Simultaneous saccharification and fermentation of lignocellulose

Simultaneous saccharification and fermentation (SSF) processes for producing ethanol from lignocellulose are capable of improved hydrolysis rates, yields, and product concentrations compared to separate hydrolysis and fermentation (SHF) systems, because the continuous removal of the sugars by the yeasts reduces the end-product inhibition of the enzyme complex. Recent experiments using Genencor 150L cellulase and mixed yeast cultures have produced yields and concentrations of ethanol from cellulose of 80% and 4.5%, respectively. The mixed culture was employed because B.clausenii has the ability to ferment cellobiose (further reducing end-product inhibition), while the brewing yeastS. cerevisiae provides a robust ability to ferment the monomeric sugars. These experimental results are combined with a process model to evaluate the economics of the process and to investigate the effect of alternative processes, conditions, and organisms.     

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.     

Characterization of an immobilized yeast cells fluidized-bed bioreactor for ethanol fermentation

The operational characterization of a fluidized-bed bioreactor for ethanol fermentation using Ca-alginate immobilized yeast cells is described. An additional air stream is supplied to the fermenter to ensure and maintain satisfactory fluidization behavior of beads and to avoid slug formation. The influence of physical properties such as bead density and liquid density on the fluidization quality and stability are discussed.     

Evaluation of O2 and CO2 transfer coefficients in a locally integrated tubular hollow fiber bioreactor

We have studied the transfer coefficients for O₂ transport to and CO₂ removal from a model cell-free system using microporous hydrophobic hollow fibers axially placed along a tubular bioreactor for ethanol production with immobilized yeast in the shell. In this locally integrated bioreactor, O₂ and CO₂ transfer rates depend strongly on the shell side liquid flow rate; O₂ flow rate in the fiber bore influences O₂ transport only at very low flow rates. Diffusion of CO₂ does not affect O₂ transport. Local and overall O₂ and CO₂ transfer coefficients have been determined for a wide range of Reynolds Numbers. The efficiency of such transfers has been demonstrated for alcohol fermentation.     

Xylose fermentation

The economic impact of conversion of xylose to ethanol for a wood-to-ethanol plant was examined, and the maximum potential reduction in the price of ethanol from utilization of xylose is estimated to be 0.42 per gallon from a base case price of0.42 per gallon from a base case price of 1.65. The sensitivity of the price of ethanol to the yield, ethanol concentration and rate of the xylose fermentation was also examined, and the price of ethanol is most affected by changes in yield and ethanol concentration, with rate of lesser importance. Current performances of various xylose conversion biocatalysts were analyzed, andC. shehatae andP. stipitis appear to be the best yeasts.     

Improved oxygen delivery in a continuous-roller-bottle reactor

Variations to the original aeration system in a continuous roller bottle reactor of novel design have been tested and compared for optimal oxygen (O) delivery. Reactor operating parameters that affect O transfer are rotation rate, liquid-volume level, fresh-feed rate, and supplementary-aeration rate. Design modifications to enhance gas-liquid O transfer include the addition of wall baffles and center baffles. The number and location of each of these baffles are compared for their effect on k_La values in the reaction chamber. The liquid feed into the system has been modified to improve the axial liquid mixing and O transfer.     

Continuous fermentation of cellulosic biomass to ethanol

Experimental results are presented for continuous conversion of pretreated hardwood flour to ethanol. A simultaneous saccharification and fermentation (SSF) system comprised ofTrichoderma reesei cellulase supplemented with additional β-glucosidase and fermentation bySaccharomyces cerevisiae was used for most experiments, with data also presented for a direct microbial conversion (DMC) system comprised ofClostridium thermocellum. Using a batch SSF system, dilute acid pretreatment of mixed hardwood at short residence time(10 s, 220°C, 1% H₂SO₄) was compared to poplar wood pretreated at longer residence time (20 min, 160°C, 0.45% H₂SO₄). The short residence time pretreatment resulted in a somewhat (10–20%) more reactive substrate, with the reactivity difference particularly notable at low enzyme loadings and/or low agitation. Based on a preliminary screening, inhibition of SSF by byproducts of short residence time pretreatment was measurable, but minor. Both SSF and DMC were carried out successfully in well-mixed continuous systems, with steady-state data obtained at residence times of 0.58–3 d for SSF as well as 0.5 and 0.75 d for DMC. The SSF system achieved substrate conversions varying from 31% at a 0.58-d residence time to 86% at a 2-d residence time. At comparable substrate concentrations (4–5 g/l) and residence times (0.5–0.58 d), substrate conversion in the DMC system (77%) was significantly higher than that in the SSF system (31%). Our results suggest that the substrate conversion in SSF carried out in CSTR is relatively insensitive to enzyme loading in the range 7–25 U/g cellulose and to substrate concentration in the range of 5–60 g/L cellulose in the feed.     

Mass transfer effects in microencapsulated hybridoma cells producing monoclonal antibodies

Rat-mouse and mouse-mouse hybridoma cell lines were used for formation of monoclonal antibodies (MAbs) in microcapsules of different sizes. Microcapsules were made of poly L-lysine-alginate hydrogel membranes. The effects of extracapsule liquid film, intra-capsule and transmembrane transfer limitations of nutrients/products on system’s performance were investigated. An agitation speed of 45 rpm (4 cm/s tip speed) was found to be optimal in spinner flasks to overcome liquid film resistances around capsules. Capsule sizes need to be reduced to smaller than 350 ε in order to eliminate intracapsule transfer limitations with a typical initial viable cell concentration of 0.5x10⁵ viable cells/mL capsule. Double coating of capsules to improve strength of capsules resulted in higher transmembrane transfer resistances.     

