Pilot scale sulfur dioxide-ethanol-water fractionation of recycled wood to sugars, bioethanol, lignin and lignosulfonates: Carbohydrate balance.

Two grades of recycled wood (Waste Wood A and Waste Wood B) were fractionated on a pilot scale (800 BD kg) to monomeric sugars, lignin and lignosulfonates using SO2-Ethanol-Water (AVAP®) technology, including pretreatment, separation of cellulosic and hemicellulosic streams, and saccharification. Carbohydrate mass balance was obtained through determination of poly-, oligo- and monosaccharides as well as sugar degradation products in process streams. High monosaccharide yields were obtained confirming laboratory scale findings. Fermentability of mixed cellulosic and hemicellulosic sugar stream was confirmed on bench scale (25 kg).

Sulfur dioxide-ethanol-water fractionation platform for conversion of recycled wood to sugars, lignin and lignosulfonates.

Recycled wood of two grades (A and B) and spruce were converted on bench (100 o.d. g) and pilot (100 o.d. kg) scales to monosugars, lignin and lignosulfonates using SO2-Ethanol-Water (AVAP®) technology. After digestion, C6 and C5 sugars were recovered at 98-100% and 87-99% for Wood A and Spruce, respectively, while the values for Wood B were 92% and 74-87%. Cellulose was hydrolysed to glucose at 90% or higher using enzyme charge of 7.1 FPU/g glucan. Hemicellulosic sugars were autohydrolyzed to 95-100% monosugars. At bench scale, monosaccharide yield was 609, 561 and 688 kg (hydrous) per BDT biomass for Wood A, Wood B and Spruce, respectively. Corresponding water insoluble lignin yield was 157, 148 and 189 kg per BDT biomass. The preliminary techno-economic evaluation revealed that conversion of recycled wood to sugars using AVAP® fractionation platform results in higher profitability in comparison to virgin wood.

Membrane assisted continuous production of solvents with integrated solvent removal using liquid-liquid extraction.

The aim of this work was to demonstrate an industrially relevant pilot scale integrated process to produce butanol and other solvents from lignocellulosic sugars produced with AVAP® biomass fractionation technology from southern pine wood. The concentrated sugars were concurrently fermented using genetically engineered Clostridium acetobutylicum to n-butanol, acetone, isopropanol and ethanol in continuous membrane assisted cell recycle fermentation with steady-state solvent productivity exceeding 10 g/L/h. The solvents from the cell free permeate were recovered with extractant of butyl butyrate in a continuous liquid-liquid extraction column and aqueous product (raffinate) along with unused sugars, nutrients, and metabolic intermediates were recycled back to the fermentors. The total solvent yield approached 0.30 g/g sugars.

Interaction of carbohydrates with alcohol dehydrogenase: Effect on enzyme activity.

Alcohol dehydrogenase was covalently conjugated with three different oxidized carbohydrates i.e., glucose, starch and pectin. All the carbohydrates inhibited the enzyme. The inhibition was studied with respect to the inhibition rate constant, involvement of thiol groups in the binding, and structural changes in the enzyme. The enzyme activity decreased to half of its original activity at the concentration of 2 mg/mL of pectin, 4 mg/mL of glucose and 10 mg/mL of starch within 10 min at pH 7. This study showed oxidized pectin to be a potent inhibitor of alcohol dehydrogenase followed by glucose and starch. Along with the aldehyde-amino group interaction, thiol groups were also involved in the binding between alcohol dehydrogenase and carbohydrates. The structural changes occurring on binding of alcohol dehydrogenase with oxidized carbohydrates was also confirmed by fluorescence spectrophotometry. Oxidized carbohydrates could thus be used as potential inhibitors of alcohol dehydrogenase.

Enhanced stability of alcohol dehydrogenase by non-covalent interaction with polysaccharides.

Non-covalent interaction of alcohol dehydrogenase with polysaccharides was studied using three neutral and three anionic polysaccharides. The process of interaction of alcohol dehydrogenase with gum Arabic was optimized with respect to the ratio of enzyme to gum Arabic, pH, and molarity of buffer. Alcohol dehydrogenase-gum Arabic complex formed under optimized conditions showed 93% retention of original activity with enhanced thermal and pH stability. Lower inactivation rate constant of alcohol dehydrogenase-gum Arabic complex within the temperature range of 45 to 60 °C implied its better stability. Half-life of alcohol dehydrogenase-gum Arabic complex was higher than that of free alcohol dehydrogenase. A slight increment was observed in kinetic constants (K(m) and V(max)) of gum Arabic-complexed alcohol dehydrogenase which may be due to interference by gum Arabic for the binding of substrate to the enzyme. Helix to turn conversion was observed in complexed alcohol dehydrogenase as compared to free alcohol dehydrogenase which may be responsible for observed stability enhancement.

