WO2010051627A1 - Enhanced ethanol fermentation using biodigestate - Google Patents
Enhanced ethanol fermentation using biodigestate Download PDFInfo
- Publication number
- WO2010051627A1 WO2010051627A1 PCT/CA2009/001575 CA2009001575W WO2010051627A1 WO 2010051627 A1 WO2010051627 A1 WO 2010051627A1 CA 2009001575 W CA2009001575 W CA 2009001575W WO 2010051627 A1 WO2010051627 A1 WO 2010051627A1
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- WO
- WIPO (PCT)
- Prior art keywords
- ethanol
- fermentation
- anaerobic
- suspension
- feedstock
- Prior art date
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Classifications
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- C—CHEMISTRY; METALLURGY
- C05—FERTILISERS; MANUFACTURE THEREOF
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- C05F3/00—Fertilisers from human or animal excrements, e.g. manure
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- 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
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- C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
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- A23K10/37—Animal feeding-stuffs from material of plant origin, e.g. roots, seeds or hay; from material of fungal origin, e.g. mushrooms from waste material
- A23K10/38—Animal feeding-stuffs from material of plant origin, e.g. roots, seeds or hay; from material of fungal origin, e.g. mushrooms from waste material from distillers' or brewers' waste
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- A—HUMAN NECESSITIES
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- A23K—FODDER
- A23K50/00—Feeding-stuffs specially adapted for particular animals
- A23K50/10—Feeding-stuffs specially adapted for particular animals for ruminants
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- C—CHEMISTRY; METALLURGY
- C05—FERTILISERS; MANUFACTURE THEREOF
- C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
- C05F7/00—Fertilisers from waste water, sewage sludge, sea slime, ooze or similar masses
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- 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
- C12P19/00—Preparation of compounds containing saccharide radicals
- C12P19/02—Monosaccharides
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- 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
- C12P7/10—Ethanol, i.e. non-beverage produced as by-product or from waste or cellulosic material substrate substrate containing cellulosic material
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- 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
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- 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
- C12P7/14—Multiple stages of fermentation; Multiple types of microorganisms or re-use of microorganisms
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- C—CHEMISTRY; METALLURGY
- C13—SUGAR INDUSTRY
- C13K—SACCHARIDES OBTAINED FROM NATURAL SOURCES OR BY HYDROLYSIS OF NATURALLY OCCURRING DISACCHARIDES, OLIGOSACCHARIDES OR POLYSACCHARIDES
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A40/00—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production
- Y02A40/10—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production in agriculture
- Y02A40/20—Fertilizers of biological origin, e.g. guano or fertilizers made from animal corpses
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/10—Biofuels, e.g. bio-diesel
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/141—Feedstock
- Y02P20/145—Feedstock the feedstock being materials of biological origin
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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- Y02P60/80—Food processing, e.g. use of renewable energies or variable speed drives in handling, conveying or stacking
- Y02P60/87—Re-use of by-products of food processing for fodder production
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/40—Bio-organic fraction processing; Production of fertilisers from the organic fraction of waste or refuse
Definitions
- Ethanol has many commercial uses, and, for example, can be used for combustion as a fuel or a fuel additive
- Ethanol also known as bioethanol
- the fermentation can be carried out by microorganisms, such as yeasts or bacteria, that can convert the sugars into ethanol through biochemical processes
- the feedstock can include organic material, generally plant material, that contains sugars
- plant material that can be used as feedstock include plants that produce and store simple sugars (e g , sugar cane and sugar beets), plants that produce and store starch (e g , grains, such as corn and wheat), and other plant material rich in cellulose and/or hemi- cellulose (e g , agricultural or forestry residues, such as plant stalks and leaves)
- ethanol by fermentation can require many materials in addition to feedstock and microorganisms
- These materials can include fresh process water, which can be added to the feedstock to create a suspension of feedstock for the microorganisms to ferment, and nutrient supplements, especially nitrogen supplements (e g , urea or ammonium compounds), which can provide the necessary nutrients to the microorganisms performing the fermentation
- nitrogen supplements e g , urea or ammonium compounds
