Characteristics of an Immobilized Yeast Cell System Using Very High Gravity for the Fermentation of Ethanol

The characteristics of ethanol production by immobilized yeast cells were investigated for both repeated batch fermentation and continuous fermentation. With an initial sugar concentration of 280?g/L during the repeated batch fermentation, more than 98% of total sugar was consumed in 65?h with an average ethanol concentration and ethanol yield of 130.12?g/L and 0.477?g ethanol/g consumed sugar, respectively. The immobilized yeast cell system was reliable for at least 10 batches and for a period of 28?days without accompanying the regeneration of Saccharomyces cerevisiae inside the carriers. The multistage continuous fermentation was carried out in a five-stage column bioreactor with a total working volume of 3.75?L. The bioreactor was operated for 26?days at a dilution rate of 0.015?h^?1. The ethanol concentration of the effluent reached 130.77?g/L ethanol while an average 8.18?g/L residual sugar remained. Due to the high osmotic pressure and toxic ethanol, considerable yeast cells died without regeneration, especially in the last two stages, which led to the breakdown of the whole system of multistage continuous fermentation.     

Continuous Ethanol Production from Cassava Through Simultaneous Saccharification and Fermentation by Self-Flocculating Yeast Saccharomyces Cerevisiae CHFY0321

In this study, a fermentor consisting of four linked stirred towers that can be used for simultaneous saccharification and fermentation (SSF) and for the accumulation of cell mass was applied to the continuous production of ethanol using cassava as the starchy material. For the continuous process with SSF, the pretreated cassava liquor and saccharification enzyme at total sugar concentrations of 175 g/L and 195 g/L were continuously fed to the fermentor with dilution rates of 0.014, 0.021, 0.031, 0.042, and 0.05 h⁻¹. Considering the maximum saccharification time, the highest volumetric productivity and ethanol yield were observed at a dilution rate of 0.042 h⁻¹. At dilution rates in the range of 0.014 h⁻¹ to 0.042 h⁻¹, high production rates were observed, and the yeast in the first to fourth fermentor showed long-term stability for 2 months with good performance. Under the optimal culture conditions with a feed sugar concentration of 195 g/L and dilution rate of 0.042 h⁻¹, the ethanol volumetric productivity and ethanol yield were 3.58 g/L∙h and 86.2%, respectively. The cell concentrations in the first to fourth stirred tower fermentors were 74.3, 71.5, 71.2, and 70.1 g dry cell/L, respectively. The self-flocculating yeast, Saccharomyces cerevisiae CHFY0321, developed by our group showed excellent fermentation results under continuous ethanol production.     

Bioethanol Production from Uncooked Raw Starch by Immobilized Surface-engineered Yeast Cells

Surface-engineered yeast Saccharomyces cerevisiae codisplaying Rhizopus oryzae glucoamylase and Streptococcus bovis α-amylase on the cell surface was used for direct production of ethanol from uncooked raw starch. By using 50 g/L cells during batch fermentation, ethanol concentration could reach 53 g/L in 7 days. During repeated batch fermentation, the production of ethanol could be maintained for seven consecutive cycles. For cells immobilized in loofa sponge, the concentration of ethanol could reach 42 g/L in 3 days in a circulating packed-bed bioreactor. However, the production of ethanol stopped thereafter because of limited contact between cells and starch. The bioreactor could be operated for repeated batch production of ethanol, but ethanol concentration dropped to 55% of its initial value after five cycles because of a decrease in cell mass and cell viability in the bioreactor. Adding cells to the bioreactor could partially restore ethanol production to 75% of its initial value.     

