EP3464555A1 - Verfahren zur züchtung von essbarem filamentösen pilz und dessen integration in der herkömmlichen zucker-zu-ethanol-herstellung - Google Patents
Verfahren zur züchtung von essbarem filamentösen pilz und dessen integration in der herkömmlichen zucker-zu-ethanol-herstellungInfo
- Publication number
- EP3464555A1 EP3464555A1 EP17806038.0A EP17806038A EP3464555A1 EP 3464555 A1 EP3464555 A1 EP 3464555A1 EP 17806038 A EP17806038 A EP 17806038A EP 3464555 A1 EP3464555 A1 EP 3464555A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fungal
- vinasse
- biomass
- process according
- ethanol
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
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Classifications
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12N—MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA
- C12N1/00—Microorganisms, e.g. protozoa; Compositions thereof; Processes of propagating, maintaining or preserving microorganisms or compositions thereof; Processes of preparing or isolating a composition containing a microorganism; Culture media therefor
- C12N1/14—Fungi; Culture media therefor
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23K—FODDER
- A23K10/00—Animal feeding-stuffs
- A23K10/30—Animal feeding-stuffs from material of plant origin, e.g. roots, seeds or hay; from material of fungal origin, e.g. mushrooms
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P1/00—Preparation of compounds or compositions, not provided for in groups C12P3/00 - C12P39/00, by using microorganisms or enzymes
- C12P1/02—Preparation of compounds or compositions, not provided for in groups C12P3/00 - C12P39/00, by using microorganisms or enzymes by using fungi
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P21/00—Preparation of peptides or proteins
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P7/00—Preparation of oxygen-containing organic compounds
- C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
- C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
- C12P7/06—Ethanol, i.e. non-beverage
- C12P7/08—Ethanol, i.e. non-beverage produced as by-product or from waste or cellulosic material substrate
Definitions
- the present invention relates to a process for edible fungal cultivation by employing vinasse or spent wash of first generation ethanol production as a substrate. More particularly, the present invention relates to a process for edible fungal cultivation in the form of pellets. Further, the present invention relates to the integration of fungal cultivation into the first generation sugar to ethanol production.
- Sugarcane or sugar beet is one of the most abundantly used feedstocks for bioethanol production worldwide.
- Ethanol is produced by fermentation of plant crops containing starch and sugar such as wheat, sugarcane, sugar beet and corn.
- Ethanol production from sugar is either directly obtained from sugarcane juice which is extracted from sugarcane or from beet sugar leaving behind bagasse that is generally used for electricity or energy generation or from molasses, a low value co-product of raw sugar production.
- cane juice is the dominant feedstock for ethanol production in most Brazilian factories, a large number of producers in Indonesia, India, the Caribbean, and a significant number in Brazil, mostly manufacture ethanol from molasses.
- Molasses is used either as a cattle feed supplement in specialized yeast propagation, as a fertilizer, or as a flavoring agent in some foods.
- fermentable sugars in molasses cannot be further upgraded to raw sugar, they can be converted to ethanol in a distillery using conventional ethanol fermenting microorganisms such as yeast.
- integrated sugarcane factories having a sugar manufacturing industry co-located with an ethanol distillery can use molasses as a feedstock for ethanol production in addition to raw cane juice directly from the mill.
- a significant number of sugarcane factories in Brazil and India and several other such factories employ this strategy of integrating sugar industries with ethanol distilleries.
- V inasse is the final by-product of biomass distillation, mainly for production of ethanol, from sugar crops (beet and sugarcane), starch crops (corn, wheat, rice, and cassava), or cellulosic material (harvesting crop residues, sugarcane bagasse, and wood).
- V inasse is usually produced as an acidic compost having pH varying from about 3.5 to about 5, a dark brown slurry, with high organic content (chemical oxygen demand 50 " 150 g L B1 ), and characterized by an unpleasant odor, with high contents of potential hazardous substances (Christofoletti et al., 2013). It has been estimated that for every liter of ethanol, around 12 " 15 L of residue is produced.
- vinasse applied to farming lands as fertilizer can cause serious water and soil pollution, such as leaching of metals to groundwater, changes in soil quality, increase of phototoxicity, unpleasant odor, as well as leading to considerable methane emissions during temporary storage or transportation and also nitrous oxide emissions (Carmo et al., 2013; Christofoletti et al., 2013; De Oliveira et al., 2013; Dias et al., 2016).
