higher than the average PHA content measured for the biomass as a whole. Optimized staining methods provided high acuity for imaging of PHA distribution when compared to other methods reported in the literature. Selective staining methods were sufficient to resolve and distinguish between distinctly different morphotypes in the biomass, and these observations of distinctions have interpreted implications for PHA recovery methods. Visualization tools facilitate meaningful insights for advancements of activated sludge processes where systematic observations, as applied in the present work, can reveal underlying details of structure-function relationships.

Exploring the Limits of Polyhydroxyalkanoate Production by Municipal Activated Sludge.

Municipal activated sludge can be used for polyhydroxyalkanoate (PHA) production, when supplied with volatile fatty acids. In this work, standardized PHA accumulation assays were performed with different activated sludge to determine (1) the maximum biomass PHA content, (2) the degree of enrichment (or volume-to-volume ratio of PHA-accumulating bacteria with respect to the total biomass), and (3) the average PHA content in the PHA-storing biomass fraction. The maximum attained biomass PHA content with different activated sludge ranged from 0.18 to 0.42 gPHA/gVSS, and the degree of enrichment ranged from 0.16 to 0.51 volume/volume. The average PHA content within the PHA-accumulating biomass fraction was relatively constant and independent of activated sludge source, with an average value of 0.58 ± 0.07 gPHA/gVSS. The degree of enrichment for PHA-accumulating bacteria was identified as the key factor to maximize PHA content when municipal activated sludge is directly used for PHA accumulation. Future optimization should focus on obtaining a higher degree of enrichment of PHA-accumulating biomass, either through selection during wastewater treatment or by selective growth during PHA accumulation. A PHA content in the order of 0.6 g PHA/g VSS is a realistic target to be achieved when using municipal activated sludge for PHA production.

Consistent production of high quality PHA using activated sludge harvested from full scale municipal wastewater treatment - PHARIO.

Production of polyhydroxyalkanoate (PHA) biopolymers by mixed microbial cultures concurrent to wastewater treatment is a valorization route for residual organic material. This development has been at pilot scale since 2011 using industrial and municipal organic residuals. Previous experience was the basis for a PHA production demonstration project: PHARIO. PHARIO was centred on processing surplus activated sludge biomass from the Bath full-scale municipal wastewater treatment plant in the Netherlands to produce PHA. Full-scale surplus activated sludge was fed to a pilot facility to produce PHA rich biomass using fermented volatile fatty acid (VFA) rich liquors from industry or primary sludge sources. A PHA rich biomass with on average 0.41 gPHA/gVSS was obtained with reproducible thermal properties and high thermal stability. A routine kilogram scale production was established over 10 months and the polymer material properties and market potential were evaluated. Surplus full-scale activated sludge, over four seasons of operations, was a reliable raw material to consistently and predictably produce commercial quality grades of PHA. Polymer type and properties were systematic functions of the mean co-polymer content. The mean co-polymer content was predictably determined by the fermented feedstock composition. PHARIO polymers were estimated to have a significantly lower environmental impact compared to currently available (bio)plastics.

Carbon-rich wastes as feedstocks for biodegradable polymer (polyhydroxyalkanoate) production using bacteria.