Continuous cultivation of dilute-acid hydrolysates to ethanol by immobilized Saccharomyces cerevisiae

The continuous cultivation of immobilized Saccharomyces cerevisiae CBS 8066 on dilute-acid hydrolysates of forest residuals was investigated. The yeast cells were immobilized in 2–4% Ca-alginate beads. The 2% beads were not stable. However, the 3 and 4% beads were stable for at least 3 wk when an extra resource of calcium ions was available in the medium. The continuous cultivation of a dilute-acid hydrolysate by the immobilized cells at dilution rates of 0.3, 0.5, and 0.6 h⁻¹ resulted in 86, 83, and 79% sugar consumption, respectively, and an ethanol yield between 0.45 and 0.48 g/g. The hydrolysate was fermentable at a dilution rate of 0.1 h⁻¹ in a free-cell system but washed out at a dilution rate of 0.2 h⁻¹. The continuous cultivation of a more inhibiting hydrolysate was not successful by either free- or immobilized-cell systems even at a low dilution rate of 0.07 h⁻¹. However, when the hydrolysate was overlimed, it was fermentable by the immobilized cells at a dilution rate of 0.2 h⁻¹.     

Continuous Production of Thermostable α-Amylase by Immobilized Bacillus Cells in a Fluidized-Bed Reactor

The exponential cells ofBacillus cereus immobilized in calcium alginate and spun into microcylindrical particles were used in a fluidized-bed reactor for continuous synthesis of thermostable α-amylase. The reactor was operated over a period of 30 d with a dilution rate of 0.33 h^-1, producing 1000–1200 U/mL of enzyme. The productivity of the reactor was in the range of 330–396 kU/h. A 20-fold increase in the productivity with respect to batch fermentation with free cells was attained.     

Ethanol fermentation in a tower fermenter using self-aggregatingSaccharomyces uvarum

A self-aggregating strain ofSaccharomyces uvarum (U4) was used as a biocatalyst to carry out continuous ethanol fermentation in a tower fermentor equipped with a cell separator. Cell aggregates (2–3 mm) formed a stable packed bed in the fermentor, and the cell separator retained yeast cells effectively. Corn steep liquor was used as a nitrogen source for the fermentation of corn syrup and black strap molasses. An ethanol productivity of 54 g/L/h was reached using corn syrup at a dilution rate of 0.7/h, and sugar concentration in the feed was 15% (w/v). For molasses fermentation, an ethanol productivity of 22 g/L/h was obtained at a dilution rate of 0.7/h, and sugar concentration in the feed was 12.5% (w/v). Ethanol yields obtained from tower fermentation are higher than those obtained from flask fermentation (96% for corn syrup fermentation and 92% for molasses fermentation). No significant loss in fermentation activity was observed after 3 mo of operation.     

Continuous ethanol extraction by pervaporation from a membrane bioreactor

In order to obtain a high productivity of ethanol, a membrane bioreactor consisting of a fermentor and a pervaporation system was applied to the continuous alcoholic fermentation process. A microporous hydrophobic polytetrafluoroethylene membrane was used for pervaporation. Glucose medium and baker's yeast were used for the fermentation. Three types of continuous fermentation experiment were carried out: conventional free-cell fermentation as the standard process; a fermentation in which product ethanol was extracted continuously by pervaporation from the membrane bioreactor; and a fermentation in which ethanol was extracted by pervaporation and part of the culture broth was simultaneously removed from the fermentation system.

The fermented ethanol was continuously extracted, and simultaneously concentrated by pervaporation, from the membrane bioreactor, and the extracted ethanol concentration was 6 to 8 times higher than in the broth. A high concentration of microorganisms was realized by immobilizing cells in the membrane bioreactor. When the ethanol concentration in the broth was kept low by pervaporation, the specific rate of ethanol production increased. However, the fraction of viable cells decreased because of the accumulation of inorganic salts fed as a nutrient, of nonvolatile by-products and of aged cells, which were not extracted by pervaporation from the fermentation solution. In order to achieve a high ethanol productivity, part of the fermentation broth must be removed from the membrane bioreactor.     

