Simultaneous saccharification and fermentation of steam-pretreated bagasse using Saccharomyces cerevisiae TMB3400 and Pichia stipitis CBS6054.

Sugarcane bagasse--a residue from sugar and ethanol production from sugar cane--is a potential raw material for lignocellulosic ethanol production. This material is high in xylan content. A prerequisite for bioethanol production from bagasse is therefore that xylose is efficiently fermented to ethanol. In the current study, ethanolic fermentation of steam-pretreated sugarcane bagasse was assessed in a simultaneous saccharification and fermentation (SSF) set-up using either Saccharomyces cerevisiae TMB3400, a recombinant xylose utilizing yeast strain, or Pichia stipitis CBS6054, a naturally xylose utilizing yeast strain. Commercial cellulolytic enzymes were used and the content of water insoluble solids (WIS) was 5% or 7.5%. S. cerevisiae TMB3400 consumed all glucose and large fraction of the xylose in SSF. Almost complete xylose conversion could be achieved at 5% WIS and 32 degrees C. Fermentation did not occur with P. stipitis CBS6054 at pH 5.0. However, at pH 6.0, complete glucose conversion and high xylose conversion (>70%) was obtained. Microaeration was required for P. stipitis CBS6054. This was not necessary for S. cerevisiae TMB3400.

Energy considerations for a SSF-based softwood ethanol plant.

Ethanol can be produced from softwood by steam pretreatment followed by simultaneous saccharification and fermentation (SSF). However, the final ethanol concentration in the SSF step is usually rather low (around 4 wt%) and as a result the energy demand in the downstream processing will be high. In an effort to reduce the energy consumption various alternatives for the downstream processing part of the process were evaluated from a technical-economic standpoint. With experimental data as a basis, the whole process was modelled using the commercial flowsheeting program Aspen Plus. The results were used in the subsequent economic evaluation, which was performed using Icarus process evaluator. A base case configuration, consisting of three thermally coupled distillation columns and multiple-effect evaporation was established. For a feed containing 3.5% ethanol (w/w) to the distillation step, the overall process demand for steam was estimated to be 19.0 MJ/L ethanol and the ethanol production cost 4.14 SEK/L (0.591 USD/L). Different alternatives were considered, such as integration of a stripper with the evaporation step, increasing the number of evaporation effects and the application of mechanical vapour recompression to the evaporation step. Replacement of evaporation with anaerobic digestion was also considered. Among these alternatives, evaporation using mechanical vapour recompression and the anaerobic digester alternative both resulted in significantly lower energy demand than the base case, 10.2 and 9.8 MJ/L, respectively, and productions costs of 3.82 (0.546 USD/L) and 3.84 SEK/L (0.549 USD/L).

Steam pretreatment of H(2)SO(4)-impregnated Salix for the production of bioethanol.

In the bioconversion of lignocellulosic materials to ethanol, pretreatment of the material prior to enzymatic hydrolysis is essential to obtain high overall yields of sugar and ethanol. In this study, steam pretreatment of fast-growing Salix impregnated with sulfuric acid has been investigated by varying the temperature (180-210 degrees C), the residence time (4, 8 or 12 min), and the acid concentration (0.25% or 0.5% (w/w) H(2)SO(4)). High sugar recoveries were obtained after pretreatment, and the highest yields of glucose and xylose after the subsequent enzymatic hydrolysis step were 92% and 86% of the theoretical, respectively, based on the glucan and xylan contents of the raw material. The most favorable pretreatment conditions regarding the overall sugar yield were 200 degrees C for either 4 or 8 min using 0.5% sulfuric acid, both resulting in a total of 55.6g glucose and xylose per 100g dry raw material. Simultaneous saccharification and fermentation experiments were performed on the pretreated slurries at an initial water-insoluble content of 5%, using ordinary baker's yeast. An overall theoretical ethanol yield of 79%, based on the glucan and mannan content in the raw material, was obtained.