- a foremost drawback is encountered by filamentous growth forms of the fungi causing several cultivation challenges, while scaling up an integration process at the existing sugar to ethanol facilities.
- the broth viscosity caused by the filamentous nature of the fungi negatively affects the mixing and aeration of the culture; mycelial clumps can wrap around impellers; all of which can lead to a decrease in production efficiency and bioreactor performance (Gibbs et al., 2000, Critical Reviews in Biotechnology, 20(1), 17-48).
- Another object of the present invention is to optimize fungal culture conditions to obtain high yield of the fungal biomass.
- Y et another object of the present invention is to provide animal feed including cattle, or poultry, or fish feed; or human feed comprising the fungal biomass of the present process and an agricultural fertilizer.
- the present invention provides a process for cultivating edible fungal biomass selected from members of the phylum Ascomycota, excluding the order, Saccharomycetales in high yield, the said process comprising;
- step (b) inoculating fungal culture in the culture medium of step (a), and maintaining a pH of upto 7 followed by incubation at a temperature range 20 to 40eC for 24 to 120 hours to obtain edible fungal biomass in high yield.
- the present invention provides the preferable concentrations wherein higher fungal yield was obtained. Accordingly, the culture medium comprising vinasse in a preferable concentration of 5% to 20% (v/v), at the most preferable incubation temperature at 35eC and incubation duration of 72 hours.
- fungal biomass is produced employing the present process in the range from about 50g/L to about 250g/L .
- the present invention provides the cultivation of edible fungal biomass selected from Ascomycetes, the fungus including, but not limited to species of Aspergillus spp., and Neurospora spp are employed herein.
- the present invention provides the integration of the process for cultivating edible fungal biomass into a conventional process of ethanol production in sugar industries.
- the present invention provides the reduction in the heavy metal content, soluble chemical oxygen demand (COD), and medium viscosity of diluted vinasse used as a substrate for edible fungal cultivation.
- COD soluble chemical oxygen demand
- the present invention provides a culture medium comprising vinasse obtained from conventional alcohol production in a concentration ranging from about 1 % to 50% (v/v) with the optional addition of nutritional supplements being optional.
- the present invention provides a fungal biomass product for use as an aquaculture or animal or human feed supplement, as a fertilizer or as a flavoring agent in certain foods.
- F igure 1 depicts integration of fungal cultivation into a conventional fermentation process, wherein fungal cultivation is carried out in a bioreactor with spent wash/ vinasse obtained from evaporation stage of conventional ethanol production process;
- F igure 2 depicts the integrated fungal cultivation step is added after the di sti 11 ati on step, pri or to the evaporati on step;
- F igure 3 depicts fermentation using fungal biomass as inoculum at optimum conditions: vinnase dilution 10% v/v, pH 5.5 (for N. intermedia) and 6.0 (for A. oryzae), temperature 35eC and time 72 h;
- F igure 4 depicts Sugars and organic acids profile: Fungal fermentation on vinasse at optimum conditions in bench scale airlift reactor (a) N. intermedia (pH 5.5) and (b) A. oryzae (pH 6.0) at vinnase dilution 10%, (v/v), temperature 35eC and time 72 h.
- the said figure represents- lactic acid (IV); glycerol ( 1 ; acetic acid (v3 ⁇ 4 glucose (a); cellobiose ( ° ) and ethanol ( * ) concentration (g/L of dilute vinasse- 10%).
- V inasse refers to the unwanted residual liquid waste generated during alcohol production from sugarcane or sugar beet; therefore, references in the present invention to vinasse are to be construed as references to spent wash.
- the present invention provides a process for cultivating edible fungal biomass selected from members of the phylum Ascomycota, excluding the order, Saccharomycetales in high yield, the said process comprising;
- the present invention provides a process for cultivation of edible fungal biomass selected from Ascomycetes, the fungus including, but not limited to species of Aspergillus spp. and Neurospora spp are employed herein.
- the concentration of vinasse employed is ranging from about 1 % to 50% (v/v), more preferably the concentration of vinasse in culture medium is ranging from about 5% to 20% (v/v).
- the most preferable concentration of vinasse used in the present invention is 10% (v/v).
- the present invention also provides applications of spent wash from fermentation processes including industrial waste streams having constituents similar to that of vinasse used in the present invention.
- the constituent make-up of vinasse as described in Tables 1(a) to 1(d) is conducive for the growth of edible fungi by the process of the present invention.
- O her culture conditions such as the pH of the culture medium is in the range from about 5 to 6.5, the temperature of cultivation is in the range from about 25eC to 45eC, and the duration for cultivation ranges from about 24hrs to 96hrs.