Research into the production of biodegradable polymers has been driven by vision for the most part from changes in policy, in Europe and America. These policies have their origins in the Brundtland Report of 1987, which provides a platform for a more sustainable society. Biodegradable polymers are part of the emerging portfolio of renewable raw materials seeking to deliver environmental, social, and economic benefits. Polyhydroxyalkanoates (PHAs) are naturally-occurring biodegradable-polyesters accumulated by bacteria usually in response to inorganic nutrient limitation in the presence of excess carbon. Most of the early research into PHA accumulation and technology development for industrial-scale production was undertaken using virgin starting materials. For example, polyhydroxybutyrate and copolymers such as polyhydroxybutyrate-co-valerate are produced today at industrial scale from corn-derived glucose. However, in recent years, research has been undertaken to convert domestic and industrial wastes to PHA. These wastes in today's context are residuals seen by a growing body of stakeholders as platform resources for a biobased society. In the present review, we consider residuals from food, plastic, forest and lignocellulosic, and biodiesel manufacturing (glycerol). Thus, this review seeks to gain perspective of opportunities from literature reporting the production of PHA from carbon-rich residuals as feedstocks. A discussion on approaches and context for PHA production with reference to pure- and mixed-culture technologies is provided. Literature reports advocate results of the promise of waste conversion to PHA. However, the vast majority of studies on waste to PHA is at laboratory scale. The questions of surmounting the technical and political hurdles to industrialization are generally left unanswered. There are a limited number of studies that have progressed into fermentors and a dearth of pilot-scale demonstration. A number of fermentation studies show that biomass and PHA productivity can be increased, and sometimes dramatically, in a fermentor. The relevant application-specific properties of the polymers from the wastes studied and the effect of altered-waste composition on polymer properties are generally not well reported and would greatly benefit the progress of the research as high productivity is of limited value without the context of requisite case-specific polymer properties. The proposed use of a waste residual is advantageous from a life cycle viewpoint as it removes the direct or indirect effect of PHA production on land usage and food production. However, the question, of how economic drivers will promote or hinder advancements to demonstration scale, when wastes generally become understood as resources for a biobased society, hangs today in the balance due to a lack of shared vision and the legacy of mistakes made with first generation bioproducts.

Modelling Mixed Microbial Culture Polyhydroxyalkanoate Accumulation Bioprocess towards Novel Methods for Polymer Production Using Dilute Volatile Fatty Acid Rich Feedstocks.

Volatile fatty acid (VFA) rich streams from fermentation of organic residuals and wastewater are suitable feedstocks for mixed microbial culture (MMC) Polyhydroxyalkanoate (PHA) production. However, many such streams have low total VFA concentration (1-10 gCOD/L). PHA accumulation requires a flow-through bioprocess if the VFAs are not concentrated. A flow through bioprocess must balance goals of productivity (highest possible influent flow rates) with goals of substrate utilization efficiency (lowest possible effluent VFA concentration). Towards these goals, dynamics of upshift and downshift respiration kinetics for laboratory and pilot scale MMCs were evaluated. Monod kinetics described a hysteresis between the upshift and downshift responses. Substrate concentrations necessary to stimulate a given substrate uptake rate were significantly higher than the concentrations necessary to sustain the attained substrate uptake rate. A benefit of this hysteresis was explored in Monte Carlo based PHA accumulation bioprocess numerical simulations. Simulations illustrated for a potential to establish continuous flow-through PHA production bioprocesses even at a low (1 gCOD/L) influent total VFA concentration. Process biomass recirculation into an engineered higher substrate concentration mixing zone, due to the constant influent substrate flow, enabled to drive the process to maximal possible PHA production rates without sacrificing substrate utilization efficiency.

Quantification of polyhydroxyalkanoate accumulated in waste activated sludge.

Polyhydroxyalkanoate accumulation experiments at pilot scale were performed with fullscale municipal waste activated sludge. Development of biomass PHA content was quantified by thermogravimetric analysis. Over 48 h the biomass reached up to 0.49 ± 0.03 gPHA/gVSS (n=4). Samples were processed in parallel to characterise the distribution of PHA in the biomass. Selective staining methods and image analysis were performed by Confocal Laser Scanning Microscopy. The image analysis indicated that nominally 55% of this waste activated sludge was engaged in PHA storage activity. Thus even if the biomass PHA content reached 0.49gPHA/gVSS, the accumulating fraction of the biomass was estimated to have attained about 0.64gPHA/gVSS. The combination of quantitative microscopy and polymer mass assessment enabled to distinguish the effect of level of enrichment in PHA storing bacteria and the average PHA storage capacity of the accumulating bacteria. The distribution of microbial 16S rRNA levels did not follow a measurable trend during PHA accumulation.

Calcium enhances polyhydroxyalkanoate production and promotes selective growth of the polyhydroxyalkanoate-storing biomass in municipal activated sludge.

