Review of Dissolved CO and H2 Measurement Methods for Syngas Fermentation.

Syngas fermentation is a promising technique to produce biofuels using syngas obtained through gasified biomass and other carbonaceous materials or collected from industrial CO-rich off-gases. The primary components of syngas, carbon monoxide (CO) and hydrogen (H2), are converted to alcohols and other chemicals through an anaerobic fermentation process by acetogenic bacteria. Dissolved CO and H2 concentrations in fermentation media are among the most important parameters for successful and stable operation. However, the difficulties in timely and precise dissolved CO and H2 measurements hinder the industrial-scale commercialization of this technique. The purpose of this article is to provide a comprehensive review of available dissolved CO and H2 measurement methods, focusing on their detection mechanisms, CO and H2 cross interference and operations in syngas fermentation process. This paper further discusses potential novel methods by providing a critical review of gas phase CO and H2 detection methods with regard to their capability to be modified for measuring dissolved CO and H2 in syngas fermentation conditions.

Biochar facilitated Biological CO2 conversion to C2-C6 alcohols and fatty acids.

Microbial CO2 utilization reduces the carbon footprint, providing economic potential. Biochar, rich in minerals and trace metals, can enhance microbial activity. This study investigates poultry litter and switchgrass biochars produced at 350 and 700 °C (PLB350, PLB700, SGB350 and SGB700, respectively) affect CO2 conversion to C2-C6 alcohols and acids by Clostridium muellerianum P21, C. ragsdalei P11 and C. carboxidivorans P7. Fermentations were in 250-mL bottles containing H2:CO2:N2 (60:20:20) shaken at 125 rpm and 37 °C. SGB350 increased alcohol titers by 1.1-2.1 fold, and PLB350 enhanced acid concentrations by 1.2-1.7 fold compared to the control without biochar. About 2.0-3.3 fold more ethanol was formed by strain P11 compared to strains P7 and P21 with SGB350. However, strain P21 produced 2.4-fold more butanol than strain P7 with SGB350, including unique hexanol production. These results highlight the potential of biochar in enhancing C2-C6 alcohol production from CO2, thereby boosting process feasibility.

The genome of the anaerobic fungus Orpinomyces sp. strain C1A reveals the unique evolutionary history of a remarkable plant biomass degrader.

Anaerobic gut fungi represent a distinct early-branching fungal phylum (Neocallimastigomycota) and reside in the rumen, hindgut, and feces of ruminant and nonruminant herbivores. The genome of an anaerobic fungal isolate, Orpinomyces sp. strain C1A, was sequenced using a combination of Illumina and PacBio single-molecule real-time (SMRT) technologies. The large genome (100.95 Mb, 16,347 genes) displayed extremely low G+C content (17.0%), large noncoding intergenic regions (73.1%), proliferation of microsatellite repeats (4.9%), and multiple gene duplications. Comparative genomic analysis identified multiple genes and pathways that are absent in Dikarya genomes but present in early-branching fungal lineages and/or nonfungal Opisthokonta. These included genes for posttranslational fucosylation, the production of specific intramembrane proteases and extracellular protease inhibitors, the formation of a complete axoneme and intraflagellar trafficking machinery, and a near-complete focal adhesion machinery. Analysis of the lignocellulolytic machinery in the C1A genome revealed an extremely rich repertoire, with evidence of horizontal gene acquisition from multiple bacterial lineages. Experimental analysis indicated that strain C1A is a remarkable biomass degrader, capable of simultaneous saccharification and fermentation of the cellulosic and hemicellulosic fractions in multiple untreated grasses and crop residues examined, with the process significantly enhanced by mild pretreatments. This capability, acquired during its separate evolutionary trajectory in the rumen, along with its resilience and invasiveness compared to prokaryotic anaerobes, renders anaerobic fungi promising agents for consolidated bioprocessing schemes in biofuels production.

Physiological response of Clostridium carboxidivorans during conversion of synthesis gas to solvents in a gas-fed bioreactor.