- the present process for cultivation of fungi is most preferably performed in a culture medium having vinasse concentration ranging from about 5% to 20% (v/v), at a temperature of 35eC for duration of 72 hours.
- cultivation is carried out at pH of 5.5 for Neurospora intermedia and 6.0 for Aspergillus oryzae.
- Table 2 describes the optimization of the fungal conditions to achieve a high yield of various edible fungi.
- the present invention provides introduction of the fungal inoculum, which is the edible ascomycete Aspergillus oryzae var. oryzae C BS 819.72 and Neurospora intermedia CBS 131.92 (Centraal bureau voor Schimmelcultures, Netherlands), maintained on potato dextrose agar (PDA) slants containing (in g/L) potato extract 4; dextrose 20; agar 15 (renewed every six months), i n the cultivati on medi um rangi ng from 1 B10 1 to 1 B10 8 spores /mL .
- the fungal inoculum added to the vinasse media as the seed culture is either in the form of spores or as mycelial filamentous biomass.
- the present invention provides the yield of fungal biomass to be ranging from about 50g/L to about 250g/L of vinasse.
- batch cultivations employing vinasse as a substrate without additional nutrient supplementation presented an efficient fungal growth ranging from about 202 g and 223 g dry fungal biomass (per liter of vinasse) for N. intermedia and A.oryzae respectively.
- the present invention provides addition of nutrient supplements not limited to but selected from the group consisting of carbon, nitrogen and other nutrients or salts.
- the present invention provides integration of the process for cultivating edible fungal biomass into a conventional process of sugar to ethanol production by using any forms of fungal bioreactor.
- the present invention discloses the use of vinasse from the existing or new ethanol plants that uses either sugar-juice or molasses for ethanol production process.
- the sugar juice or molasses in this context is either from sugar cane or from beet sugar.
- the two scenarios of the integration processes are described in Figures 1 and 2.
- FIG 1 depicts fungal cultivation carried out in a bioreactor with vinasse obtained from the evaporation stage of conventional ethanol production process in existing or new sugar industries.
- an integrated fungal cultivation step is added after the distillation step, prior to the evaporation step.
- the dilute spent wash/vinasse from distillation is sent directly to the fungal cultivation step. Accordingly, spent wash and vinasse may be interchangeably used for the purposes of the present i nvention.
- the vinasse/spent wash dilution is made ranging between 1 to 50% (v/v) resulting in the diluted vinasse with reduced content of total carbon and other constituents such as heavy metals and other ions selected from K, S, Na.
- the fungal inoculum either in the form of spore or mycelial filamentous biomass is added to the vinasse media as the seed culture.
- the fermentation media optionally is supplemented with additional nutrient sources.
- the fungal cultures include the members of phylum Ascomycota, excluding the order Saccharomycetales.
- the present invention provides the cultivation of fungal biomass in the form of pellets having size in the range of 2 mm to 4mm.
- the fungal cultivation results in ethanol production in the range of but not limited to 0.1 to 12 g/L, which in the present invention may also be referred to as additional ethanol.
- the : additional ethanol " as described in the present invention is ethanol produced from vinasse substrate using the filamentous fungi under the process conditions.
- the additional ethanol is directed to the fermentation step or directly to the distillation step of the current existing ethanol process line without additional recovery step ( F igure 2).
- the additional ethanol production improves the overall ethanol production process of any existing or new fermentation facility, typically as between 1-20%, such as the least between 1-2.5% or between 2.5-5% or between 5-10%.
- the fungal biomass is harvested by conventional processes such as drying or simple sieving, filtration or any other process of solid-liquid separation method.
- the present invention comprises fungal biomass having protein content ranging between 10 to 70% such as in between the range of 50% to 55 % or 60%.
- a representative non-purified fungal biomass according to the present invention comprises 45-55% (% of DS) protein, 5-20 % (% of DS) fat, 2-5 % (% of protein) lysine and 1-3 % (% of protein) methionine.
- the present invention provides the process of fungal cultivation is carried out in reactors selected from the group comprising reactors with type as stirred tank, airlift, bubble column or bubble distributor or bubble riser.
- reactors are constructed of material selected from the group comprising steel, concrete, fabric, metal, plastic, carbon fiber or any chemically developed material in any form as of a container.
- the fungal biomass can be used either directly or in any other forms as a nutritional substitute for human or domestic food or feed applications.