Activated sludge from municipal wastewater treatment processes can be used directly for the production of biodegradable polyesters from the family of polyhydroxyalkanoates (PHAs). However, municipal activated sludge typically cannot accumulate PHAs to very high levels and often low yields of polymer produced on substrate are observed. In the present work, it was found that the presence of calcium promotes selective growth and enrichment of the PHA-storing biomass fraction and significantly improved both PHA contents and yields. Calcium addition resulted in PHA contents of 0.60 ± 0.03 gPHA/gVSS and average PHA yields on substrate of 0.49 ± 0.03 gCODPHA/gCODHAc compared to 0.35 ± 0.01 gPHA/gVSS and 0.19 ± 0.01 gCODPHA/gCODHAc without calcium addition. After 48 h, three times more PHA was produced compared to control experiments without calcium addition. Higher PHA content and selective biomass production is proposed to be a consequence of calcium dependent increased levels of passive acetate uptake. Such more efficient substrate uptake could be related to a formation of calcium acetate complexes. Findings lead to bioprocess methods to stimulate a short-term selective growth of PHA-storing microorganisms and this enables improvements to the techno-economic feasibility for municipal waste activated sludge to become a generic resource for industrial scale PHA production.

Process conditions affect properties and outcomes of polyhydroxyalkanoate accumulation in municipal activated sludge.

The developments of mixed culture polyhydroxyalkanoate production has been directed to maximize the biomass PHA content with limited attention to polymer quality. Direct comparison of PHA accumulation literature is challenging, and even regularly contradicting in reported results, due to underlying differences that are not well expressed. A study was undertaken to systematically compare the commonly reported process conditions for PHA accumulation by full-scale municipal activated sludge. A biomass acclimation step combined with a pulse-wise feeding strategy resulted in maximum average PHA contents and product yields. pH control and active nitrification did not result in observable effects on the PHA productivity. Under these conditions a high molecular weight polymer (1536 ± 221 kDa) can be produced. Polymer extraction recoveries were influenced by the PHA molecular weight. A standard protocol for an activated sludge PHA accumulation test including downstream processing and standardized extraction has been developed and is available as supplementary material.

Simultaneous nitrification and denitrification in microbial community-based polyhydroxyalkanoate production.

Microbial community-based polyhydroxyalkanoate (PHA) production has been demonstrated repeatedly at pilot scale. Ammonium, normally present in waste streams, might be oxidized by nitrifying bacteria resulting in additional aeration energy demand. The use of low dissolved oxygen (DO) concentrations allowed to reduce nitrifying rates by up to 70% compared to non-oxygen limiting conditions. At lower DO concentrations nitrate was used as alternative electron acceptor for PHA production and therefore, a constant PHA production rate could only be maintained if nitrate was sufficiently available. An optimum DO concentration (0.9 mgO2/L) was found for which nitrification was mitigated but also exploited to supply requisite heterotrophic nitrate requirements that maintained maximum PHA production rates. PHA accumulations with such DO control was estimated to reduce oxygen demand by about 18%. This work contributes to establish fundamental insight towards viable industrial practice with the control and exploitation of nitrifying bacteria in microbial community-based PHA production.

Scaling-up microbial community-based polyhydroxyalkanoate production: status and challenges.

Conversion of organic waste and wastewater to polyhydroxyalkanoates (PHAs) offers a potential to recover valuable resources from organic waste. Microbial community-based PHA production systems have been successfully applied in the last decade at lab- and pilot-scales, with a total of 19 pilot installations reported in the scientific literature. In this review, research at pilot-scale on microbial community-based PHA production is categorized and subsequently analyzed with focus on feedstocks, enrichment strategies, yields of PHA on substrate, biomass PHA content and polymer characterization. From this assessment, the challenges for further scaling-up of microbial community-based PHA production are identified.

Community structure evolution and enrichment of glycogen-accumulating organisms producing polyhydroxyalkanoates from fermented molasses.

