Perspectives on bioenergy and biotechnology in Brazil

Brazil is one of the world’s largest producers of alcohol from biomass at low cost and is responsible for more than 1 million direct jobs. In 1973, the Brazilian Program of Alcohol (Proalcool) stimulated the creation of a bioethanol industry that has led to large economic, social, and scientific improvements. In the year 1984, 94.5% of Brazil’s cars used bioethanol as fuel. In 2003/2004, 350.3 million of sugarcane produced 24.2 million t of sugar and 14.4 billion L of ethanol for an average 4.3 million cars using ethanol. Since its inception, cumulative investment in Proalcool totals US$11 billion, and Brazil has saved US$27 billion in oil imports. The ethanol production industry from sugarcane generates 152 times more jobs than would have been the case if the same amount of fuel was produced from petroleum, and the use of ethanol as a fuel is advantageous for environmental reasons. In 2003, one of the biggest Brazilian ethanol industries started consuming 50% of the residual sugarcane bagasse to produce electrical energy (60 MW), a new alternative use of bioenergy for the Brazilian market. Other technologies for commercial uses of bagasse are in development, such as in the production of natural fibers, sweeteners (glucose and xylitol), single-cell proteins, lactic acid, microbial enzymes, and many other products based on fermentations (submerged and semisolid). Furthermore, studies aimed at the increase in the biosynthesis of sucrose and, consequently, ethanol productivity are being conducted to understand the genetics of sugarcane. Although, at present, there remain technical obstacles to the economic use of some ethanol industry residues, several research projects have been carried out and useful data generated. Efficient utilization of ethanol industry residues has created new opportunities for new value-added products, especially in Brazil, where they are produced in high quantities.     

Ethanol from babassu coconut starch

This study describes a pioneering industrial-scale experience by Tobasa in ethanol production from the amylaceous flour obtained by mechanical processing of the babassu mesocarp. Technical aspects related to enzymatic and fermentation processes, as well as overall economical aspects, are discussed. When produced in a small-size industrial plant (5000 L/d), babassu ethanol has a final cost of about $218/m³. The impact of raw materials, production, and processing (enzymes, steam, energy, and so on) on the final product cost is also presented. Babassu coconut ethanol can be produced at low cost, compared with traditional starchy raw materials or sugar cane. The net profitability of ethanol production is about 40% for babassu coconut and just 10% for sugar cane. If the estimated renewable babassu resources were entirely industrially used, 1 billion L/yr of ethanol could be produced, which would roughly correspond to 8% of the current Brazilian ethanol production.

     

Alternative approach for utilization of pentose stream from sugarcane bagasse by an induced flocculent Pichia stipitis

A new approach for the utilization of hemicellulosic hydrolysate from sugarcane bagasse is described. This approach consists of using the hydrolysate to dilute the conventional feedstock (sugarcane juice) to the usual sugar concentration (150 g/L) employed for the industrial production of ethanol. The resulting sugar mixture was used as the substrate to evaluate the performance of a continuous reactor incorporating a cell recycle module, operated at several dilution rates. An induced flocculent pentose-fermenting yeast strain was used for this bioconversion. Under the conditions used, the reactor performance was satisfactory at substrate feed rates of 30 g/(L·h) or less, corresponding to an ethanol productivity of about 11.0 g/(L·h) and an overall sugar conversion >95%. These results show real advantages over the existing alternatives for a better exploitation of surplus bagasse to increase industrial alcohol production.     

Improvement of Ethanol Production Using <Emphasis Type="Italic">Saccharomyces cerevisiae</Emphasis> by Enhancement of Biomass and Nutrient Supplementation

Optimization of ethanol production through addition of substratum and protein-lipid additives was studied. Oilseed meal extract was used as protein lipid supplement, while rice husk was used as substratum. The effect of oil seed meal extract and rice husk was observed at varying concentration of medium sugar from 8% to 20%. Of the three oil seed meal extracts used, viz. groundnut, safflower, and sunflower, safflower was found to be most efficient. The use of oilseed meal extract at 4% was found to enhance ethanol production by almost 50% and enhanced sugar tolerance from 8% to 16%. A further increase of almost 48% ethanol was observed on addition of 2 g of rice husk per 100 ml of medium. An increase in cell mass with better sugar attenuation was observed. Further optimization was sought through use of sugarcane juice as the sugar source. While 8.9% ethanol yield with 75% sugar attenuation was observed at 20% sucrose concentration, it was found to increase to 12% (v/v) with almost complete utilization of medium sugar when sugarcane juice was used. Cell weight was also observed to increase by 26%.     