Continuous wine making by delignified cellulosic materials supported biocatalyst

The continuous making of wine by a delignified cellulosic (DC) material-supported biocatalyst is reported. It was prepared by immobilizing the alcohol resistant strain AXAZ-1 on DC material. The product was found suitable for the continuous process in industrial applications. The operational stability was maintained for 2 mo with monitoring the ethanol concentration, wine, and alcohol productivities as well as the stability of °Be density at the outlet. Wine productivity was three to sixfold higher than obtained by natural fermentation, alcohol concentrations of the wine was in the range of 9.3-211.2% v/v and low volatile acidities of 0.15-20.36 g acetic acid/L were obtained. The effect of total acidity and flow rate of must were also examined. To demonstrate that the operational stability of the bioreactor is due to DC material that promotes the fermentation, and it takes place at even higher ethanol levels, an analogous system of kissiris supported biocatalyst was studied. Likewise, the tolerance in the alcohol concentration, as compared with free cells, were studied by their stability of the activity in the repeated batch fermentation of must.     

Continuous ethanol production from nonsterilized carob pod extract by immobilizedSaccharomyces cerevisiae on mineral kissiris using a two-reactor system

The continuous production of ethanol from nonsterilized carob pod extract by immobilizedSaccharomyces cerevisiae on mineral kissiris using one- and two-reactor systems has been investigated. A maximum ethanol productivity of 9.6 g/L/h was obtained at an initial sugar concentration of 200 g/L and D = 0.4 h^-1 with 68% of theoretical yield and 34% of sugar utilization using the one-reactor system. AtS ₀ = 200 g/L, D = 0.05 h^-1, 83% of theoretical yield, and 64% of sugar utilization, an ethanol productivity of 2.6 g/L/h was achieved. In the tworeactor system, a maximum ethanol productivity of 11.4 g/L/h was obtained at S₀ = 200 g/L and D = 0.4 h^-1 with 68.5% of theoretical yield and 41.5% of sugar utilization. The two-reactor system was operated at a constant dilution rate of 0.3 h^-1 for 60 d without loss of the original immobilized yeast activity. In this case, the average ethanol productivity, ethanol yield (% of theoretical), and sugar utilization were 10.7 g/L/h, 71.5%, and 48%, respectively.     

Continuous production of butanol by clostridium acetobutylicum immobilized in a fibrous bed bioreactor

We explored the influence of dilution rate and pH in continuous cultures of Clostridium acetobutylicum. A 200-mL fibrous bed bioreactor was used to produce high cell density and butyrate concentrations at pH 5.4 and 35°C. By feeding glucose and butyrate as a cosubstrate, the fermentation was maintained in the solventogenesis phase, and the optimal butanol productivity of 4.6g/(L h) and a yield of 0.42 g/g were obtained at a dilution rate of 0.9h⁻¹ and pH 4.3. Compared to the conventional acetone-butanol-ethanol fermentation, the new fermentation process greatly improved butanol yield, making butanol production from corn an attractive alternative to ethanol fermentation.     

Ethanol production from glucose and xylose by immobilized Zymomonas mobilis CP4 (pZB5)

Fermentation of glucose-xylose mixtures to ethanol was investigated in batch and continuous experiments using immobilized recombinant Zymomonas mobilis CP4(pZB5). This microorganism was immobilized by entrapment in κ-carrageenan beads having a diameter of 1.5–2.5 mm. Batch experiments showed that the immobilized cells cofermented glucose and xylose to ethanol and that the presence of glucose improved the xylose utilization rate. Batch fermentation of rice straw hydrolysate containing 76 g/L of glucose and 33.8 g/L of xylose gave an ethanol concentration of 44.3 g/L after 24 h, corresponding to a yield of 0.46 g of ethanol/g of sugars. Comparable results were achieved with a synthetic sugar control. Continuous fermentation experiments were performed in a laboratory-scale fluidized-bed bioreactor (FBR). Glucose-xylose feed mixtures were pumped through the FBR at residence times of 2–4 h. Glucose conversion to ethanol was maintained above 98% in all experiments. Xylose conversion to ethanol was highest at 91.5% for a feed containing 50 g/L of glucose and 13 g/L of xylose at a dilution rate of 0.24/h. The xylose conversion to ethanol decreased with increasing feed xylose concentration, dilution rate, and age of the immobilized cells. Volumetric ethanol productivities in the range of 6.5–15.3 g/L·h were obtained. The improved productivities achieved in the FBR compared to other bioreactor systems can help in reducing the production costs of fuel ethanol from lignocellulosic sugars. This article has been authored by a contractor of the US go vernment under contract DE-AC05-96OR22464. Accordingly, the US government retains a nonexclusive, royaltyfree license to publish or reproduce the published form of the contribution, or allow others to do so, for US government purposes.     