- Domestic feed in the present invention includes, animal, poultry, fish feed products, either as direct or as constituent of any existing or new food or feed products.
- the spent liquid resulting from the fungal biomass separation is used as the fertilizer, either directly or with the inclusion of the evaporation or drying step, as indicated in Figure 1.
- the spent liquid can be used post the evaporation of ethanol and water mixture as in Figure 2.
- the spent liquid generated is evaporated with additional ethanol produced during the fungal cultivation and is sent back (together with the water) to the existing fermentation step of the current process line.
- the present invention provides a fungal feed composition having high protein content comprising fungal biomass cultivated by the process of the present invention, wherein the protein content is in the range of 45% to 55% of the total biomass and further comprising fat content from about 5%-20 %, lysine content from about 2% - 5% and methionine content from about 1 %-3 % of the total biomass.
- the spent liquid or the spent wash can be used as a fertilizer in the agricultural field either as directly or supplemented with any other forms of solid or liquid residues such as press- mud.
- the present invention reduces the organic content of the spent wash / vinasse, with the total chemical oxygen demand (TCOD) or soluble chemical oxygen demand (SCOD) reduction in the range 5 to 100%.
- TCOD total chemical oxygen demand
- SCOD soluble chemical oxygen demand
- the reduction in organic content is described as the difference between the vinasse composition feeding into the fungal cultivation bioreactor and those going out of the bioreactor as the spent liquid.
- the present invention also reduces the viscosity of the spent wash or vinasse by about 1 to 50% reduction.
- the viscosity of the spent wash before and after fungal cultivation is considered for this purpose.
- the present invention also describes the glycerol utilization by the filamentous fungi with the maximum of 1 to 100 % reduction in the total glycerol content of the vinasse substrate either in the diluted or in the crude state.
- the present invention provides edible fungal biomass produced by the present process for use as cattle or poultry or fish feed supplement, as a fertilizer or as a flavoring agent in certain foods.
- the edible fungi can be used in appropriate concentrations and in formulations for its intended use.
- Optimal growth factors such as vinasse concentration (% v/v dilution), media pH, culture temperature, and cultivation time were screened (Table 2).
- As the nutrient constituents in vinasse mostly favored the fungal biomass production ethanol production remained limited upto 12 g (per L of vinasse media) for N. intermedia and upto 10.5 g (per L of vinasse media) for A. oryzae, at 10% (v/v) vinasse dilution (Table 2).
- the concentration of vinasse post the ethanol distillation at the industrial production stream (i.e. 20% v/v) was kept as the basal screening media, with levels of dilution 5 to 15% v/v, tested for the fungal growth.
- Prolific fungal growth was observed in the diluted vinasse samples, 10% (v/v dilution) with the maximum biomass production, 196 and 209 g/L dry fungal biomass for N. intermedia and A. oryzae respectively (Table 2).
- the significantly higher amount of chemical constituents, mainly organic acids and cations such as K, Ca and Mg (Christofoletti et al., 2013) together with low fermentable sugar levels resulted in reduced fungal growth at 20% v/v vinasse media as compared to the diluted sample.
- the initial fungal growth screening was made on the vinasse diluted to 5, 10, 20, 30, 40, 50 (% v/v). Further screening was made on the factors such as cultivation time (24, 48, 72 and 96 h); media pH (4.5, 5.0, 5.5, 6.0, 6.5 (e 0.1)); temperature (25, 35 and 45eC) and media sterilization (with and without). These factors were optimized in a sequential order, where the optimum values obtained for one specific factor was kept constant to obtain the optimum values of the following factors. Ethanol concentration and fungal biomass yield were used as the variables to determine the optimum conditions.
- N nitrogen
- P phosphorus
- NP phosphorus
- a vinasse based semi -synthetic media was custom made with the addition of ammonium sulfate, (NhU SC ) 7.5 g/L and (or) potassium dihydrogen phosphate (K H2PO4) 3.5 g/L, as sources of nitrogen and phosphorus respectively, as modified from (Sues et al., 2005).
- a culture without any additional nutrient supplements served as the control.
- the fungal cultivations were carried out aerobically in the liquid vinasse medium (with specific dilution), in 100 mL volume (in 250 ml E rlenmeyer flasks), unless otherwise specified. Cultivations were carried out for 96 h in an orbital shaking water bath (Grant OLS-Aqua pro, U K) at 35eC and 125 rpm, with samples taken every 24 h. The initial pH adjustment was made with either 2M NaOH or 1 M HCI addition. All experiments and analyses were carried out in duplicate and results reported with error bars and intervals representing two standard deviations.