- these materials can be expensive, and can prohibitively increase the costs of ethanol production, which is one of the major obstacles that presents the ethanol- based fuel from competing economically with gasoline
- water consumption in a conventional ethanol plant is about 10 gPM per million gallons annual ethanol production
- Feedstock for ethanol fermentation can include complex sugars, such as polysaccharides, which generally are difficult for microorganisms to ferment into ethanol
- complex sugars such as polysaccharides
- the feedstock can be subjected to hydrolysis reactions, where the complex sugars are converted to simpler sugars that can more readily be converted by microorganisms into ethanol
- the hydrolysis process can also be expensive, in part because of the need for materials such as fresh water and enzymes that perform the conversion
- Organic waste such as municipal wastewater or livestock manure, can release greenhouse gases, such as methane and carbon dioxide, and can be a source of air, soil, and water pollution
- Anaerobic bio-digesters can process the organic waste by treatment with organisms, which can be obligate or facultative bacteria and/or archaea These organisms can, using biochemical reactions, convert organic material into a variety of products Among these products are a mixture of gases, generally referred to as biogas, and a mixture of liquids and solids, generally referred to as biodigestate Biodigestate is generally treated as a waste material
- the present invention provides methods and systems for enhancing ethanol production and deriving value-added products from biodigestate, which is traditionally considered waste material
- the methods and systems of the invention are partly based on the discovery that biodigestate and different fractions thereof do not inhibit the activities of many enzymes required for microorganism-based fermentation process for ethanol production, and thus, can be used directly, without the addition of any fresh water or nutrient supplement, as the suspension fluid for the fermentation process This not only provides a useful utilization of biodigestate — traditionally considered a waste material — but also saved valuable resources, such as fresh water and nutrient supplement
- the methods and systems of the invention are also partly based on the surprising discovery that biodigestate or certain fractions thereof provide enhanced ethanol yield compared to fresh water, thereby further increasing the cost efficiency of ethanol production using microorganism fermentation While not wishing to be bound by any particular theory, it is possible that the observed enhanced ethanol production results from the presence of certain nutrients and other organic substances lacking in fresh water (such as water insoluble substances (WIS
- one aspect of the invention provides a method for producing ethanol, comprising: (1) adding a suspending fluid to a feedstock to produce a fermentation suspension, wherein the suspending fluid comprises an organic material that has at least partially been anaerobically digested; (2) adjusting the pH of the fermentation suspension, if necessary, to a value conductive for fermentation; and (3) fermenting the fermentation suspension to produce ethanol, wherein the suspending fluid is substantially free of fresh water (e.g., exogenously added) or nutrient supplement.
- the method further comprises inoculating the fermentation suspension with a microorganism capable of fermenting the fermentation suspension to produce ethanol.
- the microorganism may be a yeast or a bacteria, or any other microorganism that can perform fermentation to produce ethanol.
- Exemplary ethanol- producing microorganisms include yeast Saccharomyces and bacteria Zymomonas, facultative anaerobic thermophilic bacteria strains such as those described in WO/88/09379, and genetically engineered microorganisms which otherwise would not produce significant ethanol with genetic engineering. See, for example, engineered E.
- Preferred ethanol fermentation microorganisms can tolerate high concentration of ethanol (e.g., 10%, 15%, 20%, 25%, or 30%) in an AD-based fermentation broth.
- Preferred ethanol fermentation microorganisms can also breakdown non-starch cellulosic biomass efficiently, which can hydrolyze different non-grain biomass and convert it to single sugar molecule for fermentation.
- Recombinant DNA technology may be used to genetically enhance the traits of such fermentation microorganisms beneficial for ethanol fermentation.
- the suspending fluid comprises, consists essentially of, or consists anaerobic biodigestate or effluents thereof.
- the supernatant of the centrifugation process performs the best in ethanol fermentation when there is certain level of suspended solids in the supernatant.
- the supernatant is generated by centrifuging the AD effluent at 200 g, 400 g, 600 g, 800 g, 1000 g, 1500 g, 2000 g, 2500 g, 3000 g, 3500 g, 4000 g, 5000 g, 6000 g, 7500 g, or 10,000 g.
- the liquid fraction may be generated by passing the anaerobic biodigestate through a screw press (such as a "FAN” brand screw press) or other similar devices.
- a screw press such as a "FAN” brand screw press
- the AD digestate comes from a "healthy" batch of anaerobic digestion, in that the production of biogas in said healthy batch is optimum (vs. declining to near zero).