Ethanol Production from Starch Hydrolyzates using <Emphasis Type="Italic">Zymomonas mobilis</Emphasis> and Glucoamylase Entrapped in Polyvinylalcohol Hydrogel

The glucoamylase from Aspergillus niger, immobilized into poly(vinylalcohol) hydrogel lens-shaped capsules LentiKats®, was used for simultaneous saccharification and fermentation (SSF) with Zymomonas mobilis in free form. This system was stable in both the repeated batch and continuous mode of SSF. The microorganism was found to adsorb on the capsules with immobilized enzyme. This increased the ethanol productivity of the repeated batch system with 5% w/v of immobilized glucoamylase almost 2.1 times (7.2 g l^?1 h^?1) compared to free enzyme–free microorganism system (3.5 g l^?1 h^?1). The continuous SSF with the immobilized glucoamylase (11.5% w/v) tested for 15 days had productivity 10 g l^?1 h^?1, which is comparable to continuous experiments on semi-defined glucose medium (10 g l^?1 h^?1). These two systems were stable in both glucoamylase activity and microorganism productivity.     

Improving the Performance of a Continuous Process for the Production of Ethanol from Starch

In a previous work, a continuous simultaneous saccharification and fermentation process to produce ethanol from cassava starch was studied, using a set of fixed-bed reactors. The biocatalyst consisted of glucoamylase immobilized in silica particles and co-immobilized with S. cerevisiae in pectin gel. Using 3.8 U mL^?1 _reactor and 0.05 g_{wet yeast} mL^?1 _reactor at start-up, starch hydrolysis was the rate-limiting step. Maximum ethanol productivity was 5.8 g_ethanol L^?1 h^?1, with 94.0% conversion of total reducing sugars (TRS) and 83.0% of the ethanol theoretical yield. In this work, the molar mass of the substrate and the biocatalyst particle size were reduced in an attempt to improve the bioreactor performance. The diameters of silica and pectin gel particles were reduced from 100 μm and 3–4 mm, respectively, to 60 μm and 1–1.5 mm, and the degree of substrate prehydrolysis by α-amylase was increased. The bioreactor performance was assessed for different loads of immobilized glucoamylase (2.1, 2.8, and 3.8 U mL^?1 _reactor), for the same initial cell concentration (0.05 g_{wet yeast.}mL^?1 _reactor). Feeding with 154.0 g L^?1 of TRS and using 3.8 U mL^?1 _reactor, fermentation became the rate-limiting step. Productivity reached 11.7 g L^?1 h^?1, with 97.0% of TRS conversion and 92.0% of the ethanol theoretical yield. The reactor was operated during 275 h without any indication of destabilization.     

Production of Ethanol from Sweet Sorghum Juice Using VHG Technology: A Simulation Case Study

