Synthesis of Glycerol Carbonate from Ethylene Carbonate Using Zinc Stearate as a Catalyst: Operating Conditions and Kinetic Modeling.

With the advent of biodiesel as a substitute/additive for diesel, the production of glycerol has experienced an increase, as it is an unavoidable byproduct of the biodiesel process; therefore, novel products and processes based on this triol are being very actively researched. Glycerol carbonate emerges as an advanced humectant from glycerol and a monomer for diverse polycarbonates. Its production in high yields and amounts can be achieved through the solventless transcarbonation of glycerol with other organic carbonates driven by alkaline catalysts, standing out amongst the cyclic carbonates due to its reactivity. Here, we have studied the main operational variables that affect the transcarbonation reaction of glycerol and ethylene carbonate catalyzed by zinc stearate: catalyst concentration, reagent molar ratio, and temperature. Subsequently, an appropriate kinetic model was fitted to all data obtained at 80 °C and several catalyst concentrations as well as reagent molar ratios. Finally, the selected kinetic model was extended and validated by fitting it to data obtained at several temperatures, finding that the activation energy of this reaction with this catalyst is around 69.2 kJ·mol-1. The kinetic model suggests that the reaction is bimolecular and elemental and that the process is interfacial in essence, with the catalyst dispersed in a narrow space between polar (glycerol) and nonpolar (ethylene carbonate) phases.

Modulating redox metabolism to improve isobutanol production in Shimwellia blattae.

BACKGROUND: Isobutanol is a candidate to replace gasoline from fossil resources. This higher alcohol can be produced from sugars using genetically modified microorganisms. Shimwellia blattae (p424IbPSO) is a robust strain resistant to high concentration of isobutanol that can achieve a high production rate of this alcohol. Nevertheless, this strain, like most strains developed for isobutanol production, has some limitations in its metabolic pathway. Isobutanol production under anaerobic conditions leads to a depletion of NADPH, which is necessary for two enzymes in the metabolic pathway. In this work, two independent approaches have been studied to mitigate the co-substrates imbalance: (i) using a NADH-dependent alcohol dehydrogenase to reduce the NADPH dependence of the pathway and (ii) using a transhydrogenase to increase NADPH level. RESULTS: The addition of the NADH-dependent alcohol dehydrogenase from Lactococcus lactis (AdhA) to S. blattae (p424IbPSO) resulted in a 19.3% higher isobutanol production. The recombinant strain S. blattae (p424IbPSO, pIZpntAB) harboring the PntAB transhydrogenase produced 39.0% more isobutanol than the original strain, reaching 5.98 g L-1 of isobutanol. In both strains, we observed a significant decrease in the yields of by-products such as lactic acid or ethanol. CONCLUSIONS: The isobutanol biosynthesis pathway in S. blattae (p424IbPSO) uses the endogenous NADPH-dependent alcohol dehydrogenase YqhD to complete the pathway. The addition of NADH-dependent AdhA leads to a reduction in the consumption of NADPH that is a bottleneck of the pathway. The higher consumption of NADH by AdhA reduces the availability of NADH required for the transformation of pyruvate into lactic acid and ethanol. On the other hand, the expression of PntAB from E. coli increases the availability of NADPH for IlvC and YqhD and at the same time reduces the availability of NADH and thus, the production of lactic acid and ethanol. In this work it is shown how the expression of AdhA and PntAB enzymes in Shimwellia blattae increases yield from 11.9% to 14.4% and 16.4%, respectively.

Production of MCM-41 Nanoparticles with Control of Particle Size and Structural Properties: Optimizing Operational Conditions during Scale-Up.

