Energy efficiency of acetone, butanol, and ethanol (ABE) recovery by heat-integrated distillation.

Acetone, butanol, and ethanol (ABE) is an alternative biofuel. However, the energy requirement of ABE recovery by distillation is considered elevated (> 15.2 MJ fuel/Kg-ABE), due to the low concentration of ABE from fermentation broths (between 15 and 30 g/l). In this work, to reduce the energy requirements of ABE recovery, four processes of heat-integrated distillation were proposed. The energy requirements and economic evaluations were performed using the fermentation broths of several biocatalysts. Energy requirements of the processes with four distillation columns and three distillation columns were similar (between 7.7 and 11.7 MJ fuel/kg-ABE). Double-effect system (DED) with four columns was the most economical process (0.12-0.16 $/kg-ABE). ABE recovery from dilute solutions by DED achieved energy requirements between 6.1 and 8.7 MJ fuel/kg-ABE. Vapor compression distillation (VCD) reached the lowest energy consumptions (between 4.7 and 7.3 MJ fuel/kg-ABE). Energy requirements for ABE recovery DED and VCD were lower than that for integrated reactors. The energy requirements of ABE production were between 1.3- and 2.0-fold higher than that for alternative biofuels (ethanol or isobutanol). However, the energy efficiency of ABE production was equivalent than that for ethanol and isobutanol (between 0.71 and 0.76) because of hydrogen production in ABE fermentation.

Two-stage pervaporation process for effective in situ removal acetone-butanol-ethanol from fermentation broth.

Two-stage pervaporation for ABE recovery from fermentation broth was studied to reduce the energy cost. The permeate after the first stage in situ pervaporation system was further used as the feedstock in the second stage of pervaporation unit using the same PDMS/PVDF membrane. A total 782.5g/L of ABE (304.56g/L of acetone, 451.98g/L of butanol and 25.97g/L of ethanol) was achieved in the second stage permeate, while the overall acetone, butanol and ethanol separation factors were: 70.7-89.73, 70.48-84.74 and 9.05-13.58, respectively. Furthermore, the theoretical evaporation energy requirement for ABE separation in the consolidate fermentation, which containing two-stage pervaporation and the following distillation process, was estimated less than ∼13.2MJ/kg-butanol. The required evaporation energy was only 36.7% of the energy content of butanol. The novel two-stage pervaporation process was effective in increasing ABE production and reducing energy consumption of the solvents separation system.

Ethanol and High-Value Terpene Co-Production from Lignocellulosic Biomass of Cymbopogon flexuosus and Cymbopogon martinii.

Cymbopogon flexuosus, lemongrass, and C. martinii, palmarosa, are perennial grasses grown to produce essential oils for the fragrance industry. The objectives of this study were (1) to evaluate biomass and oil yields as a function of nitrogen and sulfur fertilization, and (2) to characterize their utility for lignocellulosic ethanol compared to Panicum virgatum (switchgrass). Mean biomass yields were 12.83 Mg lemongrass ha-1 and 15.11 Mg palmarosa ha-1 during the second harvest year resulting in theoretical biofuel yields of 2541 and 2569 L ethanol ha-1 respectively compared to reported 1749-3691 L ethanol ha-1 for switchgrass. Pretreated lemongrass yielded 198 mL ethanol (g biomass)-1 and pretreated palmarosa yielded 170 mL ethanol (g biomass)-1. Additionally, lemongrass yielded 85.7 kg essential oil ha-1 and palmarosa yielded 67.0 kg ha-1 with an estimated value of USD $857 and $1005 ha-1. These data suggest that dual-use crops such as lemongrass and palmarosa may increase the economic viability of lignocellulosic biofuels.

Assessment of morphological changes of Clostridium acetobutylicum by flow cytometry during acetone/butanol/ethanol extractive fermentation.