Effect of hemicellulose and lignin removal on enzymatic hydrolysis of steam pretreated corn stover.

Ethanol can be produced from lignocellulosic biomass using steam pretreatment followed by enzymatic hydrolysis and fermentation. The sugar yields, from both hemicellulose and cellulose are critical parameters for an economically-feasible ethanol production process. This study shows that a near-theoretical glucose yield (96-104%) from acid-catalysed steam pretreated corn stover can be obtained if xylanases are used to supplement cellulases during hydrolysis. Xylanases hydrolyse residual hemicellulose, thereby improving the access of enzymes to cellulose. Under these conditions, xylose yields reached 70-74%. When pre-treatment severity was reduced by using autocatalysis instead of acid-catalysed steam pretreatment, xylose yields were increased to 80-86%. Partial delignification of pretreated material was also evaluated as a way to increase the overall sugar yield. The overall glucose yield increased slightly due to delignification but the overall xylose yield decreased due to hemicellulose loss in the delignification step. The data also demonstrate that steam pretreatment is a robust process: corn stover from Europe and North America showed only minor differences in behaviour.

Simultaneous saccharification and co-fermentation of glucose and xylose in steam-pretreated corn stover at high fiber content with Saccharomyces cerevisiae TMB3400.

The two main sugars in the agricultural by-product corn stover are glucose and xylose. Co-fermentation of glucose and xylose at high content of water-insoluble solids (WIS) without detoxification is a prerequisite to obtain high ethanol concentration and to reduce production costs. A recombinant strain of Saccharomyces cerevisiae, TMB3400, was used in simultaneous saccharification and fermentation (SSF) of whole pretreated slurry of corn stover at high WIS. TMB3400 co-fermented glucose and xylose with relatively high ethanol yields giving high final ethanol concentration. The ethanol productivity increased with increasing concentration of pretreatment hydrolysate in the yeast production medium and when SSF was performed in a fed-batch mode.

Steam pretreatment of acid-sprayed and acid-soaked barley straw for production of ethanol.

Barley is an abundant crop in Europe, which makes its straw residues an interesting cellulose source for ethanol production. Steam pretreatment of the straw followed by enzymatic hydrolysis converts the cellulose to fermentable sugars. Prior to pretreatment the material is impregnated with a catalyst, for example, H2SO4, to enhance enzymatic digestibility of the pretreated straw. Different impregnation techniques can be applied. In this study, soaking and spraying were investigated and compared at the same pretreatment condition in terms of overall yield of glucose and xylose. The overall yield includes the soluble sugars in the liquid from pretreatment, including soluble oligomers, and monomer sugars obtained in the enzymatic hydrolysis. The yields obtained differed for the impregnation techniques. Acid-soaked barley straw gave the highest overall yield of glucose, regardless of impregnation time (10 or 30 min) or acid concentration (0.2 or 1.0 wt%). For xylose, soaking gave the highest overall yield at 0.2 wt% H2SO4. An increase in acid concentration resulted in a decrease in xylose yield for both acid-soaked and acid-sprayed barley straw. Optimization of the pretreatment conditions for acid-sprayed barley straw was performed to obtain yields using spraying that were as high as those with soaking. For acid-sprayed barley straw the optimum pretreatment condition for glucose, 1.0 wt% H2SO4 and 220 degrees C for 5 min, gave an overall glucose yield of 92% of theoretical based on the composition of the raw material. Pretreatment with 0.2 wt% H2SO4 at 190 degrees C for 5 min resulted in the highest overall xylose yield, 67% of theoretical based on the composition of the raw material.

Using computer simulation to assist in the robustness analysis of an ion-exchange chromatography step.