Production of Astaxanthin from Cellulosic Biomass Sugars by Mutants of the Yeast <Emphasis Type="Italic">Phaffia rhodozyma</Emphasis>

Astaxanthin is a potential high-value coproduct in an ethanol biorefinery. Three mutant strains of the astaxanthin-producing yeast Phaffia rhodozyma, which were derived from the parent strain ATCC 24202 (UCD 67-210) and designated JTM166, JTM185, and SSM19, were tested for their capability of utilizing the major sugars that can be generated from cellulosic biomass, including glucose, xylose, and arabinose, for astaxanthin production. While all three strains were capable of metabolizing these sugars, individually and in mixtures, JTM185 demonstrated the greatest sugar utilization and astaxanthin production. Astaxanthin yield by this strain (milligrams astaxanthin per gram of sugar consumed) was highest for xylose, followed by arabinose and then glucose. The kinetics of sugar utilization by strain JTM185 was studied in fermenters using mixtures of glucose, xylose, and arabinose at varied concentrations. It was found that glucose was utilized preferentially, followed by xylose, and lastly, arabinose. Astaxanthin yield was significantly affected by sugar concentrations. Highest yields were observed with sugar mixtures containing the highest concentrations of xylose and arabinose. Hydrolysates produced from sugarcane bagasse and barley straw pretreated by the soaking in aqueous ammonia method and hydrolyzed with the commercial cellulase preparation, Accellerase™ 1000, were used for astaxanthin production by the mutant strain JTM185. The organism was capable of metabolizing all of the sugars present in the hydrolysates from both biomass sources and produced similar amounts of astaxanthin from both hydrolysates, although these amounts were lower when compared to yields obtained with reagent grade sugars.     

Conversion of distiller's grain into fuel alcohol and a higher-value animal feed by dilute-acid pretreatment

Over the past three decades ethanol production in the United States has increased more than 10-fold, to approx 2.9 billion gal/yr (mid-2003), with ethanol production expected to reach 5 billion gal/yr by 2005. The simultaneous coproduction of 7 million t/yr of distiller's grain (DG) may potentially drive down the price of DG as a cattle feed supplement. The sale of residual DG for animal feed is an important part of corn dry-grind ethanol production economics; therefore, dry-grind ethanol producers are seeking ways to improve the quality of DG to increase market penetration and help stabilize prices. One possible improvement is to increase the protein content of DG by converting the residual starch and fiber into ethanol. We have developed methods for steam explosion, SO₂, and dilute-sulfuric acid pretreatment of DG for evaluation as a feedstock for ethanol production. The highest soluble sugar yields (∼77% of available carbohydrate) were obtained by pretreatment of DG at 140°C for 20 min with 3.27 wt% H₂SO₄. Fermentation protocols for pretreated DG were developed at the bench scale and scaled to a working volume of 809 L for production of hydrolyzed distiller's grain (HDG) for feeding trials. The pretreated DG was fermented with Saccharomyces cerevisiae D₅A, with ethanol yields of 73% of theoretical from available glucans. The HDG was air-dried and used for turkey-feeding trials. The inclusion of HDG into turkey poult (as a model non-ruminant animal) diets at 5 and 10% levels, replacing corn and soybean meal, showed weight gains in the birds similar to controls, whereas 15 and 20% inclusion levels showed slight decreases (−6%) in weight gain. At the conclusion of the trial, no negative effects on internal organs or morphology, and no mortality among the poults, was found. The high protein levels (58–61%) available in HDG show promising economics for incorporation of this process into corn dry-grind ethanol plants.     