Impact of varying lignocellulosic sugars on continuous solvent production in an immobilized column reactor.

The effect of varying glucose, mannose and xylose concentrations on continuous solvent production at various dilution rates was studied by multiple linear regression (MLR) modeling using an immobilized column reactor. The factors affecting the solvent production were dilution rate and concentrations of glucose and mannose. MLR-models also showed a preference of glucose as well as its inhibitory effect on xylose consumption. The fermentation process was studied at bigger scale with a volume factor of 17 with an added recirculation loop in the system. The up-scaled reactor produced 12.5 g/l of acetone-butanol-ethanol (ABE) solvents at a dilution rate of 0.23 h(-1), as compared to 13.4 g/l with a smaller column reactor. The xylose utilization was significantly higher in the modified reactor (73%) as compared to the small scale (43%).

Oil palm empty fruit bunch to biofuels and chemicals via SO2-ethanol-water fractionation and ABE fermentation.

A process has been developed for conversion of spent liquor produced by SO2-ethanol-water (SEW) fractionation of oil palm empty fruit bunch (OPEFB) fibers to biofuels by ABE fermentation. The fermentation process utilizes Clostridia bacteria that produce butanol, ethanol and acetone solvents at a total yield of 0.26 g/g sugars. A conditioning scheme is developed, which demonstrates that it is possible to utilize the hemicellulose sugars from this agricultural waste stream by traditional ABE fermentation. Fractionation as well as sugar hydrolysis in the spent liquor is hindered by the high cation content of OPEFB, which can be partly removed by acidic leaching suggesting that a better deashing method is necessary. Furthermore, it is inferred that better and more selective lignin removal is needed during conditioning to improve liquor fermentability.

Constraint-based genome-scale metabolic modeling of Clostridium acetobutylicum behavior in an immobilized column.

In this study a step-wise optimization procedure was developed to predict solvent production using continuous ABE fermentation with immobilized cells. The modeling approach presented here utilizes previously published constraint-based metabolic model for Clostridium acetobutylicum without direct flux constraints. A recently developed flux ratio constraint method was adopted for the model. An experimental data set consisting of 25 experiments using different sugar mixtures as substrates and differing dilution rates was simulated successfully with the modeling approach. Converted to end product concentrations the mean absolute error for acetone was 0.31 g/l, for butanol 0.49 g/l, and for ethanol 0.17 g/l. The modeling approach was validated with another data set from similar experimental setup. The model errors for the validation data set was 0.24 g/l, 0.60 g/l, and 0.17 g/l for acetone, butanol, and ethanol, respectively.

The two stage immobilized column reactor with an integrated solvent recovery module for enhanced ABE production.

The production of acetone, butanol, and ethanol (ABE) by fermentation is a process that had been used by industries for decades. Two stage immobilized column reactor system integrated with liquid-liquid extraction was used with immobilized Clostridium acetobutylicum DSM 792, to enhance the ABE productivity and yield. The sugar mixture (glucose, mannose, galactose, arabinose, and xylose) representative to the lignocellulose hydrolysates was used as a substrate for continuous ABE production. Maximum total ABE solvent concentration of 20.30 g L(-1) was achieved at a dilution rate (D) of 0.2h(-1), with the sugar mixture as a substrate. The maximum solvent productivity (10.85 g L(-1)h(-1)) and the solvent yield (0.38 g g(-1)) were obtained at a dilution rate of 1.0 h(-1). The maximum sugar mixture utilization rate was achieved with the present set up which is difficult to reach in a single stage chemostat. The system was operated for 48 days without any technical problems.

Wheat flour based propionic acid fermentation: an economic approach.

A process for the fermentative production of propionic acid from whole wheat flour using starch and gluten as nutrients is presented. Hydrolysis of wheat flour starch using amylases was optimized. A batch fermentation of hydrolysate supplemented with various nitrogen sources using Propionibacterium acidipropionici NRRL B 3569 was performed. The maximum production of 48.61, 9.40, and 11.06 g of propionic acid, acetic acid and succinic acid, respectively, was found with wheat flour hydrolysate equivalent to 90 g/l glucose and supplemented with 15 g/l yeast extract. Further, replacement of yeast extract with wheat gluten hydrolysate showed utilization of gluten hydrolysate without compromising the yields and also improving the economics of the process. The process so developed could be useful for production of animal feed from whole wheat with in situ production of preservatives, and also suggest utilization of sprouted or germinated wheat for the production of organic acids.

Wood pulp as an immobilization matrix for the continuous production of isopropanol and butanol.