Acetone/butanol/ethanol (ABE) fermentation by Clostridium acetobutylicum was investigated in extractive fed-batch experiments. In conventional fermentations, metabolic activity ceases when a critical threshold products concentration is reached (~21.6 g solvents l(-1)). Solvents production was increased up to 36.6 and 37.2 g l(-1), respectively, using 2-butyl-1-octanol (aqueous to organic ratio: 1:0.25 v/v) and pomace olive oil (1:1 v/v) as extraction solvents. The morphological changes of different cell types were monitored and quantified using flow cytometry. Butanol production in extractive fermentations with pomace olive oil was achieved mainly by vegetative cells, whereas the percentage of sporulating cells was lower than 10%.

In situ separation of ethanol with aqueous two-phase system and assessment of KLa for yeast growth in batch cultivation.

In the fermentation process, the separation of product and its purification is the most difficult and exigent task in the ground of biochemical engineering. Another major problem that is encountered in the fermentation is product inhibition, which leads to low conversion and low productivities. Extractive fermentation is a technique that helps in the in situ removal of product and better performance of the fermentation. An aqueous two-phase system was employed for in situ ethanol separation since the technique was biofriendly to the Saccharomyces cerevisiae and the ethanol produced. The two-phase system was obtained with polyethylene glycol 4000 (PEG 4000) and ammonium sulfate in water above critical concentrations, with the desire that the ethanol moves to the top phase while cells rest at the bottom. The overall mass transfer coefficient (KLa) was also estimated for the yeast growth at different rpm. The concentration and yield of ethanol were determined for conventional fermentation to be around 81.3% and for extractive fermentation around 87.5% at the end of the fermentation. Based on observation of both processes, extractive fermentation was found to be the best.

Application of low-cost algal nitrogen source feeding in fuel ethanol production using high gravity sweet potato medium.

Protein-rich bloom algae biomass was employed as nitrogen source in fuel ethanol fermentation using high gravity sweet potato medium containing 210.0 g l(-1) glucose. In batch mode, the fermentation could not accomplish even in 120 h without any feeding of nitrogen source. While, the feeding of acid-hydrolyzed bloom algae powder (AHBAP) notably promoted fermentation process but untreated bloom algae powder (UBAP) was less effective than AHBAP. The fermentation times were reduced to 96, 72, and 72 h if 5.0, 10.0, and 20.0 g l(-1) AHBAP were added into medium, respectively, and the ethanol yields and productivities increased with increasing amount of feeding AHBAP. The continuous fermentations were performed in a three-stage reactor system. Final concentrations of ethanol up to 103.2 and 104.3 g l(-1) with 4.4 and 5.3 g l(-1) residual glucose were obtained using the previously mentioned medium feeding with 20.0 and 30.0 g l(-1) AHBAP, at dilution rate of 0.02 h(-1). Notably, only 78.5 g l(-1) ethanol and 41.6 g l(-1) residual glucose were obtained in the comparative test without any nitrogen source feeding. Amino acids analysis showed that approximately 67% of the protein in the algal biomass was hydrolyzed and released into the medium, serving as the available nitrogen nutrition for yeast growth and metabolism. Both batch and continuous fermentations showed similar fermentation parameters when 20.0 and 30.0 g l(-1) AHBAP were fed, indicating that the level of available nitrogen in the medium should be limited, and an algal nitrogen source feeding amount higher than 20.0 g l(-1) did not further improve the fermentation performance.

Process design and economic analysis of a hypothetical bioethanol production plant using carob pod as feedstock.

A process for the production of ethanol from carob (Ceratonia siliqua) pods was designed and an economic analysis was carried out for a hypothetical plant. The plant was assumed to perform an aqueous extraction of sugars from the pods followed by fermentation and distillation to produce ethanol. The total fixed capital investment for a base case process with a capacity to transform 68,000 t/year carob pod was calculated as 39.61 millon euros (€) with a minimum bioethanol production cost of 0.51 €/L and an internal rate of return of 7%. The plant was found to be profitable at carob pod prices lower than 0.188 €/kg. An increase in the transformation capacity of the plant from 33,880 to 135,450 t/year was calculated to result in an increase in the internal rate of return from 5.50% to 13.61%. The obtained results show that carob pod is a promising alternative source for bioethanol production.

