Factors to decrease the cellulose conversion of enzymatic hydrolysis of lignocellulose at high solid concentrations

The enzymatic hydrolysis of lignocelluloses is a key step in the production of ethanol. Economic considerations for large-scale implementation of the process require operation at high solid concentrations. However, the decrease in cellulose conversion offsets the advantages of working at high solid concentrations. The conversion showed a linear decrease in the reaction of pretreated corn stover (PCS) from 2 to 20 % (w/w) and filter paper from 1 to 10 % (w/w) initial total solid content. Hydrolysis experiments with PCS at various mixing speeds showed that the mass transfer limitation could not restrict the cellulose conversion except the solid concentrations over 5 % DM(w/w). The lignin, if added separately, does not correspond directly to the decrease. At increased concentrations, furfural and 5-hydroxymethylfurfural played a part in the effect, and 5-hydroxymethylfurfural only affected exoglucanase. Product inhibition caused by glucose accumulation at increased solid concentrations was found to be a significant and perhaps principal factor. The decrease in yield was caused by the synergetic inhibition, which was more serious with increased solid concentrations.     

Modeling the enzymatic hydrolysis of dilute-acid pretreated Douglas Fir

Glucose yield from the enzymatic hydrolysis of cellulose was investigated as a function of cellulase enzyme loading (7–36 filter paper units [FPU]/g cellulose) and solids concentration (7–18% total solids) for up to 72 h on dilute sulfuric-acid pretreated Douglas Fir. The saccharification was performed on whole hydrolysate with no separation or washing of the solids. Enzyme loading had a significant effect on glucose yield; solids concentration had a much smaller effect even at higher glucose concentrations. The data were used to generate an empirical model for glucose yield, and to fit parameters of a cellulose hydrolysis kinetic model. Both models could be used for economic evaluation of a separate hydrolysis and fermentation process.     

Deficiency of Cellulase Activity Measurements for Enzyme Evaluation

Switchgrass was used as a model feedstock to determine the influence of pretreatment conditions and biomass quality on enzymatic hydrolysis using different enzyme products. Dilute sulfuric acid and soaking in aqueous ammonia pretreatments were used to produce biomass with varied levels of hemicellulose and lignin sheathing. Pretreated switchgrass solids were tested with simple enzymatic hydrolysis and simultaneous saccharification and fermentation (SSF) with three commercial enzyme products: Accellerase 1000 (Genencor), Spezyme CP (Genencor)/Novozyme 188 (Novozymes), and Celluclast/Novozyme 188 (Novozymes). Enzymes were loaded on a common activity basis (FPU/g cellulose and CBU/g cellulose). Despite identical enzyme loadings, glucose yields were significantly different for both acid and alkaline pretreatments but differences diminished as hydrolysis progressed for acid-pretreated biomass. Cellobiose concentrations in Accellerase treatments indicated an initial β-glucosidase limitation that became less significant over time. SSF experiments showed that differences in glucose and ethanol yields could not be attributed to enzyme product inhibition. Yield discrepancies of glucose or ethanol in acid pretreatment, alkaline pretreatment, and acid pretreatment/SSF were as much as 15%, 19%, and 5%. These results indicate that standardized protocols for measuring enzyme activity may not be adequate for assessing activity using pretreated biomass substrates.     

Simultaneous Enzymatic Cellulose Hydrolysis and Product Separation in a Radial-Flow Membrane Bioreactor

Hydrolysis is the heart of the lignocellulose-to-bioethanol conversion process. Using enzymes to catalyze the hydrolysis represents a more environmentally friendly pathway compared to other techniques. However, for the process to be economically feasible, solving the product inhibition problem and enhancing enzyme reusability are essential. Prior research demonstrated that a flat-sheet membrane bioreactor (MBR), using an inverted dead-end filtration system, could achieve 86.7% glucose yield from purified cellulose in 6 h. In this study, the effectiveness of flat-sheet versus radial-flow MBR designs was assessed using real, complex lignocellulose biomass, namely date seeds (DSs). The tubular radial-flow MBR used here had more than a 10-fold higher membrane surface area than the flat-sheet MBR design. With simultaneous product separation using the flat-sheet inverted dead-end filtration MBR, a glucose yield of 10.8% from pretreated DSs was achieved within 8 h of reaction, which was three times higher than the yield without product separation, which was only 3.5% within the same time and under the same conditions. The superiority of the tubular radial-flow MBR to hydrolyze pretreated DSs was confirmed with a glucose yield of 60% within 8 h. The promising results obtained by the novel tubular MBR could pave the way for an economic lignocellulose-to-bioethanol process.     