Clostridium carboxidivorans P7 is one of three microbial catalysts capable of fermenting synthesis gas (mainly CO, CO(2) , and H(2) ) to produce the liquid biofuels ethanol and butanol. Gasification of feedstocks to produce synthesis gas (syngas), followed by microbial conversion to solvents, greatly expands the diversity of suitable feedstocks that can be used for biofuel production beyond commonly used food and energy crops to include agricultural, industrial, and municipal waste streams. C. carboxidivorans P7 uses a variation of the classic Wood-Ljungdahl pathway, identified through genome sequence-enabled approaches but only limited direct metabolic analyses. As a result, little is known about gene expression and enzyme activities during solvent production. In this study, we measured cell growth, gene expression, enzyme activity, and product formation in autotrophic batch cultures continuously fed a synthetic syngas mixture. These cultures exhibited an initial phase of growth, followed by acidogenesis that resulted in a reduction in pH. After cessation of growth, solventogenesis occurred, pH increased and maximum concentrations of acetate (41 mM), butyrate (1.4 mM), ethanol (61 mM), and butanol (7.1 mM) were achieved. Enzyme activities were highest during the growth phase, but expression of carbon monoxide dehydrogenase (CODH), Fe-only hydrogenases and two tandem bi-functional acetaldehyde/alcohol dehydrogenases were highest during specific stages of solventogenesis. Several amino acid substitutions between the tandem acetaldehyde/alcohol dehydrogenases and the differential expression of their genes suggest that they may have different roles during solvent formation. The data presented here provide a link between the expression of key enzymes, their measured activities and solvent production by C. carboxidivorans P7. This research also identifies potential targets for metabolic engineering efforts designed to produce higher amounts of ethanol or butanol from syngas. .

Effects of Clostridium beijerinckii and Medium Modifications on Acetone-Butanol-Ethanol Production From Switchgrass.

The presence of lignocellulose-derived microbial inhibitory compounds (LDMICs) in lignocellulosic biomass (LB) hydrolysates is a barrier to efficient conversion of LB hydrolysates to fuels and chemicals by fermenting microorganisms. Results from this study provide convincing evidence regarding the effectiveness of metabolically engineered C. beijerinckii NCIMB 8052 for the fermentation of LB-derived hydrolysates to acetone-butanol-ethanol (ABE). The engineered microbial strain (C. beijerinckii_SDR) was produced by the integration of an additional copy of a short-chain dehydrogenase/reductase (SDR) gene (Cbei_3904) into the chromosome of C. beijerinckii NCIMB 8052 wildtype, where it is controlled by the constitutive thiolase promoter. The C. beijerinckii_SDR and C. beijerinckii NCIMB 8052 wildtype were used for comparative fermentation of non-detoxified and detoxified hydrothermolysis-pretreated switchgrass hydrolysates (SHs) with and without (NH4)2CO3 supplementation. In the absence of (NH4)2CO3, fermentation of non-detoxified SH with C. beijerinckii_SDR resulted in the production of 3.13- and 2.25-fold greater quantities of butanol (11.21 g/L) and total ABE (20.24 g/L), respectively, than the 3.58 g/L butanol and 8.98 g/L ABE produced by C. beijerinckii_wildtype. When the non-detoxified SH was supplemented with (NH4)2CO3, concentrations were similar for butanol (9.5 compared with 9.2 g/L) and ABE (14.2 compared with 13.5 g/L) produced by C. beijerinckii_SDR and C. beijerinckii_wildtype, respectively. Furthermore, when C. beijerinckii_SDR and C. beijerinckii_wildtype were cultured in detoxified SH medium, C. beijerinckii_SDR produced 1.11- and 1.18-fold greater quantities of butanol and ABE, respectively, than when there was culturing with C. beijerinckii_wildtype. When the combined results of the present study are considered, conclusions are that the microbial strain and medium modifications of the fermentation milieu resulted in greater production of fuels and chemicals from non-detoxified LB hydrolysates.

Viable strategies for enhancing acetone-butanol-ethanol production from non-detoxified switchgrass hydrolysates.

