Optimizing ethanol and methane production from steam-pretreated, phosphoric acid-impregnated corn stover.

Pretreatment is of vital importance in the production of ethanol and methane from agricultural residues. In this study, the effects of steam pretreatment with phosphoric acid on enzymatic hydrolysis (EH), simultaneous saccharification and fermentation (SSF), anaerobic digestion (AD) and the total energy output at three different temperatures were investigated. The effect of separating the solids for SSF and the liquid for AD was also studied and compared with using the whole slurry first in SSF and then in AD. Furthermore, the phosphoric acid was compared to previous studies using sulphuric acid or no catalyst. Using phosphoric acid resulted in higher yields than when no catalyst was used. However, compared with sulphuric acid, an improved yield was only seen with phosphoric acid in the case of EH. The higher pretreatment temperatures (200 and 210 °C) resulted in the highest yields after EH and SSF, while the highest methane yield was obtained with the lower pretreatment temperature (190 °C). The highest yield in terms of total energy recovery (78 %) was obtained after pretreatment at 190 °C, but a pretreatment temperature of 200 °C is, however, the best alternative since fewer steps are required (whole slurry in SSF and then in AD) and high product yields were obtained (76 %).

SSF of steam-pretreated wheat straw with the addition of saccharified or fermented wheat meal in integrated bioethanol production.

BACKGROUND: Integration of second-generation (2G) bioethanol production with existing first-generation (1G) production may facilitate commercial production of ethanol from cellulosic material. Since 2G hydrolysates have a low sugar concentration and 1G streams often have to be diluted prior to fermentation, mixing of streams is beneficial. Improved ethanol concentrations in the 2G production process lowers energy demand in distillation, improves overall energy efficiency and thus lower production cost. There is also a potential to reach higher ethanol yields, which is required in economically feasible ethanol production. Integrated process scenarios with addition of saccharified wheat meal (SWM) or fermented wheat meal (FWM) were investigated in simultaneous saccharification and (co-)fermentation (SSF or SSCF) of steam-pretreated wheat straw, while the possibility of recovering the valuable protein-rich fibre residue from the wheat was also studied. RESULTS: The addition of SWM to SSF of steam-pretreated wheat straw, using commercially used dried baker's yeast, S. cerevisiae, resulted in ethanol concentrations of about 60 g/L, equivalent to ethanol yields of about 90% of the theoretical. The addition of FWM in batch mode SSF was toxic to baker's yeast, due to the ethanol content of FWM, resulting in a very low yield and high accumulation of glucose. The addition of FWM in fed-batch mode still caused a slight accumulation of glucose, but the ethanol concentration was fairly high, 51.2 g/L, corresponding to an ethanol yield of 90%, based on the amount of glucose added.In batch mode of SSCF using the xylose-fermenting, genetically modified S. cerevisiae strain KE6-12, no improvement was observed in ethanol yield or concentration, compared with baker's yeast, despite the increased xylose utilization, probably due to the considerable increase in glycerol production. A slight increase in xylose consumption was seen when glucose from SWM was fed at a low feed rate, after 48 hours, compared with batch SSCF. However, the ethanol yield and concentration remained in the same range as in batch mode. CONCLUSION: Ethanol concentrations of about 6% (w/v) were obtained, which will result in a significant reduction in the cost of downstream processing, compared with SSF of the lignocellulosic substrate alone. As an additional benefit, it is also possible to recover the protein-rich residue from the SWM in the process configurations presented, providing a valuable co-product.

Influence of fiber degradation and concentration of fermentable sugars on simultaneous saccharification and fermentation of high-solids spruce slurry to ethanol.