An open mixed culture was enriched with glycogen-accumulating organisms (GAOs) by using a sequencing batch reactor and treating an agroindustrial waste (sugar cane molasses) under cyclic anaerobic-aerobic conditions. Over a 1-year operating period, the culture exhibited a very stable GAO phenotype with an average polyhydroxyalkanoate (PHA) content of 17% total suspended solids. However, the GAO microbial community evolved over the course of operation to a culture exhibiting unusual characteristics in producing PHAs comprised of short-chain-length monomers, namely, 3-hydroxybutyrate, 3-hydroxy-2-methylbutyrate, 3-hydroxyvalerate, and 3-hydroxy-2-methylvalerate, and also, up to 31 mol% of the medium-chain-length (MCL) monomer 3-hydroxyhexanoate (3HHx). Microbial community analysis by fluorescence in situ hybridization revealed a concurrent long-term drift in the GAO community balance, from mainly "Candidatus Competibacter phosphatis" to mainly Defluviicoccus vanus-related organisms. The production of 3HHx was confirmed by (13)C nuclear magnetic resonance (NMR) and appeared to be related to the increased presence of D. vanus-related GAOs. These results suggest a broadened spectrum of material, chemical, and mechanical properties that can be achieved for biopolymers produced by open mixed cultures from fermented waste. The increased spectrum of polymer properties brings a wider scope of potential applications.

Application of dissolved oxygen (DO) level control for polyhydroxyalkanoate (PHA) accumulation with concurrent nitrification in surplus municipal activated sludge.

Mixed microbial cultures are a viable means for polyhydroxyalkanoate (PHA) production, which can produce polymers of commercial quality with high yields. Various PHA co-polymer blends can be produced by surplus full-scale municipal activated sludge fed with fermented waste feedstocks. In biological nutrient removal, ammonia is converted to nitrate by ammonia and nitrite oxidizing bacteria (AOBs and NOBs) through nitrification and removed as nitrogen gas through denitrification. Activated sludge can be enriched with significant PHA storage potential alongside nitrogen removal by denitrifying heterotrophic and nitrifying autotrophic bacteria. The latter adds complexity and aeration demand during the aerobic side-stream PHA accumulation stage since fermented organic residuals often contain significant amounts of ammonia. In the present work, the influence of dissolved oxygen (DO) levels on both PHA accumulation and nitrification rates for a municipal activated sludge were evaluated. The objective was to identify potential for a DO control strategy for PHA accumulation, which would mitigate the unnecessary nitrification activity during PHA production. A much higher apparent Michaelis-Menten DO affinity for volatile fatty acid (VFA) consumption (KDO _VFA 0.1 ± 0.06 mg/L) was found as compared to nitrification (KDO _NH4 2.87 ± 1.31 mg/L). Consequently, with lower DO levels, PHA production was not limited by oxygen supply, while nitrogen was removed by simultaneous nitrification and denitrification processes. This study suggests a method for PHA accumulation using nitrifying activated sludge, while feeding ammonia-containing organic feedstocks by means of DO level control where: (1) NOB activity and growth are both mitigated, (2) nitrogen removal is facilitated, (3) alkalinity is controlled through simultaneous denitrification, and (4) energy demand for aeration is reduced.

Experimental data for extrusion processing and tensile properties of poly(hydroxybutyrate-co-hydroxyvalerate) (PHBV) polymer and wood fibre reinforced PHBV biocomposites.

This article features a large database on different extrusion processing conditions and the resulting tensile properties of poly(hydroxybutyrate-co-hydroxyvalerate) (PHBV) and wood fibre reinforced biocomposites. The data presented here corresponds to a comprehensive design of experiments conducted separately for both neat PHBV polymer and wood-PHBV composites, in which the effects of temperature profile, screw speed, feeding rate, feeding method, screw configuration, and wood contents (wood-PHBV composites only) of 10, 20, 30, and 40 wt% wood content were examined. For each processing condition, 5 specimens were tested under uniaxial tensile loading. Here we provide the complete set of extrusion parameters, including the observed screw torque, residence time and material output. Individual stress-strain curves for each specimens are provided, along with their calculated elastic modulus, strength, and strain at maximum load. The data is also provided as support material for the research article: "Extrusion of wood fibre reinforced Poly(hydroxybutyrate-co-hydroxyvalerate) (PHBV) biocomposites: statistical analysis of the effect of processing conditions on mechanical performance" (Vandi et al., 2018).

