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Recycling the contents of a continuous fermentor through a stripping column is proposed as a means of reducing product inhibition and lowering the cost of fuel ethanol production. A 2-L fermentor and 10-cm packed column were continuously operated for 150 days without contamination. Some fouling of the packing with attached yeast cells was observed which partially blocked the column. Cell yield was lower than in a simple continuous fermentor. Complete conversion of 200 g/L glucose feed and 90% conversion of 600 g/L glucose feed were achieved. Data were analyzed by computerized process simulation. Cost analysis indicated that, with heat recovery to reduce heating and cooling costs, the continuous fermentor/stripper is possibly a lower-cost alternative to conventional fermentation and distillation.

Membrane fatty acid composition and thermal resistance (D value) of Pediococcus sp. were determined for mid-exponential-phase (ME) and stationary-phase (ST) cells grown in tryptic soy broth (TSB) and tryptone-glucose-yeast extract (TGY) at 28 and 37°C. As the cells entered the stationary phase of growth, the unsaturated fatty acid, C18:1 n11c, produced during the exponential phase of growth was converted to its cyclic form, C19:0 Δ9c. This shift in membrane fatty acid composition was accompanied by an increase in the D values of this bacterium. Data from this study suggest that the membrane fatty acid composition of Pediococcus sp. is dependent on the growth conditions and that membrane fatty acid composition plays a critical role in thermal resistance. Thermal inactivation curves ofPediococcus sp. cells grown in TGY at 28°C indicated the presence of a cell population that is heterogeneous in thermal resistance. The growth of this bacterium in TGY at 37°C and in TSB at 28 and 37°C resulted in cell populations that were uniform in thermal resistance with a lag time for thermal inactivation. Thermal inactivation curves of ME and ST cultures were similar. The data presented here suggest that the cell population’s uniformity of thermal inactivation is independent of the growth phase of the culture.

BackgroundUS legislation requires the use of advanced biofuels to be made from non-food feedstocks. However, commercialization of lignocellulosic ethanol technology is more complex than expected and is therefore running behind schedule. This is creating a demand for non-food, but more easily converted, starch-based feedstocks other than corn that can fill the gap until the second generation technologies are commercially viable. Winter barley is such a feedstock but its mash has very high viscosity due to its high content of β-glucans. This