- an amount of urea is added to the AD effluent to enhance yield
- the AD may be used fresh, or may be stored for a period of time, such as 12 hrs, 1, 2, 3, 5, 7, 10, 2 weeks, 1 month, etc
- the liquid fraction contains about 1, 2,3, 4, 5, 6, 7, 8, 9, or
- the liquid fraction may be further fortified by a nutrient recovered from the anaerobic biodigestate
- the fractioned anaerobic biodigestate is an ultrafiltration concentrate or an ultrafiltration permeate generated from a liquid fraction of the anaerobic biodigestate, wherein said liquid fraction is generated by removing substantially all solids from the anaerobic biodigestate
- the pH of the fermentation suspension is adjusted to below 6 0, (for example, between 4 0 and 5 0) for the best enzymatic catalysis
- the method further comprises distilling the post fermentation beer to collect ethanol without pre-removal of solids from the beer
- the feedstock is high-starch wheat, corn, or other high-starch crops
- the high-starch wheat, corn, or other high-starch crops is converted in the suspending fluid at least partially into simple sugars
- the conversion comprises (with no particular order and no limitation on repeats) mechanical grinding, heating with steam, reacting with an acid, liquefaction by using alpha-amylase, and/or saccharification by using glucoamylase
- pH is controlled in an optimal range required for the wheat or crop conversion reactions
- the amount of the high-starch wheat, corn, or other crop is up to about 28% (w/v), or up to 36% (w/v) in the suspension fluid
- the method further comprises adding cellulase, xylanase, and/or acid proteolytic enzyme to the suspension fluid In certain embodiments, the method further comprises incubation the fermentation mixture at about 30-50 0 C (inclusive) for about 24 hours, 36, 48, or 72 hours
- the wet distillers grains resulting from ethanol distillation is fed to a livestock animal (e g , swine, poultry, cattle, or fish) as feed, optionally with fortified neutrient elements, or used as fertilizers with enhanced nutrient value (e.g., nitrogen increment)
- a livestock animal e g , swine, poultry, cattle, or fish
- fortified neutrient elements e.g., swine, poultry, cattle, or fish
- fertilizers with enhanced nutrient value e.g., nitrogen increment
- the suspending fluid is substantially free of non-anaerobic microorganisms
- the pH of the suspending fluid is adjusted to a value substantially incompatible for growth of non-anaerobic microorganisms In certain embodiments, the pH of the suspending fluid is adjusted to a value for optimal growth of fermentation microorganisms
- the nutrient supplement is a nitrogen supplement
- ethanol yield is enhanced or increased compared to an otherwise identical process using fresh water instead of the suspending fluid
- ethanol production is increased by 5-15%, or 7-10%, when about 20-36% or 22-28% of wheat is used
- Another aspect of the invention provides a method for hydrolyzing a feedstock, wherein the feedstock comprises polysaccharides and wherein the hydrolyzed feedstock yields more ethanol when fermented than prior to hydrolysis, the method comprising (1) adding a suspending fluid to the feedstock to produce a feedstock suspension, wherein the suspending fluid comprises organic material that has at least partially been anaerobically digested, and, (2) hydrolyzing the feedstock suspension such that at least a portion of the polysaccharides are converted into simple sugars, wherein the suspending fluid is substantially free of (exogenously added) fresh water or nutrient supplement
- the hydrolyzing step comprises (with no particular order and no limitation on repeats) mechanical grinding, heating with steam, reacting with an acid, liquefaction by using alpha-amylase, and/or saccharification by using glucoamylase
- Figure 1 is a flow chart 100 illustrating an exemplary process including steps 102, 104, and 106, for enhancing ethanol production in accordance with an embodiment of the present invention
- FIG. 2 illustrates a schematic view of an exemplary system 200 for enhancing ethanol production in accordance with an embodiment of the present invention
- the system 200 may include a bio-digester 202, wherein organic waste material 204 is subject to anaerobic biodigestion to produce biodigestate and biogas At least a part of the biodigestate 206 is transported to hydrolysis unit 214 for mixing with feedstock to produce a suspension
- the hydrolysis may be done with enzyme 208 and/or acid 210 and/or heat 212 (e g , in the form of steam, etc )
- the resulting hydrolyzed feedstock suspension 218 is then fermented to produce ethanol 224
- at least part of the biodigestate 216 can be transported to fermentator 220 directly and mixed with feedstock 218
- Feedstock 222 can also be added to produce ethanol
- Figure 3 is a flow chart 300 illustrating an exemplary process comprising steps 302, 304, and 306, for hydrolyzing a feedstock in accordance with