Alkali (NaOH) Pretreatment of Switchgrass by Radio Frequency-based Dielectric Heating

Radio-frequency (RF)-based dielectric heating was used in the alkali (NaOH) pretreatment of switchgrass to enhance its enzymatic digestibility. Due to the unique features of RF heating (i.e., volumetric heat transfer, deep heat penetration of the samples, etc.), switchgrass could be treated on a large scale, high solid content, and uniform temperature profile. At 20% solid content, RF-assisted alkali pretreatment (at 0.1 g NaOH/g biomass loading and 90°C) resulted in a higher xylose yield than the conventional heating pretreatment. The enzymatic hydrolysis of RF-treated solids led to a higher glucose yield than the corresponding value obtained from conventional heating treatment. When the solid content exceeded 25%, conventional heating could not handle this high-solid sample due to the loss of fluidity, poor mixing, and heating transfer of the samples. As a result, there was a significantly lower sugar yield, but the sugar yield of the RF-based pretreatment process was still maintained at high levels. Furthermore, the optimal particle size and alkali loading in the RF pretreatment was determined as 0.25–0.50 mm and 0.25 g NaOH/g biomass, respectively. At alkali loading of 0.20–0.25 g NaOH/g biomass, heating temperature of 90^oC, and solid content of 20%, the glucose, xylose, and total sugar yield from the combined RF pretreatment and the enzymatic hydrolysis were 25.3, 21.2, and 46.5 g/g biomass, respectively.     

High Solids Enzymatic Hydrolysis of Pretreated Lignocellulosic Materials with a Powerful Stirrer Concept

In this study, we present a powerful stirred tank reactor system that can efficiently hydrolyse lignocellulosic material at high solid content to produce hydrolysates with glucose concentration > 100 g/kg. As lignocellulosic substrates alkaline-pretreated wheat straw and organosolv-pretreated beech wood were used. The developed vertical reactor was equipped with a segmented helical stirrer, which was specially designed for high biomass hydrolysis. The stirrer was characterised according to mixing behaviour and power input. To minimise the cellulase dosage, a response surface plan was used. With the empirical relationship between glucose yield, cellulase loading and solid content, the minimal cellulase dosage was calculated to reach at least 70 % yield at high glucose and high substrate concentrations within 48 h. The optimisation resulted in a minimal enzyme dosage of 30 FPU/g dry matter (DM) for the hydrolysis of wheat straw and 20 FPU/g DM for the hydrolysis of beech wood. By transferring the hydrolysis reaction from shaking flasks to the stirred tank reactor, the glucose yields could be increased. Using the developed stirred tank reactor system, alkaline-pretreated wheat straw could be converted to 110 g/kg glucose (76 %) at a solid content of 20 % (w/w) after 48 h. Organosolv-pretreated beech wood could be efficiently hydrolysed even at 30 % (w/w) DM, giving 150 g/kg glucose (72 %).     

Determination of mercury(II) by invertase enzyme inhibition coupled with batch injection analysis

The determination of mercury(II) ions at the trace level by inhibition of the invertase enzyme-catalysed hydrolysis of sucrose into glucose and fructose coupled to electrochemical batch injection analysis was investigated using two approaches. In the first, the glucose produced was detected by injection of 100 microliters samples into the batch injection cell containing a platinum electrode modified by immobilised glucose oxidase. In the second, the glucose and fructose present in injected samples were oxidised directly at a copper-modified glassy carbon electrode. The experimental parameters were optimised and the degree of enzyme inhibition by mercury(II) ions under both conditions was measured. Mercury concentrations in the ng ml-1 range were determined by these two techniques with low sample and reagent consumption. Comparison is made between the two methods and perspectives as a screening test for field application are indicated.     