This paper presents a methodology to gain process knowledge and assist in the robustness analysis of an ion-exchange step in a protein purification process using a model-based approach. Factorial experimental design is common practice in industry today to obtain robustness characterization of unit operations with respect to variations in process parameters. This work aims at providing a better insight into what process variations affect quality and to further reduce the experimental work to the regions of process variation that are of most interest. This methodology also greatly increases the ability to predict process performance and promotes process understanding. The model calibration part of the methodology involves three consecutive steps to calibrate a steric mass action (SMA) ion-exchange chromatography model. Firstly, a number of gradient elution experiments are performed. Secondly, experimental breakthrough curves have to be generated for the proteins if the adsorption capacity of the medium for each component is not known. Thirdly, a multi-component loading experiment is performed to calibrate the multi-component effects that cannot be determined from the single-component experiments. The separation process studied in this work is the separation of polyclonal IgG from a mixture containing IgG, myoglobin and BSA. The calibrated model is used to simulate six process variations in a full factorial experiment. The results of the simulations provide information about the importance of the different process variations and the simulations are also used to determine the crucial points for the process parameter variations. The methodology can be used to assist in the robustness analysis normally performed in the pharmaceutical industry today as it is able to predict the impact on process performance resulting from variations in salt concentration, column load, protein concentration and flow rate.

Ethanol production from non-starch carbohydrates of wheat bran.

Wheat bran (WB), produced worldwide in large quantities as a by-product of the wheat milling industry, constitutes a significant underutilized source of sugars. This paper describes various methods of hydrolyzing the abundant polysaccharides in bran to yield a sugar feedstock suitable for fermentation into bioethanol. Firstly, the starch in the bran was released using amylolytic enzymes. The fibrous material remaining was further hydrolyzed. Acid hydrolysis, heat pretreatment followed by enzymatic hydrolysis and direct enzymatic hydrolysis were compared in terms of total sugar yield and pentose sugar yield. The maximum total sugar yield was achieved when small amounts of acid were added at the pretreatment step prior to enzymatic hydrolysis. This form of pretreatment released most pentosans and significantly enhanced the hydrolysis of cellulose. The overall sugar yield of this combined hydrolysis method reached 80% of the theoretical and it consisted of 13.5 g arabinose, 22.8 g xylose and 16.7 g glucose per 100 g starch-free bran.

Optimization of steam pretreatment of SO2-impregnated corn stover for fuel ethanol production.

In this study, corn stover with a dry matter content of 20% was impregnated with SO2 and then steam pretreated for various times at various temperatures. The pretreatment was evaluated by enzymatic hydrolysis of the solid material and analysis of the sugar content in the liquid. The maximum overall yield of glucose, 89% of the theoretical based on the glucan in the raw material, was achieved when the corn stover was pretreated at 200 degrees C for 10 min. The maximum overall yield of xylose, 78%, was obtained with pretreatment at 190 degrees C for 5 min.

Steam pretreatment of Salix with and without SO2 impregnation for production of bioethanol.

In the wood-to-ethanol process, pretreatment of the material is necessary prior to enzymatic hydrolysis to obtain high overall yields of sugar and ethanol. Steam pretreatment of fast-growing Salix either with or without SO2 impregnation has been investigated by varying different parameters. Overall glucose yields of above 90% and overall xylose yields higher than 80% were obtained both with and without impregnation. However, the most favorable pretreatment conditions for the separate yields of glucose and xylose differed to a lower degree using SO2-impregnated wood chips, resulting in higher total sugar yield than that obtained with non-impregnated wood chips.

Effect of reduction in yeast and enzyme concentrations in a simultaneous- saccharification-and-fermentation-based bioethanol process: technical and economic evaluation.

The ethanol production cost in a simultaneous saccharification and fermentation-based bioethanol process is influenced by the requirements for yeast production and for enzymes. The main objective of this study was to evaluate--technically and economically--the influence of these two factors on the production cost. A base case with 5 g/L of baker's yeast and an initial concentration of water-insoluble solids of 5% resulted in an experimental yield of 85%. When these data were implemented in Aspen Plus, yeast was assumed to be produced from sugars in the hydrolysate, reducing the overall ethanol yield to 69%. The ethanol production cost was 4.80 SEK/L (2.34 US$/gal). When adapted yeast was used at 2 g/L, an experimental yield of 74% was achieved and the estimated ethanol production cost was the same as in the base case. A 50% reduction in enzyme addition resulted in an increased production cost, to 5.06 SEK/L (2.47 US$/gal) owing to reduced ethanol yield.