Conceptual design of cost-effective and environmentally-friendly configurations for fuel ethanol production from sugarcane by knowledge-based process synthesis.

In this work, the hierarchical decomposition methodology was used to conceptually design the production of fuel ethanol from sugarcane. The decomposition of the process into six levels of analysis was carried out. Several options of technological configurations were assessed in each level considering economic and environmental criteria. The most promising alternatives were chosen rejecting the ones with a least favorable performance. Aspen Plus was employed for simulation of each one of the technological configurations studied. Aspen Icarus was used for economic evaluation of each configuration, and WAR algorithm was utilized for calculation of the environmental criterion. The results obtained showed that the most suitable synthesized flowsheet involves the continuous cultivation of Zymomonas mobilis with cane juice as substrate and including cell recycling and the ethanol dehydration by molecular sieves. The proposed strategy demonstrated to be a powerful tool for conceptual design of biotechnological processes considering both techno-economic and environmental indicators.

The unintended energy impacts of increased nitrate contamination from biofuels production.

Increases in corn cultivation for biofuels production, due to the Energy Independence and Security Act of 2007, are likely to lead to increases in nitrate concentrations in both surface and groundwater resources in the United States. These increases might trigger the requirement for additional energy consumption for water treatment to remove the nitrates. While these increasing concentrations of nitrate might pose a human health concern, most water resources were found to be within current maximum contaminant level (MCL) limits of 10 mg L(-1) NO(3)-N. When water resources exceed this MCL, energy-intensive drinking water treatment is required to reduce nitrate levels below 10 mg L(-1). Based on prior estimates of water supplies currently exceeding the nitrate MCL, we calculate that advanced drinking water treatment might require an additional 2360 million kWh annually (for nitrate affected areas only)--a 2100% increase in energy requirements for water treatment in those same areas--to mitigate nitrate contamination and meet the MCL requirement. We predict that projected increases in nitrate contamination in water may impact the energy consumed in the water treatment sector, because of the convergence of several related trends: (1) increasing cornstarch-based ethanol production, (2) increasing nutrient loading in surface water and groundwater resources as a consequence of increased corn-based ethanol production, (3) additional drinking water sources that exceed the MCL for nitrate, and (4) potentially more stringent drinking water standards for nitrate.

Temperature-dependent release of volatile organic compounds of eucalypts by direct analysis in real time (DART) mass spectrometry.

A method is described for the rapid identification of biogenic, volatile organic compounds (VOCs) emitted by plants, including the analysis of the temperature dependence of those emissions. Direct analysis in real time (DART) enabled ionization of VOCs from stem and leaf of several eucalyptus species including E. cinerea, E. citriodora, E. nicholii and E. sideroxylon. Plant tissues were placed directly in the gap between the DART ionization source skimmer and the capillary inlet of the time-of-flight (TOF) mass spectrometer. Temperature-dependent emission of VOCs was achieved by adjusting the temperature of the helium gas into the DART ionization source at 50, 100, 200 and 300 degrees C, which enabled direct evaporation of compounds, up to the onset of pyrolysis of plant fibres (i.e. cellulose and lignin). Accurate mass measurements facilitated by TOF mass spectrometry provided elemental compositions for the VOCs. A wide range of compounds was detected from simple organic compounds (i.e. methanol and acetone) to a series of monoterpenes (i.e. pinene, camphene, cymene, eucalyptol) common to many plant species, as well as several less abundant sesquiterpenes and flavonoids (i.e. naringenin, spathulenol, eucalyptin) with antioxidant and antimicrobial properties. The leaf and stem tissues for all four eucalypt species showed similar compounds. The relative abundances of methanol and ethanol were greater in stem wood than in leaf tissue suggesting that DART could be used to investigate the tissue-specific transport and emissions of VOCs.