Influence of High Solid Concentration on Enzymatic Hydrolysis and Fermentation of Steam-Exploded Corn Stover Biomass

Steam-exploded corn stover biomass was used as the substrate for fed-batch separate enzymatic hydrolysis and fermentation (SHF) to investigate the solid concentration ranging from 10% to 30% (w/w) on the lignocellulose enzymatic hydrolysis and fermentation. The treatment of washing the steam-exploded material was also evaluated by experiments. The results showed that cellulose conversion changed little with increasing solid concentration, and fermentation by Saccharomyces cerevisiae revealed a nearly same ethanol yield with the water-washed steam-exploded corn stover. For the washed material at 30% substrate concentration, i.e., 30% water insoluble solids (WIS), enzymatic hydrolysis yielded 103.3 g/l glucose solution and a cellulose conversion of 72.5%, thus a high ethanol level up to 49.5 g/l. With the unwashed steam-exploded corn stover, though a cellulose conversion of 70.9% was obtained in hydrolysis at 30% solid concentration (27.9% WIS), its hydrolysate did not ferment at all, and the hydrolysate of 20% solid loading containing 3.3 g/l acetic acid and 145 mg/l furfural already exerted a strong inhibition on the fermentation and ethanol production.     

Solid state polymerization of poly(lactic acid): Some fundamental parameters

Poly(lactic acid) (PLA) was submitted to solid state polymerization (SSP) in a fixed bed reactor under nitrogen flow, so as to examine technique efficiency for increasing the molecular weight and hence permitting the reduction of the melt polymerization residence times. In order to use a suitable starting material, SSP prepolymers of low and medium molecular weight were first prepared through solid state hydrolysis of commercial PLA grade under acidic and alkaline conditions. During these degradation runs, hydrolysis involved the random scission of ester groups in the polymer backbone, while the relevant kinetics and the resulting thermal properties were also examined. In a subsequent step, the prepolymers obtained were subjected to SSP at three temperatures, approximately 2.5–25.0 °C below their melting point. The process achieved an increase of up to 1.7 times the initial molecular weight, however, with different trends depending on the prepolymer characteristics, reaction temperature and time, as well as the pH of the hydrolysis medium. In addition to molecular weight build up, the effect of the SSP process on end product thermal properties was also investigated.     

Kinetic Study of Empty Fruit Bunch Using Hot Liquid Water and Dilute Acid

Empty fruit bunch (EFB), a residual product of the palm plantation, is an attractive biomass for biorefinery. As xylan is susceptible to high temperature pretreatment, it is important to setup a proper pretreatment condition to maximize the sugar recovery from EFB. Kinetic parameters of mathematical models were obtained in order to predict the concentration of xylose, glucose, furfural, and acetic acid in the hydrolysate and to find production conditions of xylose. We investigated the kinetics of hot liquid water and dilute sulfuric acid hydrolysis over a 40-min period using a self-designed setup by measuring the concentrations of released sugars (xylose, glucose) and degradation products (acetic acid and furfural). The reaction was performed within the range 160～180 °C, under reaction conditions of various concentration of sulfuric acid (0.1～0.2%) and 1:7 solid-liquid ratio in a batch reactor. The kinetic constants can be expressed by the Arrhenius equation with the activation energy for the hydrolysis of sugar and decomposition of sugar. The activation energy of xylose was determined to be 136.2187 kJ mol(-1).     

Enzymatic Hydrolysis and Succinic Acid Fermentation from Steam-Exploded Corn Stalk at High Solid Concentration by Recombinant Escherichia coli

Steam-exploded corn stalk biomass was used as the substrate for succinic acid production via lignocellulose enzymatic hydrolysis and fermentation. Succinic acid fermentation was investigated in Escherichia coli strains overexpressing cyanobacterium Anabaena sp. 7120 ecaA gene encoding carbonic anhydrase (CA). For the washed steam-exploded corn stalk at 30 % substrate concentration, i.e., 30 % water-insoluble solids (WIS), enzymatic hydrolysis yielded 97.5 g/l glucose solution and a cellulose conversion of 73.6 %, thus a high succinic acid level up to 38.6 g/l. With the unwashed steam-exploded corn stalk, though a cellulose conversion of 71.2 % was obtained in hydrolysis at 30 % solid concentration (27.9 % WIS), its hydrolysate did not ferment at all, and the hydrolysate of 25 % solid loading containing 3.8 g/l acetic acid and 168.2 mg/l furfural exerted a strong inhibition on succinic acid production.     