Optimizing ethanol and methane production from steam-pretreated, phosphoric acid-impregnated corn stover.

Pretreatment is of vital importance in the production of ethanol and methane from agricultural residues. In this study, the effects of steam pretreatment with phosphoric acid on enzymatic hydrolysis (EH), simultaneous saccharification and fermentation (SSF), anaerobic digestion (AD) and the total energy output at three different temperatures were investigated. The effect of separating the solids for SSF and the liquid for AD was also studied and compared with using the whole slurry first in SSF and then in AD. Furthermore, the phosphoric acid was compared to previous studies using sulphuric acid or no catalyst. Using phosphoric acid resulted in higher yields than when no catalyst was used. However, compared with sulphuric acid, an improved yield was only seen with phosphoric acid in the case of EH. The higher pretreatment temperatures (200 and 210 °C) resulted in the highest yields after EH and SSF, while the highest methane yield was obtained with the lower pretreatment temperature (190 °C). The highest yield in terms of total energy recovery (78 %) was obtained after pretreatment at 190 °C, but a pretreatment temperature of 200 °C is, however, the best alternative since fewer steps are required (whole slurry in SSF and then in AD) and high product yields were obtained (76 %).

Adsorption of Trichoderma reesei CBH I and EG II and their catalytic domains on steam pretreated softwood and isolated lignin.

The presence of lignin has shown to play an important role in the enzymatic degradation of softwood. The adsorption of enzymes, and their constituent functional domains on the lignocellulosic material is of key importance to fundamental knowledge of enzymatic hydrolysis. In this study, we compared the adsorption of two purified cellulases from Trichoderma reesei, CBH I (Cel7A) and EG II (Cel5A) and their catalytic domains on steam pretreated softwood (SPS) and lignin using tritium labeled enzymes. Both CBH I and its catalytic domain exhibited a higher affinity to SPS than EG II or its catalytic domain. Removal of cellulose binding domain decreased markedly the binding efficiency. Significant amounts of CBH I and EG II also bound to isolated lignin. Surprisingly, the catalytic domains of the two enzymes of T. reesei differed essentially in the adsorption to isolated lignin. The catalytic domain of EG II was able to adsorb to alkaline isolated lignin with a high affinity, whereas the catalytic domain of CBH I did not adsorb to any of the lignins tested. The results indicate that the cellulose binding domain has a significant role in the unspecific binding of cellulases to lignin.

Electronic speckle pattern interferometry: a tool for determining diffusion and partition coefficients for proteins in gels.

The aim of this study was to demonstrate electronic speckle pattern interferometry (ESPI) as a powerful tool in determining diffusion coefficients and partition coefficients for proteins in gels. ESPI employs a CCD camera instead of a holographic plate as in conventional holographic interferometry. This gives the advantage of being able to choose the reference state freely. If a hologram at the reference state is taken and compared to a hologram during the diffusion process, an interferometric picture can be generated that describes the refraction index gradients and thus the concentration gradients in the gel as well as in the liquid. MATLAB is then used to fit Fick's law to the experimental data to obtain the diffusion coefficients in gel and liquid. The partition coefficient is obtained from the same experiment from the flux condition at the interface between gel and liquid. This makes the comparison between the different diffusants more reliable than when the measurements are performed in separate experiments. The diffusion and partitioning coefficients of lysozyme, BSA, and IgG in 4% agarose gel at pH 5.6 and in 0.1 M NaCl have been determined. In the gel the diffusion coefficients were 11.2 +/- 1.6, 4.8 +/- 0.6, and 3.0 +/- 0.3 m(2)/s for lysozyme, BSA, and IgG, respectively. The partition coefficients were determined to be 0.65 +/- 0.04, 0.44 +/- 0.06, and 0.51 +/- 0.04 for lysozyme, BSA, and IgG, respectively. The current study shows that ESPI is easy to use and gives diffusion coefficients and partition coefficients for proteins with sufficient accuracy from the same experiment.