The aims of this study were to develop the kinetic model and determine kinetic parameters describing ethanol production from sweet sorghum juice using very high gravity technology in the batch fermentation of Saccharomyces cerevisiae NP01. The obtained experimental data were tested with four different types of model, based on the experimental data, accounting for the substrate limitation, substrate inhibition, product inhibition, and the combination of those three effects, respectively. The optimization technique to find kinetic parameters was non-linear regression using Marquardt method performed through numerical procedure. The chosen model with its kinetic parameters obtained in the batch mode was validated and tested against the other independent experimental data in the small batch-scale and large-scale fermenter, in order to investigate the applicability and scale-up effect of the model, respectively. Then, the obtained model with its parameters was applied in the simulations of the continuous and fed-batch operations to examine the concentration profiles of fermentation components with the variations in operating parameters such as the dilution rate, feed-flow rate, start-up time, and feed concentration. The results indicated that the kinetic model (the substrate limitation with substrate and product inhibition effects) was suitable to describe ethanol fermentation. In the continuous mode, using the dilution rate of 0.01 h^?1, the maximum ethanol concentration obtained was, approximately, 90 g/l whereas the simulated results from the fed-batch operation revealed that the maximum ethanol concentration at quasi-steady state condition was, approximately, 96 g/l. The start-up time of 21 h was the fastest time to reach the steady-state and quasi-steady state for both the continuous and fed-batch modes, respectively.     

Continuous xylose fermentation byCandida shehatae in a two-stage reactor

Recent work has identified ethanol toxicity as a major factor preventing continuous production of ethanol at the concentrations obtainable in batch culture. In this paper we investigate the use of a continuous two-stage bioreactor design to circumvent toxic effects of ethanol. Biomass is produced via continuous culture in the first stage reactor in which ethanol concentrations are either absent or maintained at low levels. The freshly grown cells are fed into the second bioreactor in which high ethanol concentrations are produced. The steady influx of fresh cells and continuous removal of spent cells helps minimize the loss of fermentative activity that results from anaerobiosis and exposure to high ethanol concentrations. A final ethanol concentration of 37 g L⁻¹ and overall yield of .32 g g⁻¹ were obtained with the two-stage reactor as compared to corresponding values of 38 g L⁻¹ and .32 g g⁻¹ obtained in batch. The volumetric rate in the two-state process was .96 g L⁻¹ as compared to .46 g L⁻¹ h⁻¹ in batch. Maintained in cooperation with the University of Wisconsin-Madison. The use of trade, firm, or corporation names in this publication is for the information and convenience of the reader. Such use does not constitute an official endorsement or approval by the US Department of Agriculture of any product or service to the exclusion of others which may be suitable.     

Pretreatment of Synthetic Dairy Wastewater Using the Sophorolipid-Producing Yeast <Emphasis Type="Italic">Candida bombicola</Emphasis>

The presence of high strength fats and oils in dairy industry wastewaters poses serious challenges for biological treatment systems, and, therefore, its pretreatment is necessary in order to remove them. In the present study, synthetic dairy wastewater prepared in the laboratory was pretreated using the sophorolipid-producing yeast Candida bombicola in a laboratory-scale bioreactor under batch, fed-batch, and continuous modes of operation. To support the yeast growth, the wastewater was supplemented with sugarcane molasses (1% w/v) and yeast extract (0.1% w/v). Results from the batch operated fermentor revealed complete utilization of fats present in the wastewater within 96 h with more than 93% COD removal efficiency. The yeast was, however, able to pretreat the wastewater more quickly and efficiently under fed-batch mode of operation than under batch operated condition in the same fermentor. Continuous experiments were carried out with a wastewater retention time of 28 h in the reactor; results showed very good performance of the system in complete utilization of fats and COD removal efficiency of more than 90%. The study proved the excellent potential of the biosurfactant-producing yeast in pretreating high-fat- and oil-containing dairy industry wastewater.     

Gas-diffusion dilution flow-injection method for the determination of ethanol in beverages without sample pretreatment

The combination of immobilized alcohol oxidase (AOD) with a gas-diffusion membrane in a flow-injection system greatly enhanced the specificity of ethanol determination. This gas-diffusion flow-injection system with amperometric detection of hydrogen peroxide had a linear range of analysis from 0.0006 up to 60% (v/v) ethanol. Silicone-modified polypropylene membranes of different thickness were used. Undiluted samples of beer, wine, spirits and medicine could be investigated with excellent correlation with standard methods (r > 0.997). The frequency of analysis was 120–180 samples h^?1 and the operational half-life of the immobilized enzyme was 8000 injections within 44 h.     