Current status of biodiesel development in Brazil

In recent years, the concept of producing biodiesel from renewable lipid sources has regained international attention. In Brazil, a national program was launched in 2002 to evaluate the technical, economic, and environmental competitiveness of biodiesel in relation to the commercially available diesel oil. Several research projects were initiated nationwide to investigate and/or optimize biodiesel production from renewable lipid sources and ethanol derived from sugarcane (ethyl esters). Once implemented, this program will not only decrease our dependence on petroleum derivatives but also create new market opportunities for agribusiness, opening new jobs in the countryside, improving the sustainability of our energy matrix, and helping the Brazilian government to support important actions against poverty. This article discusses the efforts to develop the Brazilian biodiesel program in the context of technical specifications as well as potential oilseed sources.     

Improvement Production of Hyaluronic Acid by Streptococcus zooepidemicus in Sugarcane Molasses

Microbial hyaluronic acid (HA) production has been preferred rather than extraction from animal tissue for medical and cosmetic applications. In this context, to obtain an economically competitive HA production by Streptococcus zooepidemicus, culture conditions were studied to improve the polymer production in sugarcane molasses. The highest HA production by S. zooepidemicus ATCC 39920 achieved was 2.825 g. L⁻¹ in a 4.5 L bioreactor with controlled pH (8.0) and medium containing molasses (85.35 g.L⁻¹ total sugar) pretreated with activated charcoal and yeast extract (50 g.L⁻¹). The HA produced exhibited a high molecular weight of 1.35 × 10³ kDa and the DPPH radical scavenging activity of the polymer at 1 g.L⁻¹ was 41 %. The FTIR and UV-Vis spectra showed no substantial differences in the spectral pattern between produced and standard HA. This study is a promising strategy for sugarcane molasses application by producing high value-added products such as hyaluronic acid.

     

Enzymatic hydrolysis optimization to ethanol production by simultaneous saccharification and fermentation

There is tremendous interest in using agro-industrial wastes, such as cellulignin, as starting materials for the production of fuels and chemicals. Cellulignin are the solids, which result from the acid hydrolysis of the sugarcane bagasse. The objective of this work was to optimize the enzymatic hydrolysis of the cellulose fraction of cellulignin, and to study its fermentation to ethanol using Saccharomyces cerevisiae. Cellulose conversion was optimized using response surface methods with pH, enzyme loading, solid percentage, and temperature as factor variables. The optimum conditions that maximized the conversion of cellulose to glucose, calculated from the initial dried weight of pretreated cellulignin, (43 degrees C, 2%, and 24.4 FPU/g of pretreated cellulignin) such as the glucose concentration (47 degrees C, 10%, and 25.6 FPU/g of pretreated cellulignin) were found. The desirability function was used to find conditions that optimize both, conversion to glucose and glucose concentration (47 degrees C, 10%, and 25.9 FPU/g of pretreated cellulignin). The resulting enzymatic hydrolyzate was fermented yielding a final ethanol concentration of 30.0 g/L, in only 10 h, and reaching a volumetric productivity of 3.0 g/L x h, which is close to the values obtained in the conventional ethanol fermentation of sugar cane juice (5.0-8.0 g/L x h) in Brazil.     

Inulinase production by Kluyveromyces marxianus NRRL Y-7571 using solid state fermentation

Inulinase is an enzyme relevant to fructose production by enzymatic hydrolysis of inulin. This enzyme is also applied in the production of fructo-oligosaccharides that may be used as a new food functional ingredient. Commercial inulinase is currently obtained using inulin as substrate, which is a relatively expensive raw material. In Brazil, the production of this enzyme using residues of sugarcane and corn industry (sugarcane bagasse, molasses, and corn steep liquor) is economically attractive, owing to the high amount and low cost of such residues. In this context, the aim of this work was the assessment of inulinase production by solid state fermentation using by Kluyveromyces marxianus NRRL Y-7571. The solid medium consisted of sugar cane bagasse supplemented with molasses and corn steep liquor. The production of inulinase was carried out using experimental design technique. The effect of temperature, moisture, and supplements content were investigated. The enzymatic activity reached a maximum of 445 units of inulinase per gram of dry substrate.     

