Contaminant occurrence, identification and control in a pilot-scale corn fiber to ethanol conversion process.

While interest in bioethanol production from lignocellulosic feedstocks is increasing, there is still relatively little pilot-plant data and operating experience available for this emerging industry. A series of batch and continuous fermentation runs were performed in a pilot-plant, some lasting up to six weeks, in which corn fiber-derived sugars were fermented to ethanol using glucose-fermenting and recombinant glucose/xylose-fermenting yeasts. However, contamination by Lactobacillus bacteria was a common occurrence during these runs. These contaminating microorganisms were found to readily consume arabinose, a sugar not utilized by the yeast, producing acetic and lactic acids that had a detrimental effect on fermentation performance. The infections were ultimately controlled with the antibiotic virginiamycin, but routine use of antibiotics is cost prohibitive. The severity of the problem encountered during this work is probably due to use of a highly contaminated feedstock. Lignocellulosic conversion facilities will not employ aseptic designs. Instead, techniques similar to those employed in the corn-based fuel ethanol industry to control infections will be used. Effective control may also be possible by using fermentative microorganisms that consume all biomass-derived sugars.

A bioethanol process development unit: initial operating experiences and results with a corn fiber feedstock.

Interest in bioethanol production from lignocellulosic feedstocks for use as an alternative fuel is increasing, but near-term commercialization will require a low cost feedstock. One such feedstock, corn fiber, was tested in the US Department of Energy (DOE)/National Renewable Energy Laboratory (NREL) bioethanol pilot plant for the purpose of testing integrated equipment operation and generating performance data. During initial runs in 1995, the plant was operated for two runs lasting 10 and 15 days each and utilized unit operations for feedstock handling, pretreatment by dilute sulfuric-acid hydrolysis, yeast inoculum production, and simultaneous saccharification and fermentation using a commercially available cellulase enzyme. Although significant operational problems were encountered, as would be expected with the startup of any new plant, operating experience was gained and preliminary data were generated on corn fiber pretreatment and subsequent fermentation of the pretreated material. Bacterial contamination was a significant problem during these fermentations.