A process engineering strategy was investigated towards developing a viable scheme for effective conversion of hydrothermolysis pretreated non-detoxified switchgrass hydrolysates (SH) to acetone butanol ethanol (ABE) using a metabolically engineered strain of Clostridium beijerinckii NCIMB 8052, C. beijerinckii_AKR. The engineered strain was modified by homologous integration into the chromosome and constitutive expression of Cbei_3974, which encodes an aldo-keto reductase. Intermittent feeding strategy was employed in which fermentation was initiated with 30% of the SH and the remaining 70% SH was added when the optical density (OD600nm) of C. beijerinckii attained 0.5. The ABE (14.9 g/L) produced from non-detoxified SH by the inhibitor-tolerant C. beijerinckii_AKR was comparable to the P2-glucose control medium (14.7 g/L). Using intermittent feeding, wildtype and C. beijerinckii_AKR produced similar amounts of ABE (about 17.5 g/L). This shows that intermittent feeding strategy and C. beijerinckii_AKR enhanced ABE fermentation and eliminated the need for SH detoxification prior to fermentation.

Reduction of acetone to isopropanol using producer gas fermenting microbes.

Gasification-fermentation is an emerging technology for the conversion of lignocellulosic materials into biofuels and specialty chemicals. For effective utilization of producer gas by fermenting bacteria, tar compounds produced in the gasification process are often removed by wet scrubbing techniques using acetone. In a preliminary study using biomass generated producer gas scrubbed with acetone, an accumulation of acetone and subsequent isopropanol production was observed. The effect of 2 g/L acetone concentrations in the fermentation media on growth and product distributions was studied with "Clostridium ragsdalei," also known as Clostridium strain P11 or P11, and Clostridium carboxidivorans P7 or P7. The reduction of acetone to isopropanol was possible with "C. ragsdalei," but not with P7. In P11 this reaction occurred rapidly when acetone was added in the acidogenic phase, but was 2.5 times slower when added in the solventogenic phase. Acetone at concentrations of 2 g/L did not affect the growth of P7, but ethanol increased by 41% and acetic acid concentrations decreased by 79%. In the fermentations using P11, growth was unaffected and ethanol concentrations increased by 55% when acetone was added in the acidogenic phase. Acetic acid concentrations increased by 19% in both the treatments where acetone was added. Our observations indicate that P11 has a secondary alcohol dehydrogenase that enables it to reduce acetone to isopropanol, while P7 lacks this enzyme. P11 offers an opportunity for biological production of isopropanol from acetone reduction in the presence of gaseous substrates (CO, CO2, and H2).

Well-to-wake analysis of switchgrass to jet fuel via a novel co-fermentation of sugars and CO2.

Lignocellulosic biomass such as switchgrass can be converted to n-butanol using fermentation, which can be further processed into jet fuel. Traditional acetone-butanol-ethanol (ABE) fermentation only converts sugars derived from switchgrass to ABE. Novel co-fermentation processes convert sugars and gas (CO2/H2) produced during fermentation into butanol, thus increasing ABE yields by 15.5% compared to traditional ABE fermentation. Herein, the environmental impact of a Switchgrass to Jet Fuel (STJ) pathway was assessed using life cycle assessment (LCA) from well-to-wake. LCAs were performed for greenhouse gas (GHG) emissions from jet fuel production via co-fermentation of sugars and gas for ideal and practical cases of ABE fermentation and seven other jet fuel pathways. The ideal case assumes 100% sugar recovery and 95% ABE yield. The practical case assumes 90% sugar recovery and an 80% ABE yield. Results are presented based on 100-year global warming potential (GWP) per MJ of jet fuel. Co-products were allocated using various methods. The increase in butanol yield via the co-fermentation technology reduced GWP-100 for the STJ pathway by 6.5% compared to traditional ABE fermentation. Similarly, the STJ pathway for the practical case with co-fermentation had 14.2%, 47.5%, 73.8%, and 44.4% less GWP-100 compared to HRJ, Fischer-Tropsch jet fuel from switchgrass, Fischer-Tropsch jet fuel from coal, and conventional petroleum jet fuel. The results demonstrate that the STJ pathway via co-fermentation has the potential to increase product yield while reducing GHG emissions compared to other jet fuel production pathways.

Biochar facilitated bioprocessing and biorefinery for productions of biofuel and chemicals: A review.