Optimization of steam pretreatment of corn stover to enhance enzymatic digestibility

Among the available agricultural byproducts, corn stover, with its yearly production of 10 million t (dry basis), is the most abundant promising raw material for fuel ethanol production in Hungary. In the United States, more than 216 million to fcorn stover is produced annually, of which a portion also could possibly be collected for conversion to ethanol. However, a network of lignin and hemicellulose protects cellulose, which is the major source of fermentable sugars in corn stover (approx 40% of the dry matter [DM]). Steam pretreatment removes the major part of the hemicellulose from the solid material and makes the cellulose more susceptible to enzymatic digestion. We studied 12 different combinations of reaction temperature, time, and pH during steam pretreatment. The best conditions (200°C, 5 min, 2% H₂SO₄) increased the enzymatic conversion (from cellulose to glucose) of corn stover more then four times, compared to untreated material. However, steam pretreatment at 190°C for 5 min with 2% sulfuric acid resulted in the highest overall yield of sugars, 56.1 g from 100 g of untreated material (DM), corresponding to 73% of the theoretical. The liquor following steam explosion was fermented using Saccharomyces cerevisiae to investigate the inhibitory effect of the pretreatment. The achieved ethanol yield was slightly higher than that obtained with a reference sugar solution. This demonstrates that baker's yeast could adapt to the pretreated liquor and ferment the glucose to ethanol efficiently.     

The possibility of using beef tallow biodiesel as a viscosity reference material

This study analyses the possibility of using beef tallow biodiesel transesterified with ethanol, provided by Universidade Federal Fluminense, as a viscosity reference material for biodiesels. The quantity viscosity was measured with capillary viscometers, according to Brazilian standards, in a temperature range between 20 °C and 40 °C for characterisation, and at 40 °C for homogeneity, in short-term stability (90 days) and long-term stability (450 days). Thirty-nine samples were stored, 9 at 45 °C, 6 at 4 °C and 24 at 20 °C. The behaviour of viscosity is analysed considering the estimated uncertainty of measurements for characterisation, homogeneity and stability. The reason to study a transesterified biofuel with ethanol lies in the fact that it is easy to produce this fluid from sugarcane in Brazil.     

Ethanol,the ultimate feedstock

Ethanol appears to be a key factor in the “biomass alternative” to fossil feedstocks for producing fuels and chemicals. If produced at a low enough price relative to crude oil, it and its derivates could account for 159 billion pounds, or 50%, of the US production of synthetic organic chemicals, presently valued at $113 billion. This use would consume 4.2 billion bushels, or about 54%, of the corn crop.

This study evaluated the potential savings in ethanol manufacture to be gained by applying advanced process engineering or genetic engineering of improved organisms, centering on the use of fluidized bed bioreactors operating at high cell densities with immobilized cells of either the Saccharomyces yeast or the bacterium: Zymomonas mobilis.

A new continuous plant could produce at about $1.82/gal based on Zymomonas or $1.97/gal based on the Saccharomyces yeast. The bacterium has a competitive edge as a result of its lower sensitivity to product inhibition.

There appears to be no inherent design limitation to effect the engineering improvements required for the advanced process. In a longer-term, more difficult research effort, it might be possible to reduce or eliminate product inhibition to reduce cost even further.

     

New Method for Carbohydrates Determination in Sugarcane Bagasse by HPAEC‐RPAD Using Glassy Carbon Electrode Modified with Carbon Nanotubes and Nickel Nanoparticles

Second generation ethanol can be produced from carbohydrates released from both sugarcane bagasse cell wall and sugarcane straw. The development of new method for the analysis of carbohydrates is, in this sense, seen as extremely relevant in the area of bioenergy. Based on the above considerations, the scope of this work encompasses the identification and quantification of carbohydrates composition in sugarcane bagasse without the need of sample derivatization, developing a novel analytical method using a glassy carbon electrode modified with multi‐walled carbon nanotubes containing nickel oxyhydroxide nanoparticles (GCE/MWCNT/NiOOH) and applying the modified electrode as a detector in HPAEC (High Performance Anion‐Exchange Chromatography) with reverse pulsed amperometric detection (RPAD) towards the determination of arabinose, galactose, glucose and xylose in hydrolyzed sugarcane bagasse. The carbohydrates concentrations determined in the hydrolyzed sugarcane bagasse were 6.1×10⁻⁴ mol L⁻¹, 1.0×10⁻² mol L⁻¹ and 2.8×10⁻³ mol L⁻¹ for arabinose, glucose, and xylose respectively. Our results showed that the present method is, in essence, attractive for analysis in the course of the production process of second generation ethanol production in that it does not require sample derivatization, has rapid run time, satisfactory separation, and can be used for the detection of carbohydrates without the interference of other electroactive species.     