- Figure 4 shows change of the specific gravity and potential ethanol content (% vol) from different fermentation groups up to 14 days at 22°C Legend groups Tap H 2 O tap water, UF-per Ultra Filtration (UF) permeate, UF-con Ultra Filtration (UF) concentrate, S granulate Sugar, SY super Tubor yeast Specific gravity (S G ) was measured at fermenting day of 0, 4, 7, 11 and 14 Potential ethanol content was calculated based on Oechsle scale
- Figure 5 is a comparison of wheat conversion in anaerobic digestate (AD) and tape- water by two-step enzymatic catalysis based on the glucose content (gram/gram of dry wheat)
- Figure 6 shows glucose yield after two-step enzymatic conversion with different contents of wheat in FAN-separated AD and in water
- Figure 7 shows two procedures used in wheat conversion
- Figure 8 shows ethanol yield in Simultaneous Saccharification and Fermentation
- Figure 9 shows dose-dependent ethanol yield in SSF of FAN- Separated anaerobic digestate (FSD) with different amounts of dry wheat
- Figure 10 shows ethanol yield in SSF using two-step addition procedure of AD or H 2 O
- FIG 11 shows total solid (TS) and volatile solid (VS) in post-fermenting samples
- Figure 12 is total nitrogen in post-fermenting solid from different groups
- Figure 13 shows glucose yield from FSD catalyzed with OPTIMASH XL and Accellerase
- Figure 14 shows Ethanol yield from SSF with OPTIMASH TM XL (high concentration cellulase/xylanase complex from GENENCOR R , Rochester, NY) and Accellerase * Statistical significance
- Figure 15 shows ethanol yield in FSD and F ⁇ O-wheat mixture with/without FERMGEN TM (low pH protease from GENENCOR ⁇ Rochester, NY)
- Figure 16 shows ethanol yield in FSD/wheat and H 2 O mixture with identical weights post fermentation * Statistical significance
- Figure 17 shows nutrient value in wet distiller's grain (WDG) in fermentation using anaerobic digestate
- AD alone represents the nutrient values of the anaerobic digestate alone before fermentation
- AD/wo centrif represents the nutrient values for whole AD (without centrifugation) fermented with wheat
- ADS, nnn rpm represents the nutrient values for centrifuged AD at varied speeds (at “nnn rpm” respectively) fermented with wheat
- “H 2 O control” represents the nutrient values for wheat fermented in water
- dry wheat represents the nutrient values for grounded whole wheat without fermentation
- P-F stands for "post fermentation
- Figure 18 and 19 show the result of analyzing the various nutrient elements required in animal feeds as they are present in the various mash or WDGs
- H 2 O control ADS (1000 rpm), ADS (4000 rpm), ADS (6000 rpm), AD alone, dry wheat, and AD/wo centrif, respectively
- Figure 20 shows the calculated animal feed values for the various ADS (AD supernatant) batches as compared to fresh water alone
- TD stands for “total digestible nutrients”
- NF stands for “non fiber carbohydrate”
- DE is “digestible energy”
- GE is “gross energy”
- ME is “metabolizable energy”
- H 2 O control ADS (1000 rpm), ADS (4000 rpm), ADS (6000 rpm), AD alone, dry wheat, and AD/wo centrif, respectively Detailed Description of the Invention
- a suspending fluid can be added to a feedstock to produce a fermentation suspension
- the suspending fluid can have sufficient liquid content to suspend the feedstock, and thereby reduces, and in some embodiments, largely eliminates the need for fresh process water
- the suspension fluid contains no more than 20%, 10%, 5%, 2%, 1%, or substantially no exogenously added fresh water and/or commercial nutrient supplements
- the suspending fluid may include solid materials therein, including organic material that has at least partially been anaerobically digested These solid materials contain nitrogen, and can in some embodiments eliminate the need for nutrient supplementation
- the suspending fluid may also include one or more types of anaerobic microorganisms
- the suspending fluid is substantially free of non-anaerobic microorganisms, which can be advantageous because aerobic microorganisms can interfere with fermentation processes (e g , by consuming the feedstock)
- the suspending fluid can be biodigestate produced by the anaerobic bio-digestion of organic waste
- Organic waste can be, and generally is, a mixture of discarded organic material having relatively low commercial value
- Organic waste can include by-products from various industries, including agriculture, food processing, animal and plant processing, and livestock Examples of organic waste include, but are not limited to livestock manure, animal carcasses and offal, plant material, wastewater, sewage, food processing, and any combination thereof
- Organic waste can also include human-derived waste, such as sewage and wastewater, discarded food, plant, or animal matter, and the like