Biochar is traditionally used to improve soil properties in arable land and as adsorbent or precursor of activated carbon in wastewater treatment. Recent advances have shown biochar potentials in enhancing productions of biofuels and chemicals such as bio-ethanol, butanol, methane, hydrogen, bio-diesel, hydrocarbons and carboxylic acids. The properties of biochar such as high levels of porosity, functional groups, cation exchange capacity, pH buffering capacity, electron conductivity, and macro-/micro- nutrients (Na, K, Ca, Mg, P, S, Fe, etc.) provide appropriate conditions to relieve physicochemical stresses on microorganisms through pH buffering, detoxification, nutrients supply, serving as electron carrier and supportive microbial habitats. This paper critically reviewed biochar production and characteristics, biochar utilization in anaerobic digestion, composting, microbial fermentation, hydrolysate detoxification, catalysis in biomass refinery and biodiesel synthesis. This review provides novel vision of biochar application, which could guide future research towards cleaner and more economic production of renewable fuels and bio-based chemicals.

Feasibility of using biochar as buffer and mineral nutrients replacement for acetone-butanol-ethanol production from non-detoxified switchgrass hydrolysate.

Biochar can be an inexpensive pH buffer and source of mineral and trace metal nutrients in acetone-butanol-ethanol (ABE) fermentation. This study evaluated the feasibility of replacing expensive 4-morpholineethanesulfonic acid (MES) P2 buffer and mineral nutrients with biochar made from switchgrass (SGBC), forage sorghum (FSBC), redcedar (RCBC) and poultry litter (PLBC) for ABE fermentation. Fermentations using Clostridium beijerinckii ATCC 51743 in glucose and non-detoxified switchgrass hydrolysate media were performed at 35 °C in 250 mL bottles for 72 h. Medium containing buffer and minerals without biochar was the control. Similar ABE production (about 18.0 g/L) in glucose media with SGBC, FSBC and RCBC and control was measured. However in non-detoxified switchgrass hydrolysate medium, SGBC, RCBC and PLBC produced more ABE (about 18.5 g/L) than the control (10.1 g/L). This demonstrates that biochar is an effective buffer and mineral supplement for ABE production from lignocellulosic biomass without costly detoxification process.

Measurement and prediction of mass transfer coefficients for syngas constituents in a hollow fiber reactor.

Syngas fermentation for producing biofuels and other products suffers from mass transfer limitations due to low CO and H2 solubility in liquid medium. Therefore, it is critical to characterize mass transfer rates of these gases to guide bioreactor design and optimization. This work presents a novel technique to measure the volumetric mass transfer coefficients (kia) for H2 and CO using gas chromatography in a non-porous hollow fiber reactor (HFR). The largest measured kia for H2 and CO were 840 and 420 h-1, respectively. A model was developed to predict kia for H2 and CO that agreed well with experimental data. This study is the first to measure, compare, and model both H2 and CO mass transfer coefficients in an HFR. Based on model predictions, HFRs have the potential to be a reactor of choice for syngas fermentation as a result of high mass transfer that can support high cell densities.

Enhanced ethanol production by Clostridium ragsdalei from syngas by incorporating biochar in the fermentation medium.

Biochar contains minerals and metals that can serve as nutrients for acetogens to produce ethanol via syngas fermentation. In this study, four fermentation media containing biochar from switchgrass (SGBC), forage sorghum (FSBC), red cedar (RCBC) and poultry litter (PLBC) were compared with standard yeast extract (YE) medium for syngas fermentation using Clostridium ragsdalei. Fermentations were performed in 250mL bottle reactors at 150rpm and 37°C with syngas containing CO:H2:CO2 (40:30:30) by volume. Results showed that media containing RCBC and PLBC improved ethanol production by 16.3% and 58.9%, respectively, compared to YE medium. C. ragsdalei consumed 69% more H2 and 40% more CO in PLBC medium compared to YE medium. However, no enhancement of ethanol production was observed in SGBC and FSBC media. The highest release of Na, K, Ca, Mg, S and P was from PLBC, which was considered to contribute in enhancement of ethanol production.