[Industrial exploitation of renewable resources: from ethanol production to bioproducts development]. / Valorisation des ressources renouvelables : de la production d'éthanol au développement de nouveaux bioproduits.

Plants, which are one of major groups of life forms, are constituted of an amazing number of molecules such as sugars, proteins, phenolic compounds etc. These molecules display multiple and complementary properties involved in various compartments of plants (structure, storage, biological activity etc.). The first uses of plants in industry were for food and feed, paper manufacturing or combustion. In the coming decades, these renewable biological materials will be the basis of a new concept: the "biorefiner" i.e. the chemical conversion of the whole plant to various products and uses. This concept, born in the 90ies, is analogous to today's petroleum refinery, which produces multiple fuels and derivative products from petroleum. Agriculture generates lots of co-products which were most often wasted. The rational use of these wasted products, which can be considered as valuable renewable materials, is now economically interesting and will contribute to the reduction of greenhouse has emissions by partially substituting for fossil fuels. Such substructures from biological waste products and transforming them into biofuels and new industrial products named "bioproducts". These compounds, such as bioplastics or biosurfactants, can replace equivalent petroleum derivatives. Towards that goal, lots of filamentous fungi, growing on a broad range of vegetable species, are able to produce enzymes adapted to the modification of these type of substrates. The best example, at least the more industrially developed to date, is the second generation biofuel technology using cellulose as a raw material. The process includes an enzymatic hydrolysis step which requires cellulases secreted from Trichoderma fungal species. This industrial development of a renewable energy will contribute to the diversification of energy sources used to transport and to the development of green chemistry which will partially substitute petrochemicals.

Environmental and economic evaluation of bioenergy in Ontario, Canada.

We examined life cycle environmental and economic implications of two near-term scenarios for converting cellulosic biomass to energy, generating electricity from cofiring biomass in existing coal power plants, and producing ethanol from biomass in stand-alone facilities in Ontario, Canada. The study inventories near-term biomass supply in the province, quantifies environmental metrics associated with the use of agricultural residues for producing electricity and ethanol, determines the incremental costs of switching from fossil fuels to biomass, and compares the cost-effectiveness of greenhouse gas (GHG) and air pollutant emissions abatement achieved through the use of the bioenergy. Implementing a biomass cofiring rate of 10% in existing coal-fired power plants would reduce annual GHG emissions by 2.3 million metric tons (t) of CO2 equivalent (7% of the province's coal power plant emissions). The substitution of gasoline with ethanol/gasoline blends would reduce annual provincial lightduty vehicle fleet emissions between 1.3 and 2.5 million t of CO2 equivalent (3.5-7% of fleet emissions). If biomass sources other than agricultural residues were used, additional emissions reductions could be realized. At current crude oil prices ($70/barrel) and levels of technology development of the bioenergy alternatives, the biomass electricity cofiring scenario analyzed is more cost-effective for mitigating GHG emissions ($22/t of CO2 equivalent for a 10% cofiring rate) than the stand-alone ethanol production scenario ($92/t of CO2 equivalent). The economics of biomass cofiring benefits from existing capital, whereas the cellulosic ethanol scenario does not. Notwithstanding this result, there are several factors that increase the attractiveness of ethanol. These include uncertainty in crude oil prices, potential for marked improvements in cellulosic ethanol technology and economics, the province's commitment to 5% ethanol content in gasoline, the possibility of ethanol production benefiting from existing capital, and there being few alternatives for moderate-to-large-scale GHG emissions reductions in the transportation sector.

Conversion of paper sludge to ethanol, II: process design and economic analysis.