Axial dispersion in a liquid fluidized bed of particles akin to immobilized enzymes

The axial dispersion of a liquid fluidized bed of controlled pore silica (CPS) particles has been determined by the pulse tracer method. The CPS used was the same as for enzyme immobilization, having an average diameter of 0.436 mm and mean pore size of 37.5 nm. The fluidization liquid is α-amylase liquefied manioc starch, 30% w/v, 45°C pH=4.5. Nominal bed porosities tested were 0.7 and 0.8. The results show that the axial dispersion coefficient increases with greater superficial liquid velocities. Various available correlations tested disagree with each other to a large extent and are unable to represent collected experimental data.     

Production of citronellyl acetate in a fed-batch system using immobilized lipase

Several reports exist in the literature citing the decrease in conversion rates of organic-phase catalytic synthesis reactions when acetic acid is present as a reaction component. This inhibition is thought to result from damage to either the hydration layer-protein interaction or the overall enzyme structure. In this work, the inhibitory effect of acetic acid on lipase enzyme activity was ameliorated by conducting syntheses under acetic acid-limiting conditions in a fed-batch system, resulting in higher product yields. Periodic additions of acetic acid at levels of 40 mM or less gave maximum yields of 65% conversion for the reaction of citronellol and acetic acid to form citronellyl acetate. The enzyme used was a fungal lipase fromMucor miehei, and was immobilized on macroporous synthetic resin (a Novo lipozyme Novo Nordisk, Denmark). These results represent a fourfold improvement over batch runs reported in the literature for direct esterification of terpene alcohol with acetic acid using lipozyme as a catalytic agent.     

New alcohol resistant strains ofSaccharomyces cerevisiae species for potable alcohol production using molasse

Two alcohol resistant strains of Saccharomyces cerevisiae species were isolated from a Greek vineyard plantation. The strain AXAZ-1 gave a concentration of 17.6% v/v alcohol and AXAZ-2 16.5%, when musts from raisin and sultana grapes, respectively, were employed in alcoholic fermentations. They were found to be more alcohol tolerant and fermentative in the fermentation of molasse than the traditional baker's yeast. Specifically, using an initial [symbol: see text] Be density of 16 [symbol: see text] Be at the repeated batch fermentation process, in the first as well as fourth batch, the better AXAZ-1 gave final [symbol: see text] Be densities of 6.0 and 10.5 respectively, and the baker's yeast 11.6 and 14.5.     

L-malic acid production using immobilized saccharomyces cerevisiae

L-Malate was produced from fumarate by using immobilized Saccharomyces cerevisiae cells entrapped in polyacrylamide. This preparation performed better when pretreated with malonate. Under the experimental conditions described here, succinate was not detected as a by-product of the reaction, as had been reported for other microorganisms.     

Extractive fermentation of acetic acid

In this technoeconomic evaluation of the manufacture of acetic acid by fermentation, the use of the bacterium:Acetobacter suboxydans from the old vinegar process was compared with expected performance of the newerClostridium thermoaceticum bacterium. Both systems were projected to operate as immobilized cells in a continuous, fluidized bed bioreactor, using solvent extraction to recover the product. Acetobacter metabolizes ethanol aerobically to produce acid at 100 g/L in a low pH medium. This ensures that the product is in the form of a concentrated extractable free acid, rather than as an unextractable salt. Unfortunately, yields from glucose by way of the ethanol fermentation are poor, but near the biological limits of the organisms involved.     

The effect of sodium sulfite and cobalt chloride on the oxygen transfer coefficient

An experiment was conducted in an aeration system made from 2000 mL Erlenmeyer Flask to investigate the effect of sodium sulfite with cobalt chloride and the sparging nitrogen gas on the measurement of the oxygen transfer coefficient. Twice the theoretical quantity of sodium sulfite that is required to react with dissolved oxygen, or nitrogen sparging at a rate equivalent to that of air used during the aeration process, was used to deoxygenate the water. The results obtained from the study were consistent and repeatable and showed no significant differences in the values of the oxygen transfer coefficient obtained by the two methods.     

Modeling of an immobilized-cell three-phase fluidized-bed bioreactor

A mathematical model of a three-phase, tapered, fluidized-bed bioreactor has been developed. This model includes the effects of the tapered bed, a variable dispersion coefficient, and the concentration profile inside the biocatalyst bead on the reaction rate within the bed. Parameters in this model were obtained by adjusting them, within a realistic range, such that the square of the difference between the values predicted by the model and those obtained experimentally was minimized. The model was found to predict experimentally obtained concentration profiles quite accurately. It also demonstrates the need to include the effects of variable dispersion in three-phase systems where the gas phase is being generated inside the reactor, as the dispersion coefficient varied by more than an order of magnitude across the bed.     

Urease purification from the seeds ofCajanus Cajan and its application in a biosensor construction

Urease has been purified from the seeds of Cajanus Cajan. The purification process involves three solvent extraction steps followed by DEAE-cellulose column chromatography. The specific activity of the purified enzyme is found to be 1920 U/mg with the recovery of 8%. The application of the purified enzyme in a biosensor construction is discussed.     

Optimization of the simultaneous saccharification and fermentation process using thermotolerant yeasts

Different treatments to improve the thermotolerance of fermenting yeasts for simultaneous ethanol saccharification and fermentation process of cellulosic materials have been examined. Yeasts of the generaSaccharomyces andKluyveromyces were tested for growth and fermentation at progressively higher temperatures in the range of 42–47°C. The best results were obtained withK. marxianus LG, which was then submitted to different treatments in order to achieve thermotolerant clones. A total of 35 new clones were obtained that dramatically improved the SSF of 10% Solka-floc substrate at 45°C when compared to the original strain, some with ethanol concentrations as high as 33 g/L.