Biochar enhanced ethanol and butanol production by Clostridium carboxidivorans from syngas.

Biochar has functional groups, pH buffering capacity and cation exchange capacity (CEC) that can be beneficial in syngas fermentation. This study examined the properties of biochar made from switchgrass (SGBC), forage sorghum (FSBC), red cedar (RCBC) and poultry litter (PLBC), and their effects on ethanol and butanol production from syngas using Clostridium carboxidivorans. Experiments were performed in 250 mL bottle reactors with a 50 mL working volume at 37 °C fed syngas containing CO:H2:CO2 (40:30:30 by volume). Results showed that PLBC and SGBC enhanced ethanol production by 90% and 73%, respectively, and butanol production by fourfold compared to standard yeast extract medium without biochar (control). CO and H2 utilization in PLBC and SGBC media increased compared to control. PLBC had the highest pH buffering capacity, CEC and total amount of cations compared with SGBC, FSBC and RCBC, which could have contributed to its highest enhancement of ethanol and butanol production.

Continuous aryl alcohol oxidase production under growth-limited conditions using a trickle bed reactor.

An A. nidulans strain with a pyridoxine marker was used for continuous production of aryl alcohol oxidase (AAO) in a trickle bed reactor (TBR). Modified medium with reduced zinc, no copper, and 5 g/L ascorbic acid that reduced melanin production and increased AAO productivity under growth limited conditions was used. Two air flow rates, 0.11 L/min (0.1 vvm) and 1.1 L/min (1.0 vvm) were tested. More melanin formation and reduced protein productivity were observed with air flow rate of 1.1 L/min. Three random packings were used as support for the fungus inside the TBR column, two of which were hydrophobic and one which was hydrophilic, and three different dilution rates were tested. The use of GEA BCN 030 hydrophobic packing resulted in greater AAO yield and productivity than the other packings. Increasing dilution rates favored melanin formation and citric, lactic and succinic acid accumulation, which decreased AAO yield and productivity.

Process simulation of ethanol production from biomass gasification and syngas fermentation.

The hybrid gasification-syngas fermentation platform can produce more bioethanol utilizing all biomass components compared to the biochemical conversion technology. Syngas fermentation operates at mild temperatures and pressures and avoids using expensive pretreatment processes and enzymes. This study presents a new process simulation model developed with Aspen Plus® of a biorefinery based on a hybrid conversion technology for the production of anhydrous ethanol using 1200tons per day (wb) of switchgrass. The simulation model consists of three modules: gasification, fermentation, and product recovery. The results revealed a potential production of about 36.5million gallons of anhydrous ethanol per year. Sensitivity analyses were also performed to investigate the effects of gasification and fermentation parameters that are keys for the development of an efficient process in terms of energy conservation and ethanol production.

Prevention of melanin formation during aryl alcohol oxidase production under growth-limited conditions using an Aspergillus nidulans cell factory.

An Aspergillus nidulans cell factory was genetically engineered to produce an aryl alcohol oxidase (AAO). The cell factory initiated production of melanin when growth-limited conditions were established using stationary plates and shaken flasks. This phenomenon was more pronounced when the strain was cultured in a trickle bed reactor (TBR). This study investigated different approaches to reduce melanin formation in fungal mycelia and liquid medium in order to increase the enzyme production yield. Removal of copper from the medium recipe reduced melanin formation in agar cultures and increased enzyme activities by 48% in agitated liquid cultures. Copper has been reported as a key element for tyrosinase, an enzyme responsible for melanin production. Ascorbic acid (0.44g/L) stopped melanin accumulation, did not affect growth parameters and resulted in AAO activity that was more than two-fold greater than a control treatment with no ascorbic acid.

Utilizing Anaerobic Fungi for Two-stage Sugar Extraction and Biofuel Production from Lignocellulosic Biomass.