Process design and economics are considered for conversion of paper sludge to ethanol. A particular site, a bleached kraft mill operated in Gorham, NH by Fraser Papers (15 tons dry sludge processed per day), is considered. In addition, profitability is examined for a larger plant (50 dry tons per day) and sensitivity analysis is carried out with respect to capacity, tipping fee, and ethanol price. Conversion based on simultaneous saccharification and fermentation with intermittent feeding is examined, with ethanol recovery provided by distillation and molecular sieve adsorption. It was found that the Fraser plant achieves positive cash flow with or without xylose conversion and mineral recovery. Sensitivity analysis indicates economics are very sensitive to ethanol selling price and scale; significant but less sensitive to the tipping fee, and rather insensitive to the prices of cellulase and power. Internal rates of return exceeding 15% are projected for larger plants at most combinations of scale, tipping fee, and ethanol price. Our analysis lends support to the proposition that paper sludge is a leading point-of-entry and proving ground for emergent industrial processes featuring enzymatic hydrolysis of cellulosic biomass.

Enhancing profitability of dry mill ethanol plants: process modeling and economics of conversion of degermed defibered corn to ethanol.

An Aspen Plus modeling platform was developed to evaluate the performance of the conversion process of degermed defibered corn (DDC) to ethanol in 15- and 40-million gallons per year (MGPY) dry mill ethanol plants. Upstream corn milling equipment in conventional dry mill ethanol plants was replaced with germ and fiber separation equipment. DDC with higher starch content was fed to the existing saccharification and fermentation units, resulting in higher ethanol productivity than with regular corn. The results of the DDC models were compared with those of conventional dry mill ethanol process models. A simple financial analysis that included capital and operating costs, revenues, earnings, and return on investment was created to evaluate each model comparatively. Case studies were performed on 15- and 40-MGPY base case models with two DDC process designs and DDC with a mechanical oil extraction process.

Fermentation and costs of fuel ethanol from corn with Quick-Germ process.

The Quick-Germ process developed at the University of Illinois at Urbana-Champaign is a way to obtain corn oil, but with lower capital costs than the traditional wet-milling process. Quick-Germ has the potential to increase the coproduct credits and profitability of the existing dry-grind fuel ethanol process, but the fermentability of the corn remaining after oil recovery has not been tested. Therefore, a series of pilot scale (50 L) fermentations was carefully controlled and monitored with unique methods for standard inoculation and automatic sampling. It was found that the concentration of suspended solids was significantly reduced in the Quick-Germ fermentations. When compared at the same concentration of fermentable sugars, the fermentation rate and yield were not statistically different from controls. When Quick-Germ was integrated into a state-of-the-art dry-grind fuel ethanol process, computer simulation and cost models indicated savings of approx $0.01/L of ethanol ($0.04/gal) with the Quick-Germ process. Additional savings associated with the lower suspended solids could not be quantified and were not included. However, the savings are sensitive to the price of corn oil.

Continuous countercurrent extraction of hemicellulose from pretreated wood residues.

Two-stage dilute acid pretreatment followed by enzymatic cellulose hydrolysis is an effective method for obtaining high sugar yields from wood residues such as softwood forest thinnings. In the first-stage hydrolysis step, most of the hemicellulose is solubilized using relatively mild conditions. The soluble hemicellulosic sugars are recovered from the hydrolysate slurry by washing with water. The washed solids are then subjected to more severe hydrolysis conditions to hydrolyze approx 50% of the cellulose to glucose. The remaining cellulose can further be hydrolyzed with cellulase enzyme. Our process simulation indicates that the amount of water used in the hemicellulose recovery step has a significant impact on the cost of ethanol production. It is important to keep water usage as low as possible while maintaining relatively high recovery of soluble sugars. To achieve this objective, a prototype pilot-scale continuous countercurrent screw extractor was evaluated for the recovery of hemicellulose from pretreated forest thinnings. Using the 274-cm (9-ft) long extractor, solubles recoveries of 98, 91, and 77% were obtained with liquid-to-insoluble solids (L/IS) ratios of 5.6, 3.4, and 2.1, respectively. An empirical equation was developed to predict the performance of the screw extractor. This equation predicts that soluble sugar recovery above 95% can be obtained with an L/IS ratio as low as 3.0.