- the suspending fluid may be fractioned from an anaerobic biodigestate, such that selected fractions are used in the subject methods
- the fractioned anaerobic biodigestate is a liquid fraction generated by removing substantially all solids (e g , greater than 91%, 93%, 95%, 97%, 99%, or close to 100%) from the anaerobic biodigestate This can be done by, for example, passing the anaerobic biodigestate through a FAN screw press, or other equivalent mechanical devices
- the liquid fraction resulting from this process may be used directly in the instant invention
- the liquid fraction contains about 1, 2, 3, 4, 5, 6, 7, 8, 9, r
- such liquid fraction may also be further fortified by a nutrient recovered from the anaerobic biodigestate
- a nutrient recovered from the anaerobic biodigestate Such nutrients, including nitrogen or phosphate nutrients, may be obtained (e.g., isolated, purified or enriched) from the liquid fraction of the anaerobic digestate using methods known in the art
- the fractioned anaerobic biodigestate may be an ultrafiltration concentrate (UFC) or an ultrafiltration permeate (UFP) generated from a liquid fraction of the anaerobic biodigestate, wherein the liquid fraction is generated by removing at least part of, or substantially all solids from the anaerobic biodigestate
- UAC ultrafiltration concentrate
- UFP ultrafiltration permeate
- An anaerobic bio-digester can be used to convert or extract useful products from organic waste
- Anaerobic bio-digesters can include an enclosed container, which can be a vat or vessel or housing, where anaerobic bio-digestion of organic waste takes place The anaerobic bio-digester is enclosed generally to prevent exposure to air, or other atmospheric or local contaminants
- Many anaerobic bio-digestion facilities and systems are known (e g , horizontal or plug-flow, multiple-tank, vertical tank, complete mix, and covered lagoon digesters) and any of these can be suitable for purposes of the present
- the anaerobic bio-digester is the integrated system described in the co-pending U S S N 12/004,927, filed on December 21, 2007, entitled “INTEGRATED BIO-DIGESTION FACILITY " The entire content of the co-pending '927 application is incorporated herein by reference
- the anaerobic bio-digestion of organic waste can be performed by anaerobic organisms, which can, as described hereinabove, thereby produce biogas and biodigestate (also known as anaerobic digestion effluent)
- Biogas generally contains a mixture of gaseous methane, carbon dioxide, and nitrogen (which can be in the form of ammonia), but may also contain quantities of hydrogen, sulfides, siloxanes, oxygen, and airborne particulates, and is itself a useful product that can be combusted to produce energy
- biodigestate can be produced as a result of the anaerobic bio digestion of organic material
- Biodigestate can be a mixture of a variety of materials, and can include organic material not digested by the anaerobic organisms, by-products of anaerobic bio digestion released by the organisms, and the organisms themselves
- the biodigestate can include carbohydrates, nutrients (such as nitrogen compounds and phosphates), other organics, wild yeasts, and large amounts of wastewater
- the solid content can be about 5-9% by weight, or about 5-6% by weight
- the biodigestate is sufficiently digested so that it is substantially free of non-anaerobic organisms, which may be eliminated by consumption by the anaerobic organisms, the conditions of the anaerobic bio-digestion (which in addition to the substantial absence of oxygen, can include a predetermined temperature and pH set based upon the optimal living conditions of the anaerobic organisms), or a combination thereof
- the biodigestate can be transported without being stored to the ethanol feedstock for suspension This can be done, for example, by using a pipe
- these embodiments can be advantageous because they can reduce the risk of contamination of the biodigestate by non-anaerobic organisms
- the fermentation suspension may already contain anaerobic organisms Alternatively, anaerobic microorganisms suitable for ethanol production may be inoculated to the culture
- the fermentation suspension may additionally contain other microorganisms that can interfere with fermentation by, for example, digesting the feedstock and/or digesting the organisms performing the fermentation These organisms can, however, be sensitive to pH
- the pH of the fermentation suspension can be adjusted such that the growth of the interfering microorganisms are substantially suppressed This suppression entails preventing such interfering microorganisms from disrupting / inhibiting with fermentation of the feedstock into ethanol In some embodiments, this suppression can be performed by killing the interfering microorganisms
- the pH can be adjusted to below 6 0 In certain preferred embodiments, the pH can be adjusted to fall in the range of 4 0 to 5 0