The synthesis of Mobil Composition of Matter 41 (MCM-41) mesoporous silica nanoparticles (MSNs) of controlled sizes and porous structure has been performed at laboratory and pilot plant scales. Firstly, the effects of the main operating conditions (TEOS -Tetraethyl ortosilicate- addition rate, nanoparticle maturation time, temperature, and CTAB -Cetrimonium bromide- concentration) on the synthesis at laboratory scale (1 L round-bottom flask) were studied via a Taguchi experimental design. Subsequently, a profound one-by-one study of operating conditions was permitted to upscale the process without significant particle enlargement and pore deformation. To achieve this, the temperature was set to 60 °C and the CTAB to TEOS molar ratio to 8. The final runs were performed at pilot plant scale (5 L cylindrical reactor with temperature and stirring speed control) to analyze stirring speed, type of impeller, TEOS addition rate, and nanoparticle maturation time effects, confirming results at laboratory scale. Despite slight variations on the morphology of the nanoparticles, this methodology provided MSNs with adequate sizes and porosities for biomedical applications, regardless of the reactor/scale. The process was shown to be robust and reproducible using mild synthesis conditions (2 mL⋅min-1 TEOS addition rate, 400 rpm stirred by a Rushton turbine, 60 min maturation time, 60 °C, 2 g⋅L-1 CTAB, molar ratio TEOS/CTAB = 8), providing ca. 13 g of prismatic short mesoporous 100-200 nm nanorods with non-connected 3 nm parallel mesopores.

Enzymatic hydrolysis of several pretreated lignocellulosic biomasses: Fractal kinetic modelling.

Enzymatic hydrolysis of three pre-treated lignocellulosic biomasses -LCB- (wheat straw-WS-, corn stover-CSV- and cardoon stems -CS-) is studied. These biomasses were pre-treated by two methods: diluted sulfuric acid and acid ethanol-water extraction at six severity levels (H values). Pretreated solid fractions were hydrolyzed with commercial enzyme cocktails at standard conditions. A first-order kinetic fractal model was fitted to the experimental results. This model accurately describes the hydrolysis of all biomasses at all pre-treatment conditions studied. The results show that the formal first-order kinetic constant k depends on the biomass nature. The hydrolysis rate increases as the pre-treatment severity does, while the fractal exponent value h decreases. With these pre-treatments, and in terms of k and h, WS is highly reactive and, at medium H with EW pretreatment, highly accessible; CSV has a low reactivity and high accessibility and CS has the lowest reactivity and an increasing accessibility as severity rises.

Dihydroxyacetone production from glycerol using Gluconobacter oxydans: Study of medium composition and operational conditions in shaken flasks.

The production of dihydroxyacetone from glycerol employing aerobic cultures of Gluconobacter oxydans is studied. Dihydroxyacetone is one of the most important value-added products obtained from glycerol, a by-product of biodiesel production. The effect of organic nitrogen source and initial substrate concentrations has been studied together with the possibility of product inhibition. Afterward, the influence of the main operating conditions (temperature, shaking speed, and initial biomass concentration) on in vivo glycerol dehydrogenase activity has also been considered. The results show no evidence of glycerol inhibition, but an important product inhibition was detected, which has been taken into account in a kinetic model for enzymatic activity description. In terms of operating conditions, pH was found to exert a great impact on glycerol conversion, being necessary to keep it above 4 to ensure complete glycerol conversion. The minimum temperature that maximized enzymatic activity was found to be 30°C. In addition, a surprising decoupling between biomass concentration and dihydroxyacetone production rate was observed when adding increasing nitrogen source concentrations at a fixed shaking speed. Glycerol dehydrogenase activity remains constant despite the increase in biomass concentration, contrary to what would be expected. This fact revealed the existence of a rate limiting factor, identified subsequently as oxygen transfer rate depending on the biomass concentration.

Liquor re-use strategy in lignocellulosic biomass fractionation with ethanol-water mixtures.

Liquor recycle in lignocellulosic biomass fractionation with ethanol-water has been studied. Runs have been carried out in a 6 L tank reactor with liquor recirculation. The liquors obtained in six successive fractioning operations have been analyzed together with the solid phase remnant. Experimental results revealed that the number of re-uses reduces solids recovery (from 52.2 to 42.6%) and cellulose recovery (from 28.1 to 23.3%) with minor or no effect on the hemicelluloses and lignin removal. The more remarkable effect is an increase of the glucose yield (from 76.7 to 95.3% after enzymatic hydrolysis during 72 h). The accumulation of acetic acid in the spent liquors (until 1.3 g/L) seems to be responsible of the higher enzymatic hydrolysis yield, from 76.3 (first use) to 87.7% (fifth re-use). Liquor re-use is effective to improve the sustainability of the pre-treatment obtaining a cellulose-rich solid easy to hydrolysate to sugars reducing energy consumption.