BACKGROUND: Saccharification and fermentation of pretreated lignocellulosic materials, such as spruce, should be performed at high solids contents in order to reduce the cost of the produced bioethanol. However, this has been shown to result in reduced ethanol yields or a complete lack of ethanol production. Previous studies have shown inconsistent results when prehydrolysis is performed at a higher temperature prior to the simultaneous saccharification and fermentation (SSF) of steam-pretreated lignocellulosic materials. In some cases, a significant increase in overall ethanol yield was reported, while in others, a slight decrease in ethanol yield was observed. In order to investigate the influence of prehydrolysis on high-solids SSF of steam-pretreated spruce slurry, in the present study, the presence of fibers and inhibitors, degree of fiber degradation and initial fermentable sugar concentration has been studied. RESULTS: SSF of whole steam-pretreated spruce slurry at a solids content of 13.7% water-insoluble solids (WIS) resulted in a very low overall ethanol yield, mostly due to poor fermentation. The yeast was, however, able to ferment the washed slurry and the liquid fraction of the pretreated slurry. Performing prehydrolysis at 48°C for 22 hours prior to SSF of the whole pretreated slurry increased the overall ethanol yield from 3.9 to 62.1%. The initial concentration of fermentable sugars in SSF could not explain the increase in ethanol yield in SSF with prehydrolysis. Although the viscosity of the material did not appear to decrease significantly during prehydrolysis, the degradation of the fibers prior to the addition of the yeast had a positive effect on ethanol yield when using whole steam-pretreated spruce slurry. CONCLUSIONS: The results of the present study suggest that the increase in ethanol yield from SSF when performing prehydrolysis is a result of fiber degradation rather than a decrease in viscosity. The increased concentration of fermentable sugars at the beginning of the fermentation phase in SSF following prehydrolysis did not affect the overall ethanol yield in the present study.

Ethanol and biogas production after steam pretreatment of corn stover with or without the addition of sulphuric acid.

BACKGROUND: Lignocellulosic biomass, such as corn stover, is a potential raw material for ethanol production. One step in the process of producing ethanol from lignocellulose is enzymatic hydrolysis, which produces fermentable sugars from carbohydrates present in the corn stover in the form of cellulose and hemicellulose. A pretreatment step is crucial to achieve efficient conversion of lignocellulosic biomass to soluble sugars, and later ethanol. This study has investigated steam pretreatment of corn stover, with and without sulphuric acid as catalyst, and examined the effect of residence time (5-10 min) and temperature (190-210°C) on glucose and xylose recovery. The pretreatment conditions with and without dilute acid that gave the highest glucose yield were then used in subsequent experiments. Materials pretreated at the optimal conditions were subjected to simultaneous saccharification and fermentation (SSF) to produce ethanol, and remaining organic compounds were used to produce biogas by anaerobic digestion (AD). RESULTS: The highest glucose yield achieved was 86%, obtained after pretreatment at 210°C for 10 minutes in the absence of catalyst, followed by enzymatic hydrolysis. The highest yield using sulphuric acid, 78%, was achieved using pretreatment at 200°C for 10 minutes. These two pretreatment conditions were investigated using two different process configurations. The highest ethanol and methane yields were obtained from the material pretreated in the presence of sulphuric acid. The slurry in this case was split into a solid fraction and a liquid fraction, where the solid fraction was used to produce ethanol and the liquid fraction to produce biogas. The total energy recovery in this case was 86% of the enthalpy of combustion energy in corn stover. CONCLUSIONS: The highest yield, comprising ethanol, methane and solids, was achieved using pretreatment in the presence of sulphuric acid followed by a process configuration in which the slurry from the pretreatment was divided into a solid fraction and a liquid fraction. The solid fraction was subjected to SSF, while the liquid fraction, together with the filtered residual from SSF, was used in AD. Using sulphuric acid in AD did not inhibit the reaction, which may be due to the low concentration of sulphuric acid used. In contrast, a pretreatment step without sulphuric acid resulted not only in higher concentrations of inhibitors, which affected the ethanol yield, but also in lower methane production.

Simultaneous saccharification and co-fermentation for bioethanol production using corncobs at lab, PDU and demo scales.