- the fermentation suspension can be fermented to produce ethanol under conditions (pH, temperature, etc ) conductive for ethanol production
- the methods of the invention can be advantageous because the suspending fluid used reduces or eliminates the need for fresh process water, nutrient supplementation, or both
- the subject method can also be advantageous because ethanol production can be increased due to the presence of fermentable material within the suspending fluid (but is lacking in fresh water)
- the post fermentation beer may be distilled directly to collect ethanol without pre-removal of solids from the beer This further reduces the cost of operating the ethanol plant according to the instant invention
- wet Distillers Grains are the remaining portions of the feedstock wheat that was added to the ethanol process after the distillation is complete Most of the starch from the wheat is converted to ethanol by the microorganism, while the proteins and any lipids remain unused These remaining portions of the grain are valuable and palatable as feed for cattle Therefore, in certain embodiments, the method of the invention contemplates building an integrated ethanol plant at the vicinity of an animal feedlot, wherein there is no need to use large amounts of energy to dry the wet distillers grains for long shelf life the way many ethanol plants are forced to In addition, there will be no need to use large quantities of fuel to transport the distillers grains long distances to far away markets or feedlots Instead, distillers grains can be sent to the nearby feedlot and consumed wet by the farm animals such as cattle This configuration / combination not only provides major energy savings to the ethanol plant, but also reduces the amount of fresh drinking water the cattle consume
- the suspension fluid is added to the feedstock in multiple step, e g , two steps
- the first step about 75% of the suspension fluid is added to the feedstock, e g , high-starch wheat, before the liquidation step using alpha-amylase
- the remaining 25% may be added post-liquidation, but before saccharification using glucoamylase
- the amount of the feedstock used may also be optimized In certain preferred embodiments, the amount of the high-starch wheat is added up to about 28% (w/v) in the suspension fluid
- Systems designed for carrying out the methods of the invention may include an anaerobic bio-digester, wherein organic waste material produced therefrom can be subject to anaerobic biodigestion to produce biodigestate and biogas, as noted hereinabove
- feedstock can contain complex sugars, such as polysaccharides, cellulose, or hemicelluloses, that generally can be hydrolyzed by specific chemical reagents to produce more easily fermentable sugars
- at least a portion of the biodigestate can be transported as biodigestate to a hydrolysis unit, wherein it can be mixed with feedstock to produce feedstock suspension
- the biodigestate contains material, such as cellulose or hemicelluloses, for example, that can be hydrolyzed, more sugar can be produced in hydrolysis than if fresh water is used to create the feedstock suspension
- the hydrolysis can be done by using one or more enzymes, such as alpha- amylase, glucoamylase, cellulase,
- the suspending fluid is substantially free of exogenously added fresh water or nutrient supplements
- At least a portion of the biodigestate can be transported to a fermentor Within the fermentor, biodigestate or fractions thereof can be mixed with feedstock, and ethanol can be produced after fermentation
- the invention also provides an exemplary process for hydrolyzing a feedstock in accordance with an embodiment of the present invention
- a suspending fluid including organic material that has at least partially been anaerobically digested, and preferably containing one or more anaerobic microorganisms suitable for ethanol production, and which is substantially free of non-anaerobic microorganisms, can be added to a feedstock (such as corn or wheat, preferably high-starch wheat) to produce a feedstock suspension
- a feedstock such as corn or wheat, preferably high-starch wheat
- the feedstock can be hydrolyzed
- one or more steps of mechanical grinding or milling of the feedstock may be performed, one or more enzymes may be added, and the feedstock may be heated (preferably by steam) All these steps can be performed in the subject suspending fluid, preferably without any exogenously added fresh water and/or nutrient supplements
- the feedstock suspension is hydrolyzed such that at least a portion of the polysaccharides therein are converted into simple sugars, which can subsequently be fermented to produce ethanol
- the suspension fluid contains certain complex polysaccharides, such as cellulose or hemicelluloses that can be digested by the added enzymes to produce simple sugars