- A. oryzae exhibited its adaptability to a wide pH range of the vinasse media, i.e. 5.0 to 6.5, with the maximum of 215 g/L dry fungal biomass production at pH 6.5.
- N. intermedia showed constraints with the range of culture pH, with its maximum production, 184 g/L dry biomass produced at the growth optimum at pH 5.5.
- the cultures at the range 5.0, 6.0 and 6.5 showed about 65, 61 and 75% reduction (respectively) in the fungal biomass production compared to the optimum growth at pH 5.5.
- pH of the vinasse generally ranges from 3 to 5, depending on the process and the dilution rate used during the ethanol distillation.
- the optimum growth conditions for the maximum fungal biomass production were determined as: 10% (v/v) vinnase concentration, culture pH 5.5 (for N. intermedia) and 6.0 (for A. oryzae), culture temperature 35eC and time 72 h.
- the sugar and metabolite profile of the fungal growth at the optimum conditions is depicted in Figure 4a and 4b.
- T able 1 C haracterization of vinasse substrate a) General characteristics b) Soluble sugar c) Organic acids/ metabolites and d) Ions and H eavy metals T able 1(a):
- Potassium (K) 87220 E xample 7: Scale-up in bench scale airlift reactors and glycerol utilization The optimum culture conditions were validated in a bench scale airlift bioreactor (4.5 L) (Belach Bioteknik, Sweden), with a working volume of 3.5 L . An internal loop with cylindrical geometry with a diameter 58 mm, height 400 mm and thickness 3.2 mm was used to achieve the airlift-liquid circulation. The bioreactor and the draft tube were made of transparent borosilicate glass. Fungal fermentation on vinasse media (10% ⁇ /) in the bench scale airlift reactor showed similar results as observed with the shake flask cultures, at the optimum conditions.
- a maximum fungal biomass production of 154 g and 199 g per liter of vinasse was observed with N. intermedia and A. oryzae respectively.
- the aeration rate maintained at 0. 71 vvm (volume a ir ⁇ olumemedia /min) made an effective mixing for the media possible.
- the cultivation was carried out at pH 5.5 e 0.2 (for N. intermedia) and 6.5 e 0.1 (for A. oryzae), initially adjusted with 1 M NaOH.
- Vinasse cone 10% T emperature (eC )
- Vinasse cone 10% nutrient source
- E xample 8A Pellet formation by A. oryzae in vinasse media
- a statistically developed experimental design was used to determine the optimum culture conditions for pellet formation in A. oryzae.
- a full -factorial experimental model was designed using MINITA B ⁇ 17 (Minitab Inc, State College, PA, USA) software.
- the vinasse medium dilutions (vAY) at three levels (5, 10 and 15%) and media pH at three levels (5.5, 6.0 and 6.5) were studied to determine their combinational effect on the pelletization process.
- the concentration of the fungal biomass and the pellet size (diameter) were selected as the response variables.
- a composite desirability (D) value was calculated to validate the results (Nair et al.,
- E xample 8B Pellet formation by N. intermedia in vi nasse media
- the fungal cultures were carried out aerobically in a liquid semi -synthetic potato dextrose medium (containing 20 g/L glucose and 4 g/L potato extract) or a defined synthetic medium with (g/L) glucose (or another carbon source such as sucrose, fructose, arabinose, maltose, mannose etc) 20, NH4C I 7.5, MgS04X7H20 0.5, NaCI 1.0, and K H2P04 3.5.
- T he fungus was grown aerobically at different acidic pH conditions such as 3, 3.5, 4 and 4.5, in the liquid medium.
- the average size of the pellets ranges from 2.1 e 0.2 mm and 4.5 e 0.9 mm respectively.
- Results wherein, g of ethanol, total sugars and organic acids produced per liter of vinasse (10% dilution) are shown in table 4(a) and 4(b).
- vinasse as a fermentation substrate for cultivating edible filamentous fungi enables recovery of part of the energy content or nutrients in the vinasse, in addition owing to the production of value added products such as enzymes, organic acids, ethanol or the protein- rich fungal bi omass for feed appl i cati ons.
- the present process provides cultivation of fungal cells in the form of pellets.
- the present process could potentially make a new revenue stream for existing sugar-to-ethanol facilities with minimum investment, since the produced ethanol can follow the normal stream towards existing distillation columns and evaporators at the ethanol facility.
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