The study was focused on developing a continuous method to produce an alcohol mixture suitable to be used as a gasoline supplement. The immobilized column reactor with wood pulp fibers was successfully used for the continuous production of butanol and isopropanol using Clostridium beijerinckii DSM 6423. A sugar mixture (glucose, mannose, galactose, arabinose and xylose) representing lignocellulose hydrolysate was used as a substrate for the production of solvents. The effect of dilution rate on solvent production was studied during continuous operation. The maximum total solvent concentration of 11.99 g/l was obtained at a dilution rate of 0.16 h(-1). The maximum solvent productivity (5.58 g/l h) was obtained at a dilution rate of 1.5 h(-1). The maximum solvent yield of 0.45 g/g from sugar mixture was observed at 0.25 h(-1). The system will be further used for the solvent production using wood hydrolysate as a substrate.

Butanol production from lignocellulosics.

Clostridium spp. produce n-butanol in the acetone/butanol/ethanol process. For sustainable industrial scale butanol production, a number of obstacles need to be addressed including choice of feedstock, the low product yield, toxicity to production strain, multiple-end products and downstream processing of alcohol mixtures. This review describes the use of lignocellulosic feedstocks, bioprocess and metabolic engineering, downstream processing and catalytic refining of n-butanol.

Continuous two stage acetone-butanol-ethanol fermentation with integrated solvent removal using Clostridium acetobutylicum B 5313.

The objective of this study was to optimize continuous acetone-butanol-ethanol (ABE) fermentation using a two stage chemostat system integrated with liquid-liquid extraction of solvents produced in the first stage. This minimized end product inhibition by butanol and subsequently enhanced glucose utilization and solvent production in continuous cultures of Clostridium acetobutylicum B 5313. During continuous two-stage ABE fermentation, sugarcane bagasse was used as the cell holding material for the both stages and liquid-liquid extraction was performed using an oleyl alcohol and decanol mixture. An overall solvent production of 25.32g/L (acetone 5.93g/L, butanol 16.90g/L and ethanol 2.48g/L) was observed as compared to 15.98g/L in the single stage chemostat with highest solvent productivity and solvent yield of 2.5g/Lh and of 0.35g/g, respectively. Maximum glucose utilization (83.21%) at a dilution rate of 0.051/h was observed as compared to 54.38% in the single stage chemostat.

Continuous bio-catalytic conversion of sugar mixture to acetone-butanol-ethanol by immobilized Clostridium acetobutylicum DSM 792.

Continuous production of acetone, n-butanol, and ethanol (ABE) was carried out using immobilized cells of Clostridium acetobutylicum DSM 792 using glucose and sugar mixture as a substrate. Among various lignocellulosic materials screened as a support matrix, coconut fibers and wood pulp fibers were found to be promising in batch experiments. With a motive of promoting wood-based bio-refinery concept, wood pulp was used as a cell holding material. Glucose and sugar mixture (glucose, mannose, galactose, arabinose, and xylose) comparable to lignocellulose hydrolysate was used as a substrate for continuous production of ABE. We report the best solvent productivity among wild-type strains using column reactor. The maximum total solvent concentration of 14.32 g L(-1) was obtained at a dilution rate of 0.22 h(-1) with glucose as a substrate compared to 12.64 g L(-1) at 0.5 h(-1) dilution rate with sugar mixture. The maximum solvent productivity (13.66 g L(-1) h(-1)) was obtained at a dilution rate of 1.9 h(-1) with glucose as a substrate whereas solvent productivity (12.14 g L(-1) h(-1)) was obtained at a dilution rate of 1.5 h(-1) with sugar mixture. The immobilized column reactor with wood pulp can become an efficient technology to be integrated with existing pulp mills to convert them into wood-based bio-refineries.

Continuous acetone-butanol-ethanol fermentation using SO2-ethanol-water spent liquor from spruce.

SO2-ethanol-water (SEW) spent liquor from spruce chips was successfully used for batch and continuous production of acetone, butanol and ethanol (ABE). Initially, batch experiments were performed using spent liquor to check the suitability for production of ABE. Maximum concentration of total ABE was found to be 8.79 g/l using 4-fold diluted SEW liquor supplemented with 35 g/l of glucose. The effect of dilution rate on solvent production, productivity and yield was studied in column reactor consisting of immobilized Clostridium acetobutylicum DSM 792 on wood pulp. Total solvent concentration of 12 g/l was obtained at a dilution rate of 0.21 h(-1). The maximum solvent productivity (4.86 g/l h) with yield of 0.27 g/g was obtained at dilution rate of 0.64 h(-1). Further, to increase the solvent yield, the unutilized sugars were subjected to batch fermentation.

