Ethanol production from rice straw by simultaneous saccharification and fermentation employing a non-conventional stirred reactor

Author(s)

Rafael Cunha de Assis Castro

• Document type: Doctoral Thesis
• Press: Lorena.
• Institution: Universidade de São Paulo (USP). Escola de Engenharia de Lorena (EEL/ASDI)
• Defense date: 2017-02-03

Examining board members

Inês Conceição Roberto; Solange Ines Mussatto Dragone; André Luis Ferraz; Daniel Bonoto Gonçalves; Adalberto Pessoa Junior

• Advisor: Inês Conceição Roberto

Abstract

The aim of this work was to study the ethanol production by simultaneous saccharification and fermentation (SSF) from rice straw in a non-conventional agitated reactor, called Vertical Ball Mill (VBM). It was also objective of this study to perform a techno-economic analysis from the experimental results achieved during the biomass processing, using the biorefinery concept. Initially, the rice straw was submitted to a sequential pretreatment consisting of an alkaline step (deacetylation) followed by dilute acid hydrolysis. The pretreatment effects were evaluated based on rice straw\'s structural modifications and regarding cellulose conversion (CC) from each obtained solid. Based on the results were defined the best conditions for the deacetylation step (80 mg NaOH/g of rice straw in natura, 70 °C, 45 min), acid hydrolysis (100 mg H2SO4/g deacetylated straw 121 °C, 85 min) and enzyme loading (21.5 FPU and 26.5 IU ?-glucosidase/g cellulose). Under these conditions, assays were carried out in VBM reactor to evaluate the effect of stirring speed (100-200 rpm), number of spheres (0-30) and temperature (40-46°C) on saccharification of deacetylated cellulignin and fermentation efficiency by Kluyveromyces marxianus NRRL Y-6860 in semisynthetic media. After defining the significant variables, experiments were carried out in VBM reactor by SSF configuration in batch and fed-batch operational modes. In batch SSF at 8% solids, was obtained an ethanol concentration of 23.1 g/L, with a process efficiency (?) of 89.8%, and volumetric productivity (QP) of 1.6 g /L.h, in the following operating conditions: 200 rpm, 18 spheres and 41.5 °C. However, by increasing solids content to 24%, both parameters (? and QP) were decreased by 50%. In order to improve the process parameters to 24% solids, fed-batch experiments were performed. In the best substrate feeding policy was produced 52.3 g/L ethanol (? = 67,5%) in 48-h process (QP = 1.1 g/L.h). The lignin-rich fractions from the alkaline liquor and from fed-batch fermentation residue were characterized regarding its chemical composition and physical properties and analyzed for antioxidant activity. Based on these results were suggested possible applications for both lignin-rich residues. Finally, considering the mass balance from all rice straw processing steps, a techno-economic analysis was assessed using SuperPro Designer software. The simulation procedures have indicated that, for all evaluated scenarios, the acid pretreatment step had the highest impact on operating costs, followed by the fermentation steps (xylose and glucose). It was also shown that xylose conversion into xylitol provided a better payback rather than its conversion into ethanol. Therefore, to attain a viable and profitable process for this type of rice straw based biorefinery, in addition to the diversification of products obtained from the sugary fractions, it is crucial to explore the potential of lignin-rich streams. (AU)

• FAPESP's process: 13/13953-6 - Ethanol production from rice straw by simultaneous saccharification and fermentation employing a non-conventional stirred reactor
• Grantee: Rafael Cunha de Assis Castro
• Support Opportunities: Scholarships in Brazil - Doctorate