Chlorinated-solvent-free gas chromatographic analysis of biomass containing polyhydroxyalkanoates.

An extraction and derivatization method was developed for more environmentally friendly routine quantification of polyhydroxyalkanoates (PHAs) in activated sludge biomass by gas chromatography (GC). This method can be further applied to assess relative changes in biomass carbohydrate levels relating to, for example, glycogen or extracellular polysaccharides. Further, co-extracted principal membrane fatty acids are indicative of relative changes in active biomass. The protocol is attractive for routine assessment because it does not require any chlorinated solvents, which are still almost exclusively used today for PHA analysis by GC. Acidic alcoholysis of dried microbial biomass using 3:1 butanol to concentrated (37%) hydrochloric acid at 100 degrees C for 8 h will hydrolyse and derivatize microbial storage products and membrane lipids. Esters of the hydroxyalkanoates, carbohydrates converted to levulinic acid, and long chain microbial fatty acids are reliably extracted into hexane for gas chromatographic analysis and quantification. Calibration can be achieved with benzoic, 2-hydroxyvaleric, or 2-hydroxycaproic acids as the method reference standards.

Production of polyhydroxyalkanoates by activated sludge treating a paper mill wastewater.

Production of polyhydroxyalkanoates (PHAs) in activated sludge treating wastewater represents an economical and environmental promising alternative to pure culture fermentations. A process for production of PHA from a paper mill wastewater was examined at laboratory scale. The three stage process examined consisted of acidogenic fermentation to convert wastewater organic matter to volatile fatty acids (VFAs), an activated sludge system operating under feast/famine conditions to enrich for PHA producing organisms and accumulation of PHA in batch experiments. After fermentation of the wastewater, 74% of the soluble COD was present as VFA (acetate, propionate, butyrate and valerate) and the resulting PHA after batch accumulation consisted of 31-47 mol% hydroxybutyrate and 53-69 mol% hydroxyvalerate. The maximum PHA content achieved was 48% of the sludge dry weight and the three stage process exhibited a potential to produce 0.11 kg of PHA per kg of influent COD treated.

Production of polyhydroxyalkanoates by glycogen accumulating organisms treating a paper mill wastewater.

A process for production of polyhydroxyalkanoates (PHA) by activated sludge treating a paper mill wastewater was investigated. The applied strategy was to select for glycogen accumulating organisms (GAOs) by alternating anaerobic/aerobic conditions. Acidogenic fermentation was used as pretreatment to convert various organic compounds to volatile fatty acids which are preferable substrates for PHA production. Enrichment resulted in a culture dominated by GAOs related to Defluviicoccus vanus (56%) and Candidatus Competibacter phosphatis (22%). Optimization of PHA accumulation by the enriched GAO culture was performed through batch experiments. Accumulation of PHA under anaerobic conditions was limited by the intracellular glycogen stored. Under aerobic conditions significant glycogen production (to 25% of sludge dry weight) was observed alongside PHA accumulation (to 22% of sludge dry weight). By applying a subsequent anaerobic period after an initial aerobic, the produced glycogen could be utilized for further PHA accumulation and by this strategy PHA content was increased to 42% of sludge dry weight. The PHA yield over the entire process was 0.10 kg per kg of influent COD treated which is similar to what has been achieved with a process applying feast/famine enrichment strategy with the same wastewater.

Wood-PHA Composites: Mapping Opportunities.