BACKGROUND: While simultaneous saccharification and co-fermentation (SSCF) is considered to be a promising process for bioconversion of lignocellulosic materials to ethanol, there are still relatively little demo-plant data and operating experiences reported in the literature. In the current work, we designed a SSCF process and scaled up from lab to demo scale reaching 4% (w/v) ethanol using xylose rich corncobs. RESULTS: Seven different recombinant xylose utilizing Saccharomyces cerevisiae strains were evaluated for their fermentation performance in hydrolysates of steam pretreated corncobs. Two strains, RHD-15 and KE6-12 with highest ethanol yield and lowest xylitol yield, respectively were further screened in SSCF using the whole slurry from pretreatment. Similar ethanol yields were reached with both strains, however, KE6-12 was chosen as the preferred strain since it produced 26% lower xylitol from consumed xylose compared to RHD-15. Model SSCF experiments with glucose or hydrolysate feed in combination with prefermentation resulted in 79% of xylose consumption and more than 75% of the theoretical ethanol yield on available glucose and xylose in lab and PDU scales. The results suggest that for an efficient xylose conversion to ethanol controlled release of glucose from enzymatic hydrolysis and low levels of glucose concentration must be maintained throughout the SSCF. Fed-batch SSCF in PDU with addition of enzymes at three different time points facilitated controlled release of glucose and hence co-consumption of glucose and xylose was observed yielding 76% of the theoretical ethanol yield on available glucose and xylose at 7.9% water insoluble solids (WIS). With a fed-batch SSCF in combination with prefermentation and a feed of substrate and enzymes 47 and 40 g l-1 of ethanol corresponding to 68% and 58% of the theoretical ethanol yield on available glucose and xylose were produced at 10.5% WIS in PDU and demo scale, respectively. The strain KE6-12 was able to completely consume xylose within 76 h during the fermentation of hydrolysate in a 10 m3 demo scale bioreactor. CONCLUSIONS: The potential of SSCF is improved in combination with prefermentation and a feed of substrate and enzymes. It was possible to successfully reproduce the fed-batch SSCF at demo scale producing 4% (w/v) ethanol which is the minimum economical requirement for efficient lignocellulosic bioethanol production process.

Glucose and xylose co-fermentation of pretreated wheat straw using mutants of S. cerevisiae TMB3400.

Wheat straw was pretreated and fermented to ethanol. Two strains, which had been mutated from the genetically modified Saccharomyces cerevisiae TMB3400, KE6-12 and KE6-13i, have been used in this study and the results of performance were compared to that of the original strain. The glucose and xylose co-fermentation ability was investigated in batch fermentation of steam-pretreated wheat straw (SPWS) liquid (undiluted, and diluted 1.5 and 2 times). Both strains showed improved xylose uptake in diluted SPWS liquid, and increased ethanol yields compared with the original TMB3400 strain, although xylitol formation also increased slightly. In undiluted SPWS liquid, however, only KE6-13i performed better than the original strain regarding xylose utilization. Fed-batch fermentation of 1.5 and 2 times diluted liquid was performed by adding the glucose-rich hydrolysates from enzymatic hydrolysis of the solid fraction of SPWS at a constant feed rate after 5 h of fermentation, when the glucose had been depleted. The modified strains showed improved xylose conversion; however, the ethanol yield was not significantly improved due to increased glycerol production. Fed-batch fermentation resulted in faster xylose utilization than in the batch cases.

Cellulose accessibility determines the rate of enzymatic hydrolysis of steam-pretreated spruce.

Spruce chips steam-pretreated at various conditions, according to a central composite design, were used for investigating the influence of pretreatment conditions on enzymatic hydrolysis, accounting for the individual effects of pretreatment temperature (194-220 °C), time (3-11 min) and sulfur dioxide uptake (0.7-2.5%). The materials were analyzed for several surface characteristics, including IR absorption, enzyme adsorption capacity, total surface area, cellulosic surface area, and cellulosic pore sizes. This work showed a clear correlation between rate of enzymatic hydrolysis and specific surface area. Although the lignin content of the particle surface increased at higher pretreatment temperature and residence time, the initial rate of enzymatic hydrolysis increased. Enzyme adsorption measurements and staining methods revealed that the higher rate of hydrolysis of these materials was due to increased accessibility of the cellulose. An accessible cellulose fraction is thus more important than a low surface lignin content for the enzymatic hydrolysis of steam-pretreated spruce.

Enhancement of the enzymatic digestibility of sugarcane bagasse by steam pretreatment impregnated with hydrogen peroxide.

Sugarcane bagasse was subjected to steam pretreatment impregnated with hydrogen peroxide. Analyses were performed using 2(3) factorial designs and enzymatic hydrolysis was performed at two different solid concentrations and with washed and unwashed material to evaluate the importance of this step for obtaining high cellulose conversion. Similar cellulose conversion were obtained at different conditions of pretreatment and hydrolysis. When the cellulose was hydrolyzed using the pretreated material in the most severe conditions of the experimental design (210 °C, 15 min and 1.0% hydrogen peroxide), and using 2% (w/w) water-insoluble solids (WIS), and 15 FPU/g WIS, the cellulose conversion was 86.9%. In contrast, at a milder pretreatment condition (190 °C, 15 min and 0.2% hydrogen peroxide) and industrially more realistic conditions of hydrolysis (10% WIS and 10 FPU/g WIS), the cellulose conversion reached 82.2%. The step of washing the pretreated material was very important to obtain high concentrations of fermentable sugars.