Continuous production of isopropanol and butanol using Clostridium beijerinckii DSM 6423.

Clostridium beijerinckii DSM 6423 was studied using different continuous production methods to give maximum and stable production of isopropanol and n-butanol. In a single-stage continuous culture, when wood pulp was added as a cell holding material, we could increase the solvent productivity from 0.47 to 5.52 g L⁻¹ h⁻¹ with the yield of 54% from glucose. The overall solvent concentration of 7.51 g L⁻¹ (39.4% isopropanol and 60.6% n-butanol) with the maximum solvent productivity of 0.84 g L⁻¹ h⁻¹ was obtained with two-stage continuous culture. We were able to run the process for more than 48 overall retention times without losing the ability to produce solvents.

Cyclosporin A--a review on fermentative production, downstream processing and pharmacological applications.

In present times, the immunosuppressants have gained considerable importance in the world market. Cyclosporin A (CyA) is a cyclic undecapeptide with a variety of biological activities including immunosuppressive, anti-inflammatory, antifungal and antiparasitic properties. CyA is produced by various types of fermentation techniques using Tolypocladium inflatum. In the present review, we discuss the biosynthetic pathway, fermentative production, downstream processing and pharmacological activities of CyA.

Statistical optimization for improved production of cyclosporin a in solid-state fermentation.

This work evaluates the effect of different amino acids on production of CyA production in solid-state fermentation that was previously optimized for different fermentation parameters by one-factor-at-a-time for the maximum production of CyA by Tolypocladium inflatum MTCC 557. Based on the Plackett-Burman design, glycerol, ammonium sulfate, FeCl3, and inoculum size were selected for further optimization by response surface methodology (RSM). After identifying effective nutrients, RSM was used to develop mathematical model equations, study responses, and establish the optimum concentrations of the key nutrients for higher CyA production. It was observed that supplementation of medium containing (% w/w) glycerol, 1.53; ammonium sulfate, 0.95; FeCl3, 0.18; and inoculum size 6.4 ml/5g yielded a maximum of 7,106 mg/kg as compared with 6,480 mg CyA/kg substrate using one factor at a time. In the second step, the effect of amino acids on the production of CyA was studied. Addition of L-valine and L-leucine in combination after 20 h of fermentation resulted in maximum production of 8,166 mg/kg.

Medium optimization by orthogonal array and response surface methodology for cholesterol oxidase production by Streptomyces lavendulae NCIM 2499.

This paper deals with the optimization of culture conditions for the production of cholesterol oxidase (COD) by Streptomyces lavendulae NCIM 2499 using the one-factor-at-a-time method, orthogonal array method and response surface methodology (RSM) approaches. The one-factor-at-a-time method was adopted to investigate the effects of medium components (i.e. carbon and nitrogen) and environmental factors (i.e. initial pH) on biomass growth and COD production. Subsequently, an L12 orthogonal matrix was used to evaluate the significance of glycerol, soyabean meal, malt extract, K2HPO4, MgSO4 and NaCl. The effects of media components were ranked according to their effects on the production of COD as malt extract > soyabean meal > K2HPO4 > NaCl > MgSO4 > glycerol. The subsequent optimization of the four most significant factors viz. malt extract, soyabean meal, K2HPO4 and NaCl, was carried out by employing a central composite rotatable design (CCRD) of RSM. There was a 2.48-fold increase in productivity of COD as compared to the unoptimized media by using these statistical approaches.

A novel medium for the enhanced production of cyclosporin A by Tolypocladium inflatum MTCC 557 using solid state fermentation.

Cyclosporin A (CyA) produced by Tolypocladium inflatum is a promising drug owing to its immunosuppressive and antifungal activities. From an industrial point of view, the necessity to obtain a suitable and economic medium for higher production of CyA was the aim of this work. The present study evaluated the effect of different fermentation parameters in solid state fermentation, such as selection of solid substrate, hydrolysis of substrates, initial moisture content, supplementation of salts, additional carbon, and nitrogen sources, as well as the inoculum age and size, on production of CyA by Tolypocladium inflatum MTCC 557. The fermentation was carried out at 25+/-2 degrees for 9 days. A combination of hydrolyzed wheat bran flour and coconut oil cake (1:1) at 70% initial moisture content supported a maximum production of 3,872+/-156 mg CyA/kg substrate as compared with 792+/-33 mg/kg substrate before optimization. Furthermore, supplementation of salts, glycerol (1%w/w), and ammonium sulfate (1%w/w) increased the production of CyA to 5,454+75 mg/kg substrate. Inoculation of 5 g of solid substrate with 6 ml of 72-h-old seed culture resulted in a maximum production of 6,480+95 mg CyA/kg substrate.