Continuous production of butanol from starch-based packing peanuts

Acetone, butanol, ethanol (ABE, or solvents) were produced from starch-based packing peanuts in batch and continuous reactors. In a batch reactor, 18.9 g/L of total ABE was produced from 80 g/L packing peanuts in 110 h of fermentation. The initial and final starch concentrations were 69.6 and 11.1 g/L, respectively. In this fermentation, ABE yield and productivity of 0.32 and 0.17 g/(L·h) were obtained, respectively. Compared to the batch fermentation, continuous fermentation of 40 g/L of starch-based packing peanuts in P2 medium resulted in a maximum solvent production of 8.4 g/L at a dilution rate of 0.033 h⁻¹. This resulted in a productivity of 0.27 g/(L·h). However, the reactor was not stable and fermentation deteriorated with time. Continuous fermentation of 35 g/L of starch solution resulted in a similar performance. These studies were performed in a vertical column reactor using Clostridium beijerinckii BA101 and P2 medium. It is anticipated that prolonged exposure of culture to acrylamide, which is formed during boiling/autoclaving of starch, affects the fermentation negatively.     

Butanol production by Clostridium beijerinckii BA101 in an immobilized cell biofilm reactor

Acetone butanol ethanol was produced in a continuous immobilized cell (biofilm) plug-flow reactor inoculated with Clostridium beijerinckii BA101. To achieve high reactor productivity, C. beijerinckii BA101 cells were immobilized by adsorption onto clay brick. The continuous plug-flow reactor offers high productivities owing to reduced butanol inhibition and increased cell concentration. Although high productivity was achieved, it was at the expense of low sugar utilization (30.3%). To increase sugar utilization, the reactor effluent was recycled. However, this approach is complicated by butanol toxicity. The effluent was recycled after removal of butanol by pervaporation to reduce butanol toxicity in the reactor. Recycling of butanolfree effluent resulted in a sugar utilization of 100.7% in addition to high productivity of 10.2g/(L·h) at a dilution rate of 1.5 h⁻¹. A dilution rate of 2.0h⁻¹ resulted in a reactor productivity of 16.2g/(L·h) and sugar utilization of 101.4%. It is anticipated that this reactor-recovery system would be economical for butanol production when using C. beijerinckii BA101.     

Continuous Production of Ethanol from Starch Using Glucoamylase and Yeast Co-Immobilized in Pectin Gel

This work presents a continuous simultaneous saccharification and fermentation (SSF) process to produce ethanol from starch using glucoamylase and Saccharomyces cerevisiae co-immobilized in pectin gel. The enzyme was immobilized on macroporous silica, after silanization and activation of the support with glutaraldehyde. The silica–enzyme derivative was co-immobilized with yeast in pectin gel. This biocatalyst was used to produce ethanol from liquefied manioc root flour syrup, in three fixed bed reactors. The initial reactor yeast load was 0.05 g wet yeast/ml of reactor (0.1 g wet yeast/g gel), used in all SSF experiments. The enzyme concentration in the reactor was defined by running SSF batch assays, using different amount of silica–enzyme derivative, co-immobilized with yeast in pectin gel. The chosen reactor enzyme concentration, 3.77 U/ml, allowed fermentation to be the rate-limiting step in the batch experiment. In this condition, using initial substrate concentration of 166.0 g/l of total reducing sugars (TRS), 1 ml gel/1 ml of medium, ethanol productivity of 8.3 g/l/h was achieved, for total conversion of starch to ethanol and 91% of the theoretical yield. In the continuous runs, feeding 163.0 g/l of TRS and using the same enzyme and yeast concentrations used in the batch run, ethanol productivity was 5.9 g ethanol/l/h, with 97% of substrate conversion and 81% of the ethanol theoretical yield. Diffusion effects in the extra-biocatalyst film seemed to be reduced when operating at superficial velocities above 3.7 × 10⁻⁴ cm/s.