A Dynamic Model for Cellulosic Biomass Hydrolysis: a Comprehensive Analysis and Validation of Hydrolysis and Product Inhibition Mechanisms

The objective of this study is to perform a comprehensive enzyme kinetics analysis in view of validating and consolidating a semimechanistic kinetic model consisting of homogeneous and heterogeneous reactions for enzymatic hydrolysis of lignocellulosic biomass proposed by the U.S. National Renewable Energy Laboratory (Kadam et al., Biotechnol Prog 20(3):698–705, 2004) and its variations proposed in this work. A number of dedicated experiments were carried out under a range of initial conditions (Avicel® versus pretreated barley straw as substrate, different enzyme loadings and different product inhibitors such as glucose, cellobiose and xylose) to test the hydrolysis and product inhibition mechanisms of the model. A nonlinear least squares method was used to identify the model and estimate kinetic parameters based on the experimental data. The suitable mathematical model for industrial application was selected among the proposed models based on statistical information (weighted sum of square errors). The analysis showed that transglycosylation plays a key role at high glucose levels. It also showed that the values of parameters depend on the selected experimental data used for parameter estimation. Therefore, the parameter values are not universal and should be used with caution. The model proposed by Kadam et al. (Biotechnol Prog 20(3):698–705, 2004) failed to predict the hydrolysis phenomena at high glucose levels, but when combined with transglycosylation reaction(s), the prediction of cellulose hydrolysis behaviour over a broad range of substrate concentrations (50–150 g/L) and enzyme loadings (15.8–31.6 and 1–5.9 mg protein/g cellulose for Celluclast and Novozyme 188, respectively) was possible. This is the first study introducing transglycosylation into the semimechanistic model. As long as these type of models are used within the boundary of their validity (substrate type, enzyme source and substrate concentration), they can support process design and technology improvement efforts at pilot and full-scale studies.     

Monitoring temporal evolution of silicate species during hydrolysis and condensation of silicates using mass spectrometry

The first stages of solid-state formation from solution can be crucial in determining the properties of the resulting solids. We are trying to approach prenucleation reactions of silicates from an aqueous solution containing tetraalkylammoniumhydroxides (TAAOH) and tetraalkoxysilanes (TAOS) by analyzing hydrolysis and condensation using electrospray mass spectrometry (ESI MS). Time-resolved measurements were performed using different reactor systems to show the stepwise hydrolysis of the silanes and subsequent condensation of silicate monomers via oligomers to form larger units. We approached the precipitation point by varying the pH and the concentrations of the reactants. The results show the evolution of different silicate species occurring during condensation. No defined molecular entities were identified at pH values close to precipitation, which suggests that under the conditions used, solids are probably not formed from defined building blocks.     

Adding value to the Brazilian sisal: acid hydrolysis of its pulp seeking production of sugars and materials

The present work is inserted into the broad context of the upgrading of lignocellulosic fibers. Sisal was chosen in the present study because more than 50% of the world’s sisal is cultivated in Brazil, it has a short life cycle and its fiber has a high cellulose content. Specifically, in the present study, the subject addressed was the hydrolysis of the sisal pulp, using sulfuric acid as the catalyst. To assess the influence of parameters such as the concentration of the sulfuric acid and the temperature during this process, the pulp was hydrolyzed with various concentrations of sulfuric acid (30–50%) at 70 °C and with 30% acid (v/v) at various temperatures (60–100 °C). During hydrolysis, aliquots were withdrawn from the reaction media, and the solid (non-hydrolyzed pulp) was separated from the liquid (liquor) by filtering each aliquot. The sugar composition of the liquor was analyzed by HPLC, and the non-hydrolyzed pulps were characterized by viscometry (average molar mass), and X-ray diffraction (crystallinity). The results support the following conclusions: acid hydrolysis using 30% H₂SO₄ at 100 °C can produce sisal microcrystalline cellulose and the conditions that led to the largest glucose yield and lowest decomposition rate were 50% H₂SO₄ at 70 °C. In summary, the study of sisal pulp hydrolysis using concentrated acid showed that certain conditions are suitable for high recovery of xylose and good yield of glucose. Moreover, the unreacted cellulose can be targeted for different applications in bio-based materials. A kinetic study based on the glucose yield was performed for all reaction conditions using the kinetic model proposed by Saeman. The results showed that the model adjusted to all 30–35% H₂SO₄ reactions but not to greater concentrations of sulfuric acid. The present study is part of an ongoing research program, and the results reported here will be used as a comparison against the results obtained when using treated sisal pulp as the starting material.     