Evaluation and Optimization of Organic Acid Pretreatment of Cotton Gin Waste for Enzymatic Hydrolysis and Bioethanol Production

This paper investigates the efficiency of the organic acids on the pretreatment of an industrially generated cotton gin waste for the removal of lignin, thereby releasing cellulose and hemicellulose as fermentable sugar components. Cotton gin waste was pretreated with various organic acids namely lactic acid, oxalic acid, citric acid, and maleic acid. Among these, maleic acid was found to be the most efficient producing maximum xylose sugar (126.05?±?0.74 g/g) at the optimum pretreatment condition of 150 °C, 500 mM, and 45 min. The pretreatment efficiency was comparable to the conventional dilute sulfuric acid pretreatment. A lignin removal of 88% was achieved by treating maleic acid pretreated biomass in a mixture of sodium sulfite and sodium chlorite. The pretreated biomass was further evaluated for the release of sugar by enzymatic hydrolysis and subsequently bioethanol production from hydrolysates. The maximum 686.13 g/g saccharification yield was achieved with maleic acid pretreated biomass which was slightly higher than the sulfuric acid (675.26 g/g) pretreated waste. The fermentation of mixed hydrolysates(41.75 g/l) produced 18.74 g/l bioethanol concentration with 2.25 g/l/h ethanol productivity and 0.48 g/g ethanol yield using sequential use of Saccharomyces cerevisiae and Pichia stipitis yeast strains. The production of bioethanol was higher than the ethanol produced using co-culture in comparison to sequential culture. Thus, it has been demonstrated that the maleic acid pretreatment and fermentation using sequential use of yeast strains are efficient for bioethanol production from cotton gin waste.     

Natural radionuclides content and radon exhalation rate from Brazilian phosphogypsum piles

Phosphogypsum is a waste of the wet-acid process for producing phosphoric acid from phosphate rock. For every ton of phosphoric acid obtained, from the reaction of phosphate rock with sulphuric acid, about four tons of phosphogypsum are produced. The level of radioactivity present in the phosphogypsum, among other impurities, prevents its reuse for a variety of purposes. Large quantities of phosphogypsum have been produced worldwide. In 2006, the annual production was estimated to be about 170 million tons. Brazilian annual production of phosphogypsum reaches 5.5 million tons. Brazil, like other countries that produce phosphate fertilizer, tries to find solutions for the safe applications of phosphogypsum, in order to minimize the impact caused by its disposal. Most of the worldwide phosphogypsum is stockpiled, posing environmental concerns. The monitoring of air and groundwater pollution, radon exhalation rate and direct exposure to gamma radiation for workers should be considered. The aim of this study is to evaluate the natural radionuclides content and the radon exhalation rate from phosphogypsum piles from Ultrafertil and Fosfertil fertilizer industries. Samples of this material were analyzed by gamma ray spectrometry for their radionuclide content. Radon exhalation rate was measured by the activated charcoal collector method. A theoretical model for radon exhalation calculation, suggested by UNSCEAR, was applied in order to corroborate the experimental results.     

Use of Different Extracts of Coffee Pulp for the Production of Bioethanol

Coffee is one of the most important agricultural products in Brazil. More than 50 % of the coffee fruit is not used for the production of commercial green coffee and is therefore discarded, usually ending up in the environment. The goal of this work was to select an efficient process for obtaining coffee pulp extract and to evaluate the use of this extract in bioethanol production. The effects of heat treatment and trituration on the yield and composition of the extract were investigated by measuring the amounts of reducing sugars, starch, pectin, and phenolic compounds. The extraction process was most efficient at room temperature using grinding followed by pressing. Five different fermentation media were tested: sugarcane juice or molasses diluted with water or with coffee pulp extract and a medium with only coffee pulp extract. Batch fermentations were carried out at 30 °C for 24 h, and samples were taken to obtain measurements of the total reducing sugars, cell count, and ethanol concentration. The addition of coffee pulp extract did not influence the fermentation or yeast viability, and it can thus be mixed with sugarcane juice or molasses for the production of bioethanol, with a yield of approximately 70 g/L.     