Techno-economic evaluation of 2nd generation bioethanol production from sugar cane bagasse and leaves integrated with the sugar-based ethanol process.

BACKGROUND: Bioethanol produced from the lignocellulosic fractions of sugar cane (bagasse and leaves), i.e. second generation (2G) bioethanol, has a promising market potential as an automotive fuel; however, the process is still under investigation on pilot/demonstration scale. From a process perspective, improvements in plant design can lower the production cost, providing better profitability and competitiveness if the conversion of the whole sugar cane is considered. Simulations have been performed with AspenPlus to investigate how process integration can affect the minimum ethanol selling price of this 2G process (MESP-2G), as well as improve the plant energy efficiency. This is achieved by integrating the well-established sucrose-to-bioethanol process with the enzymatic process for lignocellulosic materials. Bagasse and leaves were steam pretreated using H3PO4 as catalyst and separately hydrolysed and fermented. RESULTS: The addition of a steam dryer, doubling of the enzyme dosage in enzymatic hydrolysis, including leaves as raw material in the 2G process, heat integration and the use of more energy-efficient equipment led to a 37 % reduction in MESP-2G compared to the Base case. Modelling showed that the MESP for 2G ethanol was 0.97 US$/L, while in the future it could be reduced to 0.78 US$/L. In this case the overall production cost of 1G + 2G ethanol would be about 0.40 US$/L with an output of 102 L/ton dry sugar cane including 50 % leaves. Sensitivity analysis of the future scenario showed that a 50 % decrease in the cost of enzymes, electricity or leaves would lower the MESP-2G by about 20%, 10% and 4.5%, respectively. CONCLUSIONS: According to the simulations, the production of 2G bioethanol from sugar cane bagasse and leaves in Brazil is already competitive (without subsidies) with 1G starch-based bioethanol production in Europe. Moreover 2G bioethanol could be produced at a lower cost if subsidies were used to compensate for the opportunity cost from the sale of excess electricity and if the cost of enzymes continues to fall.

Separate hydrolysis and co-fermentation for improved xylose utilization in integrated ethanol production from wheat meal and wheat straw.

BACKGROUND: The commercialization of second-generation bioethanol has not been realized due to several factors, including poor biomass utilization and high production cost. It is generally accepted that the most important parameters in reducing the production cost are the ethanol yield and the ethanol concentration in the fermentation broth. Agricultural residues contain large amounts of hemicellulose, and the utilization of xylose is thus a plausible way to improve the concentration and yield of ethanol during fermentation. Most naturally occurring ethanol-fermenting microorganisms do not utilize xylose, but a genetically modified yeast strain, TMB3400, has the ability to co-ferment glucose and xylose. However, the xylose uptake rate is only enhanced when the glucose concentration is low. RESULTS: Separate hydrolysis and co-fermentation of steam-pretreated wheat straw (SPWS) combined with wheat-starch hydrolysate feed was performed in two separate processes. The average yield of ethanol and the xylose consumption reached 86% and 69%, respectively, when the hydrolysate of the enzymatically hydrolyzed (18.5% WIS) unwashed SPWS solid fraction and wheat-starch hydrolysate were fed to the fermentor after 1 h of fermentation of the SPWS liquid fraction. In the other configuration, fermentation of the SPWS hydrolysate (7.0% WIS), resulted in an average ethanol yield of 93% from fermentation based on glucose and xylose and complete xylose consumption when wheat-starch hydrolysate was included in the feed. Increased initial cell density in the fermentation (from 5 to 20 g/L) did not increase the ethanol yield, but improved and accelerated xylose consumption in both cases. CONCLUSIONS: Higher ethanol yield has been achieved in co-fermentation of xylose and glucose in SPWS hydrolysate when wheat-starch hydrolysate was used as feed, then in co-fermentation of the liquid fraction of SPWS fed with the mixed hydrolysates. Integration of first-generation and second-generation processes also increases the ethanol concentration, resulting in a reduction in the cost of the distillation step, thus improving the process economics.

A kinetic model for quantitative evaluation of the effect of hydrogen and osmolarity on hydrogen production by Caldicellulosiruptor saccharolyticus.