- AD anaerobic biodigestates
- the UFP and UFC fractions were generated using a lab system that does not contain lime before the ultrafiltration system
- a unit of the FAN-separated liquid digestate generated about 80% permeate and 20% concentrate
- granulate sugar was dissolved in AD (pH - 8 1) and tap water (pH - 5 5) to a concentration of about 28 g/dl, respectively, and pH was adjusted to ⁇ 5 4 with 12 N HC 1 Fermentation was conducted in 1 0 liter volume in a 3 5 liter fermenting bottle for 14 to 24 days Fermenting process was observed daily by measuring change in specific gravity of the mixtures using a hydrometer
- the potential ethanol content (% volume) was calculated using Oechsle Scale (see, for example, en wikipedia dot org/wiki/Oechsle_scale)
- the Oechsle Scale is a hydrometer scale measuring the density of grape must, which is an indication of grape ripeness and sugar content used in wine-making It is named for Charles Oechsle and it is widely used in the German, Swiss and Luxemburgish wine- making industries
- one degree Oechsle corresponds to one gram of the difference between the mass of one liter of must at 20 0 C and 1,000 gram (the mass of 1 liter of water)
- must with a mass of 1084 grams per liter has 84°Oe
- the mass difference between equivalent volumes of must and water is almost entirely due to the dissolved sugar in the must Since the alcohol in wine is produced by fermentation of the sugar, the Oechsle scale is used to predict the maximal possible alcohol content of the finished wine
- Ethanol Ethanol S.G BP Ethanol (g/dL) (g/g (%) in 1 st @ (g/di) glucose) Distill 0 C DS
- AD does not inhibit alpha-amylases and glucoamylase during the conversion process from wheat to glucose It also provides a comparison between the conversion rates of tape- water and AD when they were used as media
- alpha-amylase catalyzes wheat to starch
- the latter catalyzes starch to glucose
- alpha-amylase (Spezyme XTRA) and glucoamylase (G-ZYME 480 ethanol) from Genencor R Inc were used in two-step conversion experiments D-glucose assay was adapted for evaluating the conversion rate of wheat in AD and water Specifically, wheat (soft white wheat-Andrew) ground using a hammer mill was obtained from Highmark Renewables Research Different contents of unscreened wheat were prepared both in AD and tap water Final concentrations for different treatment groups were 70, 140, 175, and 280 grams of wheat / 1 liter of medium Twelve experiments were set up in 1 0 liter medium using 2 0 liter beakers
- the first step of liquefaction by Spezyme XTRA was carried out at 85°C, pH 5 0 to 6 0 for 60 minutes, and the second step of saccharification by G-ZYME TM 480 was at 60 0 C, pH 4 0 to 4 5 for 30 minutes, respectively, after dose and reaction time were optimized
- Samples were taken before and after two enzymes were added, and were centrifuged at 4,750 rpm for 15 minutes
- the supernatant was collected and diluted with H 2 O
- the glucose concentration in the supernatant was determined by glucose assay, either by glucose assay kit (Sigma GAHK20-1KT) or YSI instalment with specific standard Total carbohydrate in AD was also analyzed to determine whether there was available carbohydrate as substrate contributing to conversion
- Results showed that there was no significant difference of glucose yield during wheat conversion by two enzymes in AD and tap water (Figure 5) Efficiency of wheat conversion reached an average wheat conversion rate (-56%) When different alpha-amylase and glucoamylase from different
- carbohydrate As expected, small amounts of total carbohydrate existed in AD, but was not accessible for breaking down by the conversion enzymes.
- the carbohydrate is most likely in a non- dissolved form, and is assumed to be cellulose or hemi-cellulose (rather than starch- based polysaccharides).
- the example provided direct comparison between final ethanol content of the beer from SSF using AD- and water-wheat mixtures. It also optimized the process of SSF in lab scale, and investigated which component in AD, nutrients, carbohydrate, proteases or microbes, contributed to ethanol production increase.
- the SSF experiment was set up in 250 ml flasks containing 28 or 36 grams of dry wheat in 100 or 130 ml AD (FSD and UFP) and water, respectively.
- ⁇ 3-glucanase / xylanase mixture (OPTIMASH BG from Genencor R , Rochester, NY) was tested for catalysis of non- starch carbohydrates in wheat and/or AD in addition to two standard conversion enzymes used in Example 2.
- Liquefaction was processed at 85°C for 1.0 hr as described above in Example 2.
- G-ZYME 480 from Genencor R , Rochester, NY
- BG were added at 60 0 C for 30 minutes during saccharification.
- Super yeast X-press powder (AG grade for bioethanol) was pitched in distill water at 34°C for 20 minutes, and then aliquots were added to the flasks with yeast nutrients to start ethanol fermentation.