Lignocellulosic biomass is a vast and underutilized resource for the production of sugars and biofuels. However, the structural complexity of lignocellulosic biomass and the need for multiple pretreatment and enzymatic steps for sugar release renders this process economically challenging. Here, we report a novel approach for direct, single container, exogenous enzyme-free conversion of lignocellulosic biomass to sugars and biofuels using the anaerobic fungal isolate strain C1A. This approach utilizes simple physiological manipulations for timely inhibition and uncoupling of saccharolytic and fermentative capabilities of strain C1A, leading to the accumulation of sugar monomers (glucose and xylose) in the culture medium. The produced sugars, in addition to fungal hyphal lysate, are subsequently converted by Escherichia coli strain K011 to ethanol. Using this approach, we successfully recovered 17.0% (w/w) of alkali-pretreated corn stover (20.0% of its glucan and xylan content) as sugar monomers in the culture media. More importantly, 14.1% of pretreated corn stover (17.1% of glucan and xylan content) was recovered as ethanol at a final concentration of 28.16 mM after the addition of the ethanologenic strain K011. The high ethanol yield obtained is due to its accumulation as a minor fermentation end product by strain C1A during its initial growth phase, the complete conversion of sugars to ethanol by strain K011, and the possible conversion of unspecified substrates in the hyphal lysate of strain C1A to ethanol by strain K011. This study presents a novel, versatile, and exogenous enzyme-free strategy that utilizes a relatively unexplored group of organisms (anaerobic fungi) for direct biofuel production from lignocellulosic biomass.

Ethanol production during semi-continuous syngas fermentation in a trickle bed reactor using Clostridium ragsdalei.

An efficient syngas fermentation bioreactor provides a mass transfer capability that matches the intrinsic kinetics of the microorganism to obtain high gas conversion efficiency and productivity. In this study, mass transfer and gas utilization efficiencies of a trickle bed reactor during syngas fermentation by Clostridium ragsdalei were evaluated at various gas and liquid flow rates. Fermentations were performed using a syngas mixture of 38% CO, 28.5% CO2, 28.5% H2 and 5% N2, by volume. Results showed that increasing the gas flow rate from 2.3 to 4.6sccm increased the CO uptake rate by 76% and decreased the H2 uptake rate by 51% up to Run R6. Biofilm formation after R6 increased cells activity with over threefold increase in H2 uptake rate. At 1662h, the final ethanol and acetic acid concentrations were 5.7 and 12.3g/L, respectively, at 200ml/min of liquid flow rate and 4.6sccm gas flow rate.

Continuous xylanase production with Aspergillus nidulans under pyridoxine limitation using a trickle bed reactor.

A trickle bed reactor (TBR) with recycle was designed and tested using Aspergillus nidulans with a pyridoxine marker and over-expressing/secreting recombinant client xylanase B (XynB). The pyridoxine marker prevented the fungus from synthesizing its own pyridoxine and fungus was unable to grow when no pyridoxine was present in the medium; however, enzyme production was unaffected. Uncontrolled mycelia growth that led to clogging of the TBR was observed when fungus without a pyridoxine marker was used for XynB production. Using the fungus with pyridoxine marker, the TBR was operated continuously for 18 days and achieved a XynB output of 41 U/ml with an influent and effluent flow rate of 0.5 ml/min and a recycle flow rate of 56 ml/min. Production yields in the TBR were 1.4 times greater than a static tray culture and between 1.1 and 67 times greater than yields for SSF enzyme production stated in the literature.

Process development for biological production of butanol from Eastern redcedar.

Eastern redcedar is an invasive softwood species in Oklahoma and across grasslands in the Central Plains of the United States and potential feedstock for butanol production. Butanol has higher energy content than ethanol and can be upgraded to jet and diesel fuels. The objective of this study was to develop a process for production of butanol from redcedar. Results showed that Clostridium acetobutylicum ATCC 824 and Clostridium beijerinckii NCIMB 8052 did not grow in fermentation medium with citrate buffer. However, both strains grew in the medium with acetate buffer, resulting in 3-4g/L greater butanol than without acetate. Detoxification of redcedar hydrolyzate was required to increase butanol concentration from 1 to 13g/L. Hydrolyzate was detoxified by activated carbon to remove inhibitors. Fermentations in detoxified redcedar hydrolyzate reached 13g/L butanol and 19g/L total ABE, comparable to glucose control. This shows the potential for redcedar use in butanol production.