The effects of water interactions in cellulose suspensions on mass transfer and saccharification efficiency at high solids loadings

Water is essential to the hydrolysis and conversion of lignocellulosic materials as it is both the medium through which enzymes diffuse to and products diffuse away from the reaction sites and a reactant in the hydrolysis reaction of the glycosidic bonds within the polysaccharides. However, little is known about how water interactions with the biomass change with solids content and how this affects mass transfer resistances during high solids saccharification. Nuclear magnetic resonance spectroscopy measurements of the T ₂ relaxation times of water in cellulose suspensions were used to demonstrate that increases in solids content led to increases in the physical constraint of water in the suspensions. Moreover, the addition of either glucose (a monosaccharide which end-product inhibits β-glucosidase) or mannose (a stereoisomer of glucose that does not end-product inhibit β-glucosidase) further increased water constraint at all solids contents. The presence of either monosaccharide constrained water and inhibited saccharification rates to similar extents. This observation, coupled with the absence of cellobiose produced in the reactions, demonstrated that the presence of soluble sugars can negatively impact saccharification efficiency simply by increasing water constraint in cellulose suspensions before impacting enzyme activity. Furthermore, results are presented that demonstrate strong correlations between water constraint in cellulose suspensions with diffusivities of enzyme and monosaccharides within the system. These results are discussed in the context of increased viscosity of the aqueous fraction in the suspension resulting from increased water-cellulose and water-solute interactions that ultimately increases diffusion resistances and decreases saccharification rates.     

Escherichia coli-catalyzed bioelectrochemical oxidation of acetate in the presence of mediators

Bioelectrocatalytic oxidation of acetate was investigated under anaerobic conditions by using Escherichia coli K-12 (IFO 3301) cells cultured on aerobic media containing poly-peptone, glucose or acetate as the sole carbon source. It was found that all E. coli cells cultured on the three media work as good catalysts of the electrochemical oxidation of acetate as well as glucose with Fe(CN)6(3-), 2,3-dimethoxy-5-methyl-1,4-benzo-quinone (Q0), 2,6-dichloro-indophenol, or 2-methyl-1,4-naphthoquinone as artificial electron acceptors (mediators). Acetate-grown E. coli cells exhibited the highest relative activity of the acetate oxidation against the glucose oxidation. On the other hand, all the artificial electron acceptors used work as inhibitors for the catalytic oxidation of acetate at increased concentrations. The inhibition phenomenon can be interpreted in terms of competitive substrate inhibition as a whole. Apparent values of Michaelis constant, catalytic constant, and inhibition constant were evaluated by amperometric methods. Q0 is an effective artificial mediator as evidenced by a large reaction rate constant between the cell and Q0 at least at low concentrations (<50 microM). However, Fe(CN)6(3-) is a promising mediator in biosensor applications because the inhibition constant is very large and it works as an electron acceptor even under aerobic conditions.     

Process Evaluation of Enzymatic Hydrolysis with Filtrate Recycle for the Production of High Concentration Sugars

