High solids loading biorefinery for the production of cellulosic sugars from bioenergy sorghum.

A novel process applying high solids loading in chemical-free pretreatment and enzymatic hydrolysis was developed to produce sugars from bioenergy sorghum. Hydrothermal pretreatment with 50% solids loading was performed in a pilot scale continuous reactor followed by disc refining. Sugars were extracted from the enzymatic hydrolysis at 10% to 50% solids content using fed-batch operations. Three surfactants (Tween 80, PEG 4000, and PEG 6000) were evaluated to increase sugar yields. Hydrolysis using 2% PEG 4000 had the highest sugar yields. Glucose concentrations of 105, 130, and 147 g/L were obtained from the reaction at 30%, 40%, and 50% solids content, respectively. The maximum sugar concentration of the hydrolysate, including glucose and xylose, obtained was 232 g/L. Additionally, the glucose recovery (73.14%) was increased compared to that of the batch reaction (52.74%) by using two-stage enzymatic hydrolysis combined with fed-batch operation at 50% w/v solids content.

A comparative account of glucose yields and bioethanol production from separate and simultaneous saccharification and fermentation processes at high solids loading with variable PEG concentration.

A process strategy to aid in optimal enzymatic hydrolysis through the addition of polyethylene glycol (PEG6000) was tested for separate hydrolysis and fermentation (SHF) and simultaneous saccharification and fermentation (SSF). Pretreated wheat straw at 30% solids (w/w) loading was enzymatically hydrolyzed with 0, 0.5, 1, 1.5, 2 and 2.5% of PEG6000 through SHF and SSF. During SHF, bioethanol concentration of 107.5 g/L (2.5% PEG6000) was achieved. SSF ethanol concentration were about 113 g/L at 1.5% PEG6000 addition. A technoeconomic feasibility showed a return on investment (ROI) of 8.13% using 0.5% PEG6000 for SHF (96 h) and 12.25% ROI for SSF control (72 h). Life cycle assessment for the various scenarios indicated higher environmental gains for best cases of SSF over SHF. The study shows the SSF approach (0% PEG6000; 72 h) facilitates higher process efficiencies; technoeconomic gains and high environmental sustainability for future scale-up and commercial realization.

A novel method for real-time estimation of insoluble solids and glucose concentrations during enzymatic hydrolysis of biomass.

The study describes a novel method using instantaneous mixing torque and rotational speed to estimate insoluble solids and glucose concentrations during enzymatic hydrolysis of biomass. This method is cost-effective for real-time monitoring and control of enzymatic hydrolysis and potentially scalable. The model was developed using biomass slurries at three solids loading (20, 30 and 45%) at various rotational speeds from 50 to 400 rpm. The results showed a significant drop in mixing torque at 12 h with high solids loading. Maximum glucose concentration (205 g/l) during hydrolysis was achieved at 45% solids loading. Insoluble solids and glucose concentration as a function of torque and rotational speeds were modeled using a modified Herschell-Bulkley model. The model describes the experimental observations with high fidelity (R2 = 0.84) and can be used for real time monitoring of many multiphase reaction systems as enzymatic hydrolysis of lignocellulosic biomass and dry grind corn ethanol processes.

Effect of solids loading on ethanol production: Experimental, economic and environmental analysis.

This study explores the effect of high-solids loading for a fed batch enzymatic hydrolysis and fermentation. The solids loading considered was 19%, 30% and 45% using wheat straw and corn stover as a feedstock. Based on the experimental results, techno-economic analysis and life cycle assessments were performed. The experimental results showed that 205±25.8g/L glucose could be obtained from corn stover at 45% solids loading after 96h which when fermented yielded 115.9±6.37g/L ethanol after 60h of fermentation. Techno-economic analysis showed that corn stover at 45% loading yielded the highest ROI at 8% with a payback period less than 12years. Similarly, the global warming potential was lowest for corn stover at 45% loading at -37.8gCO2 eq./MJ ethanol produced.