Polyhydroxyalkanoate (PHA) biopolymers are emerging as attractive new sustainable polymers due to their true biodegradability and highly tuneable mechanical properties. However, despite significant investments, commercialisation barriers are hindering the capacity growth of PHA. In this work, we investigated the market potential for wood plastic composites (WPCs) based on PHAs. We considered the latest global production capacity of PHAs, estimated at 66,000 tonnes/year, and examined the implications of using PHAs for WPC production on the WPC market. Results indicate that a hypothetical usage of the current global PHA production for WPC manufacture would only represent the equivalent of 4.4% of the global WPC market, which is currently experiencing a 10.5% compounded annual growth rate. An economic assessment revealed that a wood-PHA composite as a drop-in alternative WPC product could cost as little as 37% of the cost of its neat PHA counterpart. Thus, WPCs with PHA offer a means to access benefits of PHA in engineering applications at reduced costs; however, further developments are required to improve strain at failure. The successful adoption of wood-PHA composites into the market is furthermore reliant on support from public sector to encourage biodegradable products where recycling is not a ready solution.

Tracers for investigating pathogen fate and removal mechanisms in mesocosms.

The purpose of the present investigation has been to develop a tracer suite that has application in in-situ assessment and optimization of physical and biological removal and elimination mechanisms of pathogens within laboratory scale biological treatment systems. The tracer suite includes three pathogen indicators, namely, a conserved non-viable particle (fluorescently labelled microspheres, FLM), a non-conserved non-viable particle (fluorescently labelled bioparticles, FLB), and a non-conserved viable particle (Nalidixic acid resistant E. coli, NAREC). The tracer triplet principles were developed with practical experiments on planted, and unplanted subsurface flow wetland mesocosms treating a synthetic domestic wastewater. The tracers monitor for physical removal mechanisms (FLM), elimination activity (FLB), and removal thresholds (NAREC). FLM enumeration was simplified by calibration of particle concentration with respect to acetone-extractable fluorescence. Similarly, FLB elimination was assessed by bulk fluorescence using two characteristic excitation-emission wavelength pairs: 494/519 and 220/319 nm. NAREC results indicated that first order removal kinetics may only proceed down to limiting threshold concentrations.

The Evolution of Polymer Composition during PHA Accumulation: The Significance of Reducing Equivalents.

This paper presents a systematic investigation into monomer development during mixed culture Polyhydroxyalkanoates (PHA) accumulation involving concurrent active biomass growth and polymer storage. A series of mixed culture PHA accumulation experiments, using several different substrate-feeding strategies, was carried out. The feedstock comprised volatile fatty acids, which were applied as single carbon sources, as mixtures, or in series, using a fed-batch feed-on-demand controlled bioprocess. A dynamic trend in active biomass growth as well as polymer composition was observed. The observations were consistent over replicate accumulations. Metabolic flux analysis (MFA) was used to investigate metabolic activity through time. It was concluded that carbon flux, and consequently copolymer composition, could be linked with how reducing equivalents are generated.

Carbon recovery from wastewater through bioconversion into biodegradable polymers.

Polyhydroxyalkanoates (PHA) are biodegradable polyesters that can be produced in bioprocesses from renewable resources in contrast to fossil-based bio-recalcitrant polymers. Research efforts have been directed towards establishing technical feasibility in the use of mixed microbial cultures (MMC) for PHA production using residuals as feedstock, mainly consisting of industrial process effluent waters and wastewaters. In this context, PHA production can be integrated with waste and wastewater biological treatment, with concurrent benefits of resource recovery and sludge minimization. Over the past 15 years, much of the research on MMC PHA production has been performed at laboratory scale in three process elements as follows: (1) acidogenic fermentation to obtain a volatile fatty acid (VFA)-rich stream, (2) a dedicated biomass production yielding MMCs enriched with PHA-storing potential, and (3) a PHA accumulation step where (1) and (2) outputs are combined in a final biopolymer production bioprocess. This paper reviews the recent developments on MMC PHA production from synthetic and real wastewaters. The goals of the critical review are: a) to highlight the progress of the three-steps in MMC PHA production, and as well to recommend room for improvements, and b) to explore the ideas and developments of integration of PHA production within existing infrastructure of municipal and industrial wastewaters treatment. There has been much technical advancement of ideas and results in the MMC PHA rich biomass production. However, clear demonstration of production and recovery of the polymers within a context of product quality over an extended period of time, within an up-scalable commercially viable context of regional material supply, and with well-defined quality demands for specific intent of material use, is a hill that still needs to be climbed in order to truly spur on innovations for this field of research and development.