Effect of washing on yield in one- and two-step steam pretreatment of softwood for production of ethanol.

Two-step steam pretreatment of softwood on laboratory scale has previously been shown to result in higher yields than one-step steam pretreatment. In this study, these results are verified on a larger scale. In an industrial process filtration and washing of the material between the two pretreatment steps are difficult without release of pressure. A worst case without filtration or washing was thus investigated to determine the influence of poor washing on the yield of sugars and the formation of byproducts. Steam pretreatment with SO(2) impregnation was investigated using three different procedures. One-step steam pretreatment was performed at 215 degrees C for 5 min. Two different kinds of two-step steam pretreatment were performed at 190 degrees C for 2 min in the first step and at 210 degrees C for 5 min in the second step. In one case the slurry obtained after the first pretreatment step was separated into a liquid and a solid phase, where the water-insoluble solid material was washed with water and then used for pretreatment in the second step. In the other case of two-step steam pretreatment, neither separation nor washing was performed. The pretreated material was evaluated using both enzymatic hydrolysis and fed-batch simultaneous saccharification and fermentation. Both two-step steam pretreatment process configurations investigated resulted in higher yields of ethanol (300 L/ton) than one-step steam pretreatment (227 L/ton). Separation and washing of the material between the pretreatment steps in the two-step steam pretreatment process did not improve the overall sugar yield, although the formation of sugar degradation products was reduced.

Techno-economic evaluation of producing ethanol from softwood: comparison of SSF and SHF and identification of bottlenecks.

The aim of the study was to evaluate, from a technical and economic standpoint, the enzymatic processes involved in the production of fuel ethanol from softwood. Two base case configurations, one based on simultaneous saccharification and fermentation (SSF) and one based on separate hydrolysis and fermentation (SHF), were evaluated and compared. The process conditions selected were based mainly on laboratory data, and the processes were simulated by use of Aspen plus. The capital costs were estimated using the Icarus Process Evaluator. The ethanol production costs for the SSF and SHF base cases were 4.81 and 5.32 SEK/L or 0.57 and 0.63 USD/L (1 USD = 8.5SEK), respectively. The main reason for SSF being lower was that the capital cost was lower and the overall ethanol yield was higher. A major drawback of the SSF process is the problem with recirculation of yeast following the SSF step. Major economic improvements in both SSF and SHF could be achieved by increasing the income from the solid fuel coproduct. This is done by lowering the energy consumption in the process through running the enzymatic hydrolysis or the SSF step at a higher substrate concentration and by recycling the process streams. Running SSF with use of 8% rather than 5% nonsoluble solid material would result in a 19% decrease in production cost. If after distillation 60% of the stillage stream was recycled back to the SSF step, the production cost would be reduced by 14%. The cumulative effect of these various improvements was found to result in a production cost of 3.58 SEK/L (0.42 USD/L) for the SSF process.

Process considerations and economic evaluation of two-step steam pretreatment for production of fuel ethanol from softwood.

To increase the overall ethanol yield from softwood, the steam pretreatment stage can be carried out in two steps. The two-step pretreatment process was evaluated from a techno-economic standpoint and compared with the one-step pretreatment process. The production plants considered were designed to utilize spruce as raw material and have a capacity of 200,000 tons/year. The two-step process resulted in a higher ethanol yield and a lower requirement for enzymes. However, the two-step process is more capital-intensive and has a higher energy requirement. The estimated ethanol production cost was the same, 4.13 SEK/L (55.1 cent /L) for both alternatives. For the two-step process different energy-saving options were considered, such as a higher concentration of water-insoluble solids in the filter cake before the second step, and the possibility of excluding the pressure reduction between the steps. The most optimistic configuration, with 50% water-insoluble solids in the filter cake in the feed to the second pretreatment step, no pressure reduction between the pretreatment steps, and 77% overall ethanol yield (0.25 kg EtOH/kg dry wood), resulted in a production cost of 3.90 SEK/L (52.0 cent /L). This shows the potential for the two-step pretreatment process, which, however, remains to be verified in pilot trials.