Industrial Sustainability of Competing Wood Energy Options in Canada

The amount of sawmill residue available in Canada to support the emerging cellulosic ethanol industry was examined. A material flow analysis technique was employed to determine the amount of sawmill residue that could possibly be available to the ethanol industry per annum. A combination of two key trends—improved efficiency of lumber recovery and increased uptake of sawmill residues for self-generation and for wood pellet production—have contributed to a declining trend of sawmill residue availability. Approximately 2.3 × 10⁶ bone-dry tonnes per year of sawmill residue was estimated to be potentially available to the cellulosic ethanol industry in Canada, yielding 350 million liters per year of cellulosic ethanol using best practices. An additional 2.7 billion liters of cellulosic ethanol might be generated from sawmill residue that is currently used for competing wood energy purposes, including wood pellet generation. Continued competition between bioenergy options will reduce the industrial sustainability of the forest industry. Recommendations for policy reforms towards improved industrial sustainability practices are provided.     

Molecular Cloning,Characterization, and Expression Analysis of Lignin Genes from Sugarcane Genotypes Varying in Lignin Content

Sugarcane (Saccharum spp.) is one of the highest biomass-producing plant and the best lignocellulosic feedstock for ethanol production. To achieve more efficient conversion of biomass to ethanol, a better understanding of the main factors affecting biomass recalcitrance is needed. Therefore, with this objective, here, we report a systematic study on lignin content, deposition, identification, and cloning of genes involved in lignin biosynthesis and their differential expression in five sugarcane clones, EC11003, EC11010, IK 76-91, IK 76-99, and Co 86032. Lignin content among the clones varied from 26.87 to 23.19 % with the highest in the clone EC11010 and the lowest in high sugar Co86032. Lignin deposition studied through phloroglucinol staining of the cell walls implied that the sclerenchyma cells of the energy canes (EC11010 and EC11003) have more lignin deposition followed by the Erianthus (IK 76-91 and IK 76-99) clones whereas Co86032 has the minimum amount of lignin deposition. We cloned partial coding regions of important genes of lignification COMT (650 bp), CCR (332 bp), and PAL (650 bp) from Erianthus, wild relative of sugarcane followed by the expression analysis through real-time PCR. Differential expression analysis showed high level of expression for the three genes in the energy cane EC11010.     

Sugarcane proteomics: Establishment of a protein extraction method for 2‐DE in stalk tissues and initiation of sugarcane proteome reference map

Sugarcane is an important commercial crop cultivated for its stalks and sugar is a prized commodity essential in human nutrition. Proteomics of sugarcane is in its infancy, especially when dealing with the stalk tissues, where there is no study to date. A systematic proteome analysis of stalk tissue yet remains to be investigated in sugarcane, wherein the stalk tissue is well known for its rigidity, fibrous nature, and the presence of oxidative enzymes, phenolic compounds and extreme levels of carbohydrates, thus making the protein extraction complicated. Here, we evaluated five different protein extraction methods in sugarcane stalk tissues. These methods are as follows: direct extraction using lysis buffer (LB), TCA/acetone precipitation followed by solubilization in LB, LB containing thiourea (LBT), and LBT containing tris, and phenol extraction. Both quantitative and qualitative protein analyses were performed for each method. 2‐DE analysis of extracted total proteins revealed distinct differences in protein patterns among the methods, which might be due to their physicochemical limitations. Based on the 2‐D gel protein profiles, TCA/acetone precipitation‐LBT and phenol extraction methods showed good results. The phenol method showed a shift in pI values of proteins on 2‐D gel, which was mostly overcome by the use of 2‐D cleanup kit after protein extraction. Among all the methods tested, 2‐D cleanup‐phenol method was found to be the most suitable for producing high number of good‐quality spots and reproducibility. In total, 30 and 12 protein spots commonly present in LB, LBT and phenol methods, and LBT method were selected and subjected to eLD‐IT‐TOF‐MS/MS and nESI‐LC‐MS/MS analyses, respectively, and a reference map has been established for sugarcane stalk tissue proteome. A total of 36 nonredundant proteins were identified. This is a very first basic study on sugarcane stalk proteome analysis and will promote the unexplored areas of sugarcane proteome research.