- SSF Fermentation was set at 32°C for 48 hours in water bath. Three SSF experiments were performed. The first experiment was aimed to test the effect of both AD and BG on final ethanol yield; the second was to test dose-dependent ethanol yield in 100 ml FSD with dry wheat of 12, 20 and 28 grams and BG, and the third was to test effect of two-step addition of AD or water (3/4 of total volume of liquid for liquefaction and the 1/4 total volume of liquid post liquefaction and before saccharification) on ethanol yield ( Figure 7)
- AD ⁇ -(2-aminoethyl)-2-aminoethylcholine
- glucoamylase glucoamylase
- glucanase / xylanase The example demonstrates that these carbohydrates in AD can be broken down by different enzyme combinations for enhanced bioethanol production
- the example also provides an analysis regarding what such carbohydrates in AD are, and how much they contribute to ethanol production
- the example further provides evidence to show that ethanol yield could be enhanced using protease during conversion and fermentation of AD- and IH ⁇ O-mixtures
- the FSD used in this experiment contained 5 to 7% total solid Utilization of the same volume of FSD and water mixed with same amount of wheat will result in discrepancy of final volume of the beer after fermentation
- volume difference of the beer between two mixtures were analyzed 5% less volume of beer was observed in FSD-wheat mixture than that in H2 ⁇ -wheat mixture
- the volume correction factor was 0 95 for final ethanol yield when the same volume of FSD was used to replace water
- FSD- and H 2 O-mixture with the exact same weights, we found that the ethanol yield in FSD wheat mixture with a final volume of 95 ml increased -15% when compared to that of the H 2 O-wheat mixture with a final volume 100 ml ( Figure 16)
- ethanol yield was enhanced to about 28% or 18% by addition of cellulases, OPTIMASH TM XL and ACCELLERASE 1000, respectively, via a modified liquefaction procedure at 50 0 C for a long in
- anaerobic digestate has no inhibitory effect on a variety of converting / hydrolytic enzymes as well as the yeast-driven fermentation process
- non-starch carbohydrate such as lignocellulosic biomass
- post-fermenting beer was distillable to produce clear ethanol without pre- removal of solids
- the "mash” or the wet distiller's grain-like material in the post-fermentation digestate and wheat can be used for animal feed (e.g., swine, poultry, fish, and cattle), optionally with fortified nutrient elements
- animal feed e.g., swine, poultry, fish, and cattle
- fortified nutrient elements The same material may also be used as fertilizer
- WDG wet distiller's grain
- AD alone represents the nutrient values of the anaerobic digestate alone before fermentation
- AD/wo centrif represents the nutrient values for whole AD fermented with wheat (“P-F” stands for “post fermentation")
- ADS nnn rpm represents the nutrient values for centrifuged AD at different speeds and fermented with wheat
- H 2 O control control represents the nutrient values for wheat fermented in water
- Figure 18 and 19 show the result of analyzing the various nutrient elements required in animal feeds as they are present in the various mash or WDGs
- the results show that the various ADS batches contained slightly varied concentrations of the elements Note that the concentrations of metal elements can be adjusted by using simple centrifugation at different speeds
- the mash or WDGs with different contents of metal elements could directly feed animals during special growth phases to meet their physiological requirements
- Figure 20 shows the calculated animal feed values for the various ADS batches as compared to fresh water alone The results show that the various ADS batches are at least as nutritious, if not more nutritious, than the water alone control
- thermophilic anaerobic bacteria for bioethanol production from hemicellulose Biochemical Society Transactions (part 2), 32 283, 2004
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Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2009311225A AU2009311225A1 (en) | 2008-11-04 | 2009-11-04 | Enhanced ethanol fermentation using biodigestate |
EP09824306.6A EP2344651A4 (en) | 2008-11-04 | 2009-11-04 | Enhanced ethanol fermentation using biodigestate |
MX2011004601A MX2011004601A (en) | 2008-11-04 | 2009-11-04 | Enhanced ethanol fermentation using biodigestate. |
CA 2742567 CA2742567A1 (en) | 2008-11-04 | 2009-11-04 | Enhanced ethanol fermentation using biodigestate |
BRPI0921483A BRPI0921483A2 (en) | 2008-11-04 | 2009-11-04 | improved ethanol fermentation using biodigested |
CN2009801437889A CN102203266A (en) | 2008-11-04 | 2009-11-04 | Enhanced ethanol fermentation using biodigestate |
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EP (1) | EP2344651A4 (en) |
CN (1) | CN102203266A (en) |
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BR (1) | BRPI0921483A2 (en) |
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EP3585757B1 (en) * | 2017-02-23 | 2024-03-20 | Cleanbay Renewables Llc | A process for forming a product solution from poultry waste digestate |
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Also Published As
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US20100136629A1 (en) | 2010-06-03 |
AU2009311225A1 (en) | 2010-05-14 |
EP2344651A1 (en) | 2011-07-20 |
MX2011004601A (en) | 2011-06-16 |
US20140302566A1 (en) | 2014-10-09 |
BRPI0921483A2 (en) | 2019-09-24 |
EP2344651A4 (en) | 2013-11-20 |
CN102203266A (en) | 2011-09-28 |
TW201022446A (en) | 2010-06-16 |
CA2742567A1 (en) | 2010-05-14 |
AR074261A1 (en) | 2011-01-05 |
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