Hydrolysis of nonstarch carbohydrates of wheat-starch effluent for ethanol production.

A (polysaccharide-rich) waste stream derived from a combined starch and ethanol factory was investigated regarding hydrolysis of the nonstarch carbohydrates for ethanol production. The material was characterized and processed to yield the maximum amount of sugars. The starch fraction was hydrolyzed with amylolytic enzymes, and the resulting fibrous material was separated by filtration. This material, denoted starch-free fibers (SFF), was subjected to heat treatment followed by enzymatic hydrolysis to recover the other major carbohydrate components, namely, cellulose and hemicellulose, in monomeric form. Heat treatment in a microwave oven efficiently solubilized a fraction of these polysaccharides and made the material more accessible to the cellulolytic and hemicellulolytic enzymes used in the subsequent enzymatic hydrolysis. The maximum sugar yield after enzymatic hydrolysis, achieved with pretreatment at 170 degrees C for 40 min, was 34.1 g per 100 g SFF, comprising 12.8 g glucose, 13.9 g xylose and 7.4 g arabinose, corresponding to 66%, 71% and 51% of the theoretical, respectively.

Isolation and characterization of water-soluble hemicelluloses from flax shive.

Partially depolymerized, water-soluble hemicelluloses were solubilized from flax shive employing hydrothermal microwave treatment and thereafter subjected to ion-exchange chromatography, enzymatic purification and/or size-exclusion chromatography (SEC). The oligo- and polysaccharide fractions thus obtained were characterized with respect to molar mass, molar mass distribution, degree of polymerization (DP) and degree of substitution with acetyl moieties (DSAc) by employing SEC in combination with MALDI-TOF mass spectrometry. The major portion of the water-soluble flax hemicellulose consisted of an O-acetyl-4-O-methylglucuronoxylan exhibiting a DPp value (i.e., peak-average DP) of 28. When the DSAc for this O-acetyl-4-O-methylglucuronoxylan was calculated on the basis of the MALDI-MS spectra obtained without and following deacetylation, a value of 0.7 was obtained. In addition, an O-acetyl-glucomannan (DPp=9, DS=0.4) and minor quantities of small neutral O-acetyl-xylooligosaccharides were also isolated from the mixture of water-soluble hemicelluloses released from the flax shive by microwave treatment.

Recirculation of process streams in fuel ethanol production from softwood based on simultaneous saccharification and fermentation.

The effect of process stream recirculation on ethanol production from steam- pretreated softwood based on simultaneous saccharification and fermentation (SSF) was investigated for two process configurations. In the first configuration, a part of the stillage stream after distillation was recycled and, in the second configuration, the liquid after SSF was recycled. The aim was to minimize the energy consumption in the distillation of the fermentation broth and in the evaporation of the stillage, as well as the use of fresh water. However, recirculation leads to an increased concentration of nonvolatiles in the first configuration, and of both volatiles and nonvolatiles in the second configuration. These substances might be inhibitory to the enzymes and the yeast in SSF. When 60% of the fresh water was replaced by stillage, the ethanol yield and the productivity were the same as for the configuration without recirculation. The ethanol production cost was reduced by 17%. In the second configuration, up to 40% of the fresh water could be replaced without affecting the final ethanol yield, although the initial ethanol productivity decreased. The ethanol production cost was reduced by 12%. At higher degrees of recirculation, fermentation was clearly inhibited, resulting in a decrease in ethanol yield while hydrolysis seemed unaffected.