Thermal and operational deactivation of Aspergillus fumigatus ß-glucosidase in ethanol/water pretreated wheat straw enzymatic hydrolysis.

The stabilization effects on a novel commercial ß-glucosidase preparation from Aspergillus fumigatus during saccharification of ethanol-water pretreated wheat straw were analysed in comparison to this enzyme stability during cellobiose hydrolysis. For this purpose, the kinetics of ß-glucosidase residual activity during cellobiose hydrolysis from 40 till 70 °C were studied, resulting in the fitting of a first-order partial deactivation model. Furthermore, a subsequent fitting of a kinetic model including this first-order deactivation equation and a Michaelis-Menten equation with double competitive inhibition by glucose and uncompetitive inhibition by cellobiose to released glucose was successful. Finally, global enzyme deactivation and prospective deactivation of enzyme remaining in the liquid phase were evaluated during wheat straw hydrolysis at 50 °C as a relevant saccharification process. Results suggest that the presence of a solid substrate dramatically reduces the global deactivation rate of the enzyme and, in addition, there is no loss the stability of the enzyme in the liquid phase along the saccharification process, even for 72 h.

Resting cells isobutanol production by Shimwellia blattae (p424IbPSO): Influence of growth culture conditions.

Isobutanol is a promising gasoline additive and could even be a potential substitute used directly as combustible. In this work, the production of isobutanol from glucose by Shimwellia blattae (p424IbPSO) in resting cell cultures is studied. This production has two stages, involving a resting cell phase that has not been studied before. The cell growth was carried out under different operating conditions: temperature and medium composition (YE, ammonium, and IPTG concentrations), looking for the highest isobutanol production. Moreover, the cells were collected at three different growth times checking their isobutanol production capacity. The best operating conditions have been determined as: 30°C of temperature, a medium containing 1.5 g L-1 YE and 1.4 g L-1 of ammonium as nitrogen sources, adding 0.5 mM IPTG as inducer. The cells collected at early growth times are significantly more active. The use of S. blattae (p424IbPSO) in resting cells is a good strategy for the production of isobutanol from glucose yielding better results than in batch growth cultures, a yield of 60% attainment of theoretical maximum yield is obtained under optimal conditions. In addition, it has been demonstrated that if the cells are cultured at higher temperatures and with high IPTG concentrations, inclusion bodies are formed in the cytoplasm inhibiting the isobutanol production in the resting cell stage.

Pre-treatment of corn stover, Cynara cardunculus L. stems and wheat straw by ethanol-water and diluted sulfuric acid: Comparison under different energy input conditions.

Ethanol-water (EW) and diluted sulfuric acid (DSA) pre-treatment have been studied for lignocellulosic biomass (corn stover, Cynara cardunculus L. stems and wheat straw). Both pre-treatments have been compared taken into account: solids recovery, glucans recovery, xylans removed, delignification and glucose yield. In all cases, the amount of energy involved has been taken as a criterion for sustainability. In general terms, EW is more efficient to remove lignin and DSA more appropriate to hydrolysate xylans. The combined effect of delignification and xylans removal is responsible for the improvement in the enzymatic cellulose hydrolysis. Under conditions of moderate-low energy inputs, EW pre-treatment yields better results than DSA with glucose yields in the range of 50-60% for EW pre-treated corn stover and cardoon stems; while wheat straw pulps reach up to 80%. So, multiple raw materials biorefinery needs a previous study to fit the type and conditions of the pre-treatment to each feedstock.

Physico-chemical kinetic modelling of hydrolysis of a steam-explosion pre-treated corn stover: A two-step approach.

A physico-chemical kinetic model for the hydrolysis of pre-treated corn stover is proposed. This model takes into account two reactions in series, the hydrolysis of cellulose to cellobiose and the production of glucose from cellobiose. Experiments have been carried out with an industrial enzymatic cocktail from Trichoderma reesei containing endo and exoglucanases and a very low activity of ß-glucosidase. Kinetic parameters were calculated by fitting the proposed model to experimental data of cellulose and glucose concentrations with time. The kinetic parameters fulfilled all relevant statistical and physical criteria. The kinetic model has been validated with published saccharification data regarding differently pre-treated corn stover and enzymatic cocktail, in this case with a very high ß-glucosidase activity (as it is common in modern industrial cellulase cocktails). In both cases, the kinetic model proposed could be fitted very appropriately to cellulose hydrolysis data.

Behavior of several pseudomonas putida strains growth under different agitation and oxygen supply conditions.

The growth rate of four strains of Pseudomonas putida, KT2440, KT2442, KTH2, and KTH2 (pESOX3), under different fluid dynamic conditions has been studied. The cultures were conducted in a stirred tank bioreactor by changing the stirrer speed. Several process variables, such as biomass concentration, dissolved oxygen concentration, oxygen mass transfer rate and oxygen uptake rate, have been measured or calculated. Also cell viability was determined by viable colony counting in Petri dishes and culture samples were subjected into a transmission electron microscopy analysis, in order to describe the integrity of the individual cells. The experimental results show that the genetically modified organisms, the strains KTH2 and KTH2 (pESOX3), present a different growth under low agitation conditions, and low oxygen supply level, while the growth of the wild type strains, KT2440 and KT2442, followed the typical sigmoidal evolution that could be described by the logistic equation. The presence of outer membrane vesicles has been observed in the GMO strains. When the cultures were conducted at low stirrer speed, and so at low oxygen transfer rate, these vesicles were detected, indicating the bacterial response to oxidative stress, caused by the catalytic activity of the HpaC enzyme. For all of the strains tested, no hydrodynamic stress has been detected, even at very high agitation levels. © 2018 American Institute of Chemical Engineers Biotechnol. Prog., 34:900-909, 2018.

Wheat straw fractionation by ethanol-water mixture: Optimization of operating conditions and comparison with diluted sulfuric acid pre-treatment.

The fractionation of wheat straw by ethanol-water (EW) pre-treatment was studied regarding its main operating conditions: time, temperature, L/S ratio and ethanol percentage were optimized by using an orthogonal experimental design (Taguchi). Afterwards, diluted sulfuric acid (DSA) hydrolysis and EW treatments have been compared in terms of energy consumption and yield of a cellulosic solid residue able to be enzymatically hydrolyzed to glucose. Experimental results show that temperature is the only variable of EW with a significant effect on the quality of the pretreated solids. EW pre-treatment of wheat straw is more effective than DSA hydrolysis due to its higher capacity of delignification. Moreover, a high glucose yield (80%) can be obtained by enzymatic hydrolysis of a solid pretreated with a moderate energy input EW (160 °C, 45 min) while wheat straw needs of a higher energy input during DSA to produce a similar yield of glucose after saccharification.

Enzymatic saccharification of acid pretreated corn stover: Empirical and fractal kinetic modelling.

Enzymatic hydrolysis of corn stover was studied at agitation speeds from 50 to 500rpm in a stirred tank bioreactor, at high solid concentrations (20% w/w dry solid/suspension), 50°C and 15.5mgprotein·gglucane(-1). Two empirical kinetic models have been fitted to empirical data, namely: a potential model and a fractal one. For the former case, the global order dramatically decreases from 13 to 2 as agitation speed increases, suggesting an increment in the access of enzymes to cellulose in terms of chemisorption followed by hydrolysis. For its part, the fractal kinetic model fits better to data, showing its kinetic constant a constant augmentation with increasing agitation speed up to a constant value at 250rpm and above, when mass transfer limitations are overcome. In contrast, the fractal exponent decreases with rising agitation speed till circa 0.19, suggesting higher accessibility of enzymes to the substrate.

Influence of fluid dynamic conditions on enzymatic hydrolysis of lignocellulosic biomass: Effect of mass transfer rate.

The effect of fluid dynamic conditions on enzymatic hydrolysis of acid pretreated corn stover (PCS) has been assessed. Runs were performed in stirred tanks at several stirrer speed values, under typical conditions of temperature (50°C), pH (4.8) and solid charge (20% w/w). A complex mixture of cellulases, xylanases and mannanases was employed for PCS saccharification. At low stirring speeds (<150rpm), estimated mass transfer coefficients and rates, when compared to chemical hydrolysis rates, lead to results that clearly show low mass transfer rates, being this phenomenon the controlling step of the overall process rate. However, for stirrer speed from 300rpm upwards, the overall process rate is controlled by hydrolysis reactions. The ratio between mass transfer and overall chemical reaction rates changes with time depending on the conditions of each run.

Influence of oxygen transfer on Pseudomonas putida effects on growth rate and biodesulfurization capacity.

The growth rate and desulfurization capacity accumulated by the cells during the growth of Pseudomonas putida KTH2 under different oxygen transfer conditions in a stirred and sparged tank bioreactor have been studied. Hydrodynamic conditions were changed using different agitation conditions. During the culture, several magnitudes associated to growth, such as the specific growth rate, the dissolved oxygen concentration and the carbon source consumption have been measured. Experimental results indicate that cultures are influenced by the fluid dynamic conditions into the bioreactor. An increase in the stirrer speed from 400 to 700 rpm has a positive influence on the cell growth rate. Nevertheless, the increase of agitation from 700 to 2000 rpm hardly has any influence on the growth rate. The effect of fluid dynamics on the cells development of the biodesulfurization (BDS) capacity of the cells during growth is different. The activities of the intracellular enzymes involved in the 4S pathway change with dissolved oxygen concentration. The enzyme activities have been evaluated in cells at several growth time and different hydrodynamic conditions. An increase of the agitation from 100 to 300 rpm has a positive influence on the development of the overall BDS capacity of the cells during growth. This capacity shows a decrease for higher stirrer speeds and the activity of the enzymes monooxygenases DszC and DszA decreases dramatically. The highest value of the activity of DszB enzyme was obtained with cells cultured at 100 rpm, while this activity decreases when the stirrer speed was increased higher than this value.

1,3-Propanediol production by Klebsiella oxytoca NRRL-B199 from glycerol. Medium composition and operational conditions.

Production of 1,3-propanediol from glycerol using Klebsiella oxytoca NRRL-B199 has been studied. Medium composition has been optimized by means of a statistical design based on the Taguchi method. Strong influences of glycerol and phosphate concentrations have been detected on biomass and product yields. Other factors, such as magnesium concentration and K:Na ratio, have shown a small influence on both responses, biomass and product concentrations. An optimized medium composition has been proposed, leading to a final 1,3-propanediol concentration of 12.4 g/L with a selectivity of 72% with respect to glycerol consumed at shaken bottle-scale. Once the medium composition had been optimized, the scale-up from shaken bottles to STBR was conducted. Several experiments in a 2 L STBR have been conducted in order to determine the best operating conditions concerning temperature and agitation. Under the best operating conditions, i.e., a programmed variable stirring rate ranging from 50 to 100 rpm and a temperature of 37 °C, a final concentration of 13.5 g/L of 1,3-propanediol with a selectivity of 86% with respect to the glycerol consumed was obtained.

Disproportionation of rosin on an industrial Pd/C catalyst: reaction pathway and kinetic model discrimination.

In this work, a phenomenological study of the isomerisation and disproportionation of rosin acids using an industrial 5% Pd on charcoal catalyst from 200 to 240°C is carried out. Medium composition is determined by elemental microanalysis, GC-MS and GC-FID. Dehydrogenated and hydrogenated acid species molar amounts in the final product show that dehydrogenation is the main reaction. Moreover, both hydrogen and non-hydrogen concentration considering kinetic models are fitted to experimental data using a multivariable non-linear technique. Statistical discrimination among the proposed kinetic models lead to the conclusion hydrogen considering models fit much better to experimental results. The final kinetic model involves first-order isomerisation reactions of neoabietic and palustric acids to abietic acid, first-order dehydrogenation and hydrogenation of this latter acid, and hydrogenation of pimaric acids. Hydrogenation reactions are partial first-order regarding the acid and hydrogen.

Analysis of dibenzothiophene desulfurization in a recombinant Pseudomonas putida strain.

Biodesulfurization was monitored in a recombinant Pseudomonas putida CECT5279 strain. DszB desulfinase activity reached a sharp maximum at the early exponential phase, but it rapidly decreased at later growth phases. A model two-step resting-cell process combining sequentially P. putida cells from the late and early exponential growth phases was designed to significantly increase biodesulfurization.

Bioreactor scale-up and oxygen transfer rate in microbial processes: an overview.

In aerobic bioprocesses, oxygen is a key substrate; due to its low solubility in broths (aqueous solutions), a continuous supply is needed. The oxygen transfer rate (OTR) must be known, and if possible predicted to achieve an optimum design operation and scale-up of bioreactors. Many studies have been conducted to enhance the efficiency of oxygen transfer. The dissolved oxygen concentration in a suspension of aerobic microorganisms depends on the rate of oxygen transfer from the gas phase to the liquid, on the rate at which oxygen is transported into the cells (where it is consumed), and on the oxygen uptake rate (OUR) by the microorganism for growth, maintenance and production. The gas-liquid mass transfer in a bioprocess is strongly influenced by the hydrodynamic conditions in the bioreactors. These conditions are known to be a function of energy dissipation that depends on the operational conditions, the physicochemical properties of the culture, the geometrical parameters of the bioreactor and also on the presence of oxygen consuming cells. Stirred tank and bubble column (of various types) bioreactors are widely used in a large variety of bioprocesses (such as aerobic fermentation and biological wastewater treatments, among others). Stirred tanks bioreactors provide high values of mass and heat transfer rates and excellent mixing. In these systems, a high number of variables affect the mass transfer and mixing, but the most important among them are stirrer speed, type and number of stirrers and gas flow rate used. In bubble columns and airlifts, the low-shear environment compared to the stirred tanks has enabled successful cultivation of shear sensitive and filamentous cells. Oxygen transfer is often the rate-limiting step in the aerobic bioprocess due to the low solubility of oxygen in the medium. The correct measurement and/or prediction of the volumetric mass transfer coefficient, (k(L)a), is a crucial step in the design, operation and scale-up of bioreactors. The present work is aimed at the reviewing of the oxygen transfer rate (OTR) in bioprocesses to provide a better knowledge about the selection, design, scale-up and development of bioreactors. First, the most used measuring methods are revised; then the main empirical equations, including those using dimensionless numbers, are considered. The possible increasing on OTR due to the oxygen consumption by the cells is taken into account through the use of the biological enhancement factor. Theoretical predictions of both the volumetric mass transfer coefficient and the enhancement factor that have been recently proposed are described; finally, different criteria for bioreactor scale-up are considered in the light of the influence of OTR and OUR affecting the dissolved oxygen concentration in real bioprocess.

Prediction of gas-liquid mass transfer coefficient in sparged stirred tank bioreactors.

Oxygen mass transfer in sparged stirred tank bioreactors has been studied. The rate of oxygen mass transfer into a culture in a bioreactor is affected by operational conditions and geometrical parameters as well as the physicochemical properties of the medium (nutrients, substances excreted by the micro-organism, and surface active agents that are often added to the medium) and the presence of the micro-organism. Thus, oxygen mass transfer coefficient values in fermentation broths often differ substantially from values estimated for simple aqueous solutions. The influence of liquid phase physicochemical properties on kLa must be divided into the influence on k(L) and a, because they are affected in different ways. The presence of micro-organisms (cells, bacteria, or yeasts) can affect the mass transfer rate, and thus kLa values, due to the consumption of oxygen for both cell growth and metabolite production. In this work, theoretical equations for kLa prediction, developed for sparged and stirred tanks, taking into account the possible oxygen mass transfer enhancement due to the consumption by biochemical reactions, are proposed. The estimation of kLa is carried out taking into account a strong increase of viscosity broth, changes in surface tension and different oxygen uptake rates (OURs), and the biological enhancement factor, E, is also estimated. These different operational conditions and changes in several variables are performed using different systems and cultures (xanthan aqueous solutions, xanthan production cultures by Xanthomonas campestris, sophorolipids production by Candida bombicola, etc.). Experimental and theoretical results are presented and compared, with very good results.