Process simulation and lab trials were carried out to demonstrate and confirm the efficiency of the concept that recycling hydrolysate at low total solid enzymatic hydrolysis is one of the options to increase the sugar concentration without mixing problems. Higher sugar concentration can reduce the capital cost for fermentation and distillation because of smaller retention volume. Meanwhile, operation cost will also decrease for less operating volume and less energy required for distillation. With the computer simulation, time and efforts can be saved to achieve the steady state of recycling process, which is the scenario for industrial production. This paper, to the best of our knowledge, is the first paper discussing steady-state saccharification with recycling of the filtrate form enzymatic hydrolysis to increase sugar concentration. Recycled enzymes in the filtrate (15–30% of the original enzyme loading) resulted in 5–10% higher carbohydrate conversion compared to the case in which recycled enzymes were denatured. The recycled hydrolysate yielded 10% higher carbohydrate conversion compared to pure sugar simulated hydrolysate at the same enzyme loading, which indicated hydrolysis by-products could boost enzymatic hydrolysis. The high sugar concentration (pure sugar simulated) showed inhibition effect, since about 15% decrease in carbohydrate conversion was observed compared with the case with no sugar added. The overall effect of hydrolysate recycling at WinGEMS simulated steady-state conditions with 5% total solids was increasing the sugar concentration from 35 to 141 g/l, while the carbohydrate conversion was 2% higher for recycling at steady state (87%) compared with no recycling strategy (85%). Ten percent and 15% total solid processes were also evaluated in this study.     

Imidazole Processing of Wheat Straw and Eucalyptus Residues—Comparison of Pre-Treatment Conditions and Their Influence on Enzymatic Hydrolysis

Biomass pre-treatment is a key step in achieving the economic competitiveness of biomass conversion. In the present work, an imidazole pre-treatment process was performed and evaluated using wheat straw and eucalyptus residues as model feedstocks for agriculture and forest-origin biomasses, respectively. Results showed that imidazole is an efficient pre-treatment agent; however, better results were obtained for wheat straw due to the recalcitrant behavior of eucalyptus residues. The temperature had a stronger effect than time on wheat straw pre-treatment but at 160 °C and 4 h, similar results were obtained for cellulose and hemicellulose content from both biomasses (ca. 54% and 24%, respectively). Lignin content in the pre-treated solid was higher for eucalyptus residues (16% vs. 4%), as expected. Enzymatic hydrolysis, applied to both biomasses after different pre-treatments, revealed that results improved with increasing temperature/time for wheat straw. However, these conditions had no influence on the results for eucalyptus residues, with very low glucan to glucose enzymatic hydrolysis yield (93% for wheat straw vs. 40% for eucalyptus residues). Imidazole can therefore be considered as a suitable solvent for herbaceous biomass pre-treatment.     

Sweet Sorghum as Feedstock for Ethanol Production: Enzymatic Hydrolysis of Steam-Pretreated Bagasse

Sweet sorghum is an attractive feedstock for ethanol production. The juice extracted from the fresh stem is composed of sucrose, glucose, and fructose and can therefore be readily fermented to alcohol. The solid fraction left behind, the so-called bagasse, is a lignocellulosic residue which can also be processed to ethanol. The objective of our work was to test sweet sorghum, the whole crop, as a potential raw material of ethanol production, i.e., both the extracted sugar juice and the residual bagasse were tested. The juice was investigated at different harvesting dates for sugar content. Fermentability of juices extracted from the stem with and without leaves was compared. Sweet sorghum bagasse was steam-pretreated using various pretreatment conditions (temperatures and residence times). Efficiency of pretreatments was characterized by the degree of cellulose hydrolysis of the whole pretreated slurry and the separated fiber fraction. Two settings of the studied conditions (190 °C, 10 min and 200 °C, 5 min) were found to be efficient to reach conversion of 85–90%.     

Electrochemical properties of hydrophilic weak-acid membranes from hydrolysed polyacrylonitrile—I. Effect of cross-linking and chemical composition

Gels cross-linked to various degrees and containing various amounts of nitrile, amide and carboxylic groups were prepared by polymerizing acrylonitrile at various concentrations in aqueous 70 per cent ZnCl₂ solution and by hydrolysis of polymers for various times in HCl vapours. Chemical characteristics of gels, concentration membrane potentials, membrane functions and permselectivities in KCl solutions were determined. It was proved that under the conditions used (pH close to 7, content of acrylic acid in the copolymer only 1·4–3·9 mole %). cross-linking is the decisive factor for permselectivity and ideality of the membrane functions. Cross-linking yielded almost 100 per cent permselectivity values and a slope of the membrane function of about 55 mV/decade. Further hydrolysis impairs the ideality of membranes, since the increase in swelling outweighs the effect of the increase in concentration of the active groups. Variability of the density of the ionizable groups is not sufficient to explain differences in the behaviour of the membranes under investigation.