Ethanol fermentation technologies from sugar and starch feedstocks.

Pervaporation is one of the most active areas in membrane research, and the pervaporation process has been shown to be an indispensable component for chemical separations. In this paper, the recent development in pervaporation membranes and pervaporation processes is reviewed, and some outstanding questions involved in membrane pervaporation are discussed with emphasis on the following issues:  mass transport in the membrane, membrane material selection, concentration polarization in the boundary layer, pressure buildup in hollow fiber membranes, asymmetric and composite membranes, and the activation energy for permeation. We attempt to provide insight into this dynamic field and to highlight some of the outstanding problems yet to be solved or clarified.

Liquid Separation by Membrane Pervaporation: A Review

Although several separation technologies are technically capable of removing volatile products from fermentation broths, distillation remains the dominant technology. This is especially true for the recovery of biofuels such as ethanol. In this paper, the status of an emerging membrane-based technology, called pervaporation, for this application is reviewed. Several issues and research priorities which will impact the ability of pervaporation to be competitive for biofuel recovery from fermentation systems are identified and discussed. They include: increased energy efficiency; reduction of capital cost for pervaporation systems; longer term trials with actual fermentation broths; optimized integration of pervaporation with fermentor; synergy of performing both alcohol recovery and solvent dehydration by pervaporation with dephlegmation fractional condensation technology; and updated economic analyses of pervaporation at various biofuel production scales. Pervaporation is currently viable for biofuel recovery in a number of situations, but more widespread application will be possible when progress has been made on these issues. Published in 2005 for SCI by John Wiley & Sons, Ltd.

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A review of pervaporation for product recovery from biomass fermentation processes

Because biomass is a widely available, renewable resource, its utilisation for the production of energy has great potential for reducing CO2 emissions and thereby preventing global warming. In this mini-review the `state of the art' of several fermentation processes is discussed, starting with the most advanced process of ethanol production. This is followed by methane production, an established process for waste water purification which is gaining more attention because of the inherent energy production. Subsequently ABE fermentation is discussed and finally the biological production of hydrogen. The last section proposes a new way to assess and compare the different processes by relating their merit to `work content' values and `lost work' instead of the combustion values of their products. It is argued that, especially when dealing with energy from biomass, the application of this methodology will provide a uniform valuation for different processes and products. The described fermentation processes enable the supply of pure energy carriers, either gaseous or liquid, from biomass, yet the introduction of these processes is hampered by two major problems. The first is related to technological shortcomings in the mobilisation of fermentable components from the biomass. The second, having a much greater impact, is linked with socio-economics: until full externality costs are attributed to fossil fuels, accounting for their role in pollution and global warming, the competitiveness of the processes described here will hardly stand a chance.

Utilisation of biomass for the supply of energy carriers

Multi-column distillation followed by molecular sieve adsorption is currently the standard method for producing fuel-grade ethanol from dilute fermentation broths in modern corn-to-ethanol facilities. As the liquid biofuels industry transitions to lignocellulosic feedstocks, expands the end-product portfolio to include other alcohols, and encounters more dilute alcohol concentrations, alternative separation technologies which are more energy efficient than the conventional approach will be in demand. In this review, alcohol recovery technology options and alcohol dehydration technology options for the production of ethanol and 1-butanol are reviewed and compared, with an emphasis on the energy footprint of each approach. Select hybrid technologies are also described. Published in 2008 by John Wiley & Sons, Ltd

Separation technologies for the recovery and dehydration of alcohols from fermentation broths

Technologies for butanol recovery integrated with fermentations

Extraction can successfully be used for in-situ alcohol recovery in butanol fermentations to increase the substrate conversion. An advantage of extraction over other recovery methods may be the high capacity of the solvent and the high selectivity of the alcohol/water separation. Extraction, however, is a comprehensive operation, and the design of an extraction apparatus can be complex. The aim of this study is to assess the practical applicability of liquid-liquid extraction and membrane solvent extraction in butanol fermentations. In this view various aspects of extraction processes were investigated. Thirty-six chemicals were tested for the distribution coefficient for butanol, the selectivity of alcohol/water separation and the toxicity towards Clostridia. Convenient extractants were found in the group of esters with high molar mass. Liquid-liquid extraction was carried out in a stirred fermenter and a spray column. The formation of emulsions and the fouling of the solvent in a fermentation broth causes problems with the operation of this type of equipment. With membrane solvent extraction, in which the solvent is separated from the broth by a membrane, a dispersion-free extraction is possible, leading to an easy operation of the equipment. In this case the mass transfer in the membrane becomes important. With membrane solvent extraction the development of a process is emphasized in which the extraction characteristics of the solvent are combined with the property of silicone rubber membranes to separate butanol from water. In the case of apolar solvents with a high molar mass, the characteristics of the membrane process are determined completely by the solvent. In the case of polar solvents (e.g. ethylene glycol), the permselectivity of the membrane can profitably be used. This concept leads to a novel type of extraction process in which alcohol is extracted with a water-soluble solvent via a hydrophobic semipermeable membrane. This extraction process has been investigated for the recovery of butanol and ethanol from water. A major drawback in all processes with membrane solvent extraction was the permeation of part of the solvent to the aqueous phase. The extraction processes were coupled to batch, fed batch and continuous butanol fermentations to affirm the applicability of the recovery techniques in the actual process. In the batch and fed batch fermentations a three-fold increase in the substrate consumption could be achieved, in the continuous fermentation about 30% increase.

Butanol recovery from fermentations by liquid-liquid extraction and membrane solvent extraction

In the butanol/isopropanol batch fermentation adsorption of alcohols can increase the substrate conversion. The fouling of adsorbants by cells and medium components is severe, but this has no measured effect on the adsorption capacity of butanol in at least three successive fermentations. With the addition of some adsorbants it was found that the fermentation was drawn towards the production of butyric and acetic acid.

In situ product recovery by adsorption in the butanol/isopropanol batch fermentation

In a butanol batch fermentation the substrate consumption was increased threefold using in-situ product recovery by gas-stripping, in comparison with a control fermentation without product recovery. In a continuous fermentation in-situ recovery led to an increase in the biomass concentration, resulting in a threefold increase in productivity. The substrate consumption was increased by 10%. An external stripper was used as apparatus for the butanol recovery.

Batch and continuous butanol fermentations with free cells: integration with product recovery by gas-stripping

Glucose and xylose can be converted continuously and simultaneously to butanol using immobilized cells. Xylose is only converted when glucose is completely consumed and the biocatalyst is not fully inhibited by butanol. With pervaporation for in-situ butanol recovery the complete conversion of a feed containing 60 kg/m3 of mixed sugars is achieved.

W. J. Groot

Papers

Technologies for butanol recovery integrated with fermentations

Butanol recovery from fermentations by liquid-liquid extraction and membrane solvent extraction

In situ product recovery by adsorption in the butanol/isopropanol batch fermentation

Batch and continuous butanol fermentations with free cells: integration with product recovery by gas-stripping

Continuous production of butanol from a glucose/xylose mixture with an immobilized cell system coupled to pervaporation