BACKGROUND: Caldicellulosiruptor saccharolyticus has attracted increased interest as an industrial hydrogen (H2) producer. The aim of the present study was to develop a kinetic growth model for this extreme thermophile. The model is based on Monod kinetics supplemented with the inhibitory effects of H2 and osmotic pressure, as well as the liquid-to-gas mass transfer of H2. RESULTS: Mathematical expressions were developed to enable the simulation of microbial growth, substrate consumption and product formation. The model parameters were determined by fitting them to experimental data. The derived model corresponded well with experimental data from batch fermentations in which the stripping rates and substrate concentrations were varied. The model was used to simulate the inhibition of growth by H2 and solute concentrations, giving a critical dissolved H2 concentration of 2.2 mmol/L and an osmolarity of 0.27 to 29 mol/L. The inhibition by H2, being a function of the dissolved H2 concentration, was demonstrated to be mainly dependent on H2 productivity and mass transfer rate. The latter can be improved by increasing the stripping rate, thereby allowing higher H2 productivity. The experimentally determined degree of oversaturation of dissolved H2 was 12 to 34 times the equilibrium concentration and was comparable to the values given by the model. CONCLUSIONS: The derived model is the first mechanistically based model for fermentative H2 production and provides useful information to improve the understanding of the growth behavior of C. saccharolyticus. The model can be used to determine optimal operating conditions for H2 production regarding the substrate concentration and the stripping rate.

Evaluation of steam-treated giant bamboo for production of fermentable sugars.

Giant bamboo plantations are currently being established in the Southern Africa region and can be considered as potential lignocellulosic feedstock for the production of second generation bioethanol. In this study, giant bamboo internodal material was subjected to sulphur dioxide (SO(2)) impregnated steam pretreatment prior to enzymatic hydrolysis. The effect of temperature, residence time, and acidity on the overall sugar recovery and byproduct formation was studied using response surface response technology according to a central composite experimental design (CCD) at a fixed SO(2) concentration of 2.5% (w/w liquid) after impregnation. The results showed that pretreatment conditions with combined severity factor (CSF) values and enzyme dosages greater than 1.72 and 30 FPU/g water insoluble solid, respectively, were required to obtain an efficient glucan digestibility and a good overall glucose recovery. Up to 81.2% of the sugar in the raw material was recovered for a CSF of 2.25. However, considering overall sugar yield and byproducts concentration, the pretreated material obtained with a CSF of 1.62 can be considered as the most appropriate for SSF experiments using a xylose-utilizing yeast. At these conditions, it could be possible to obtain up to 247 L of ethanol per dry ton of giant bamboo considering hexose and pentose sugars fermentation. This amount could be increased up to 292 L of ethanol per dry ton of giant bamboo with the maximum sugar yield obtained (CSF = 2.25) if the microorganism possesses robust fermentative characteristics as well as a high resistance to pretreatment by-products.

The influence of ferrous sulfate utilization on the sugar yields from dilute-acid pretreatment of softwood for bioethanol production.

By employing metal salts in dilute-acid pretreatment the severity can be reduced due to reduced activation energy. This study reports on a dilute-acid steam pretreatment of spruce chips by addition of a small amount of ferrous sulfate to the acid catalyst, i.e., either SO2, H2SO3 or H2SO4. The utilization of ferrous sulfate resulted in a slightly increased overall glucose yield (from 74% to 78% of the theoretical value) in pretreatment with SO2 and H2SO3. Impregnation with ferrous sulfate and sulfuric acid did not give any improvement compared with pretreatment based solely on H2SO4.

Bioconversion of industrial hemp to ethanol and methane: the benefits of steam pretreatment and co-production.

Several scenarios for ethanol production, methane production (by anaerobic digestion) and co-production of these, using autumn harvested hemp as substrate, were investigated and compared in terms of gross energy output. Steam pretreatment improved the methane production rate compared with mechanical grinding. The methane yield of steam pretreated stems was similar both with and without pre-hydrolysis with cellulolytic enzymes. Co-production of ethanol and methane from steam pretreated stems gave a high yield of transportation fuel, 11.1-11.7 MJ/kg processed stem dry matter (DM); more than twice that of ethanol production alone from hexoses, 4.4-5.1 MJ/kg processed stem DM. Co-production from the whole hemp plant would give 2600-3000 L ethanol and 2800-2900 m(3) methane, in total 171-180 GJ per 10,000 m(2) of agricultural land, based on a biomass yield of 16 Mg DM. Of this, the yeast and enzymes from ethanol production were estimated to contribute 700 m(3) (27 GJ) of methane.

Process design and economics of on-site cellulase production on various carbon sources in a softwood-based ethanol plant.

On-site cellulase enzyme fermentation in a softwood-to-ethanol process, based on SO(2)-catalysed steam pretreatment followed by simultaneous saccharification and fermentation, was investigated from a techno-economic aspect using Aspen Plus© and Aspen Icarus Process Evaluator© softwares. The effect of varying the carbon source of enzyme fermentation, at constant protein and mycelium yields, was monitored through the whole process. Enzyme production step decreased the overall ethanol yield (270 L/dry tonne of raw material in the case of purchased enzymes) by 5-16 L/tonne. Capital cost was found to be the main cost contributor to enzyme fermentation, constituting to 60-78% of the enzyme production cost, which was in the range of 0.42-0.53 SEK/L ethanol. The lowest minimum ethanol selling prices (4.71 and 4.82 SEK/L) were obtained in those scenarios, where pretreated liquid fraction supplemented with molasses was used as carbon source. In some scenarios, on-site enzyme fermentation was found to be a feasible alternative.

Techno-economic evaluation of stillage treatment with anaerobic digestion in a softwood-to-ethanol process.

BACKGROUND: Replacing the energy-intensive evaporation of stillage by anaerobic digestion is one way of decreasing the energy demand of the lignocellulosic biomass to the ethanol process. The biogas can be upgraded and sold as transportation fuel, injected directly into the gas grid or be incinerated on-site for combined heat and power generation. A techno-economic evaluation of the spruce-to-ethanol process, based on SO2-catalysed steam pretreatment followed by simultaneous saccharification and fermentation, has been performed using the commercial flow-sheeting program Aspen Plus™. Various process configurations of anaerobic digestion of the stillage, with different combinations of co-products, have been evaluated in terms of energy efficiency and ethanol production cost versus the reference case of evaporation. RESULTS: Anaerobic digestion of the stillage showed a significantly higher overall energy efficiency (87-92%), based on the lower heating values, than the reference case (81%). Although the amount of ethanol produced was the same in all scenarios, the production cost varied between 4.00 and 5.27 Swedish kronor per litre (0.38-0.50 euro/L), including the reference case. CONCLUSIONS: Higher energy efficiency options did not necessarily result in lower ethanol production costs. Anaerobic digestion of the stillage with biogas upgrading was demonstrated to be a favourable option for both energy efficiency and ethanol production cost. The difference in the production cost of ethanol between using the whole stillage or only the liquid fraction in anaerobic digestion was negligible for the combination of co-products including upgraded biogas, electricity and district heat.

Improved one-step steam pretreatment of SO2-impregnated softwood with time-dependent temperature profile for ethanol production.

In the production of ethanol from lignocellulosic material, pretreatment of the raw material before enzymatic hydrolysis and fermentation is essential to obtain high overall yields of sugar and ethanol. Two-step steam pretreatment results in higher ethanol yields from softwood than the standard one-step pretreatment process. However, the difficulty with separation and washing of the material at high pressure between the two pretreatment steps is a major drawback. In this study, a new one-step pretreatment procedure was investigated, in which the time-temperature profile was varied during pretreatment. The efficiency of pretreatment was assessed by performing simultaneous saccharification and fermentation on the pretreated slurries. Pretreatment of SO(2)-impregnated softwood performed by varying the temperature (190-226 degrees C), the residence time (5-10 min), and the mode of temperature increase (linear or stepwise), resulted in recovery of about 90% of the mannose and glucose present in the raw material. The highest ethanol yield, 75% of theoretical based on the glucan and mannan content of the raw material, was obtained at pretreatment conditions of 190 degrees C for 12 min. Similar ethanol yields were achieved when running the pretreatment as one-step (190-200 degrees C), two levels of temperature, at shorter residence time (7 min), which results in lower capital costs for the process.

Ethanol production from mixtures of wheat straw and wheat meal.

BACKGROUND: Bioethanol can be produced from sugar-rich, starch-rich (first generation; 1G) or lignocellulosic (second generation; 2G) raw materials. Integration of 2G ethanol with 1G could facilitate the introduction of the 2G technology. The capital cost per ton of fuel produced would be diminished and better utilization of the biomass can be achieved. It would, furthermore, decrease the energy demand of 2G ethanol production and also provide both 1G and 2G plants with heat and electricity. In the current study, steam-pretreated wheat straw (SPWS) was mixed with presaccharified wheat meal (PWM) and converted to ethanol in simultaneous saccharification and fermentation (SSF). RESULTS: Both the ethanol concentration and the ethanol yield increased with increasing amounts of PWM in mixtures with SPWS. The maximum ethanol yield (99% of the theoretical yield, based on the available C6 sugars) was obtained with a mixture of SPWS containing 2.5% water-insoluble solids (WIS) and PWM containing 2.5% WIS, resulting in an ethanol concentration of 56.5 g/L. This yield was higher than those obtained with SSF of either SPWS (68%) or PWM alone (91%). CONCLUSIONS: Mixing wheat straw with wheat meal would be beneficial for both 1G and 2G ethanol production. However, increasing the proportion of WIS as wheat straw and the possibility of consuming the xylose fraction with a pentose-fermenting yeast should be further investigated.

Impact of dual temperature profile in dilute acid hydrolysis of spruce for ethanol production.

BACKGROUND: The two-step dilute acid hydrolysis (DAH) of softwood is costly in energy demands and capital costs. However, it has the advantage that hydrolysis and subsequent removal of hemicellulose-derived sugars can be carried out under conditions of low severity, resulting in a reduction in the level of sugar degradation products during the more severe subsequent steps of cellulose hydrolysis. In this paper, we discuss a single-step DAH method that incorporates a temperature profile at two levels. This profile should simulate the two-step process while removing its major disadvantage, that is, the washing step between the runs, which leads to increased energy demand. RESULTS: The experiments were conducted in a reactor with a controlled temperature profile. The total dry matter content of the hydrolysate was up to 21.1% w/w, corresponding to a content of 15.5% w/w of water insoluble solids. The highest measured glucose yield, (18.3 g glucose per 100 g dry raw material), was obtained after DAH cycles of 3 min at 209 degrees C and 6 min at 211 degrees C with 1% H2SO4, which resulted in a total of 26.3 g solubilized C6 sugars per 100 g dry raw material. To estimate the remaining sugar potential, enzymatic hydrolysis (EH) of the solid fraction was also performed. EH of the solid residue increased the total level of solubilized C6 sugars to a maximum of 35.5 g per 100 g dry raw material when DAH was performed as described above (3 min at 210 degrees C and 2 min at 211 degrees C with 1% H2SO4). CONCLUSION: The dual-temperature DAH method did not yield decisively better results than the single-temperature, one-step DAH. When we compared the results with those of earlier studies, the hydrolysis performance was better than with the one-step DAH but not as well as that of the two-step, single-temperature DAH. Additional enzymatic hydrolysis resulted in lower levels of solubilized sugars compared with other studies on one-step DAH and two-step DAH followed by enzymatic hydrolysis. A two-step steam pretreatment with EH gave rise to a considerably higher sugar yield in this study.

Effects of enzyme feeding strategy on ethanol yield in fed-batch simultaneous saccharification and fermentation of spruce at high dry matter.

BACKGROUND: To make lignocellulosic fuel ethanol economically competitive with fossil fuels, it is necessary to reduce the production cost. One way to achieve this is by increasing the substrate concentration in the production process, and thus reduce the energy demand in the final distillation of the fermentation broth. However, increased substrate concentration in simultaneous saccharification and fermentation (SSF) processes has been shown to result in reduced ethanol yields and severe stirring problems. Because the SSF medium is being continuously hydrolyzed, running the process in fed-batch mode could potentially reduce the stirring problems and lead to increased ethanol yields in high-solids SSF. Different enzyme feeding strategies, with the enzymes either present in the reactor from start-up or fed into the reactor together with the substrate, have been studied, along with the influence of the enzyme feeding strategy on the final ethanol yield and productivity. RESULTS: In the present study, SSF was run successfully with 10% and 14% water-insoluble solids (WIS) in batch and fed-batch mode. The mixing of the material in the reactor was significantly better in fed-batch than batch mode, and similarly high or higher ethanol yields were achieved in fed-batch mode compared with batch SSF in some cases. No general trend in the dependence of ethanol yield on enzyme feeding strategy was found. CONCLUSIONS: The optimum enzyme feeding strategy appears to depend on the conditions during SSF, such as the WIS concentration and the concentration of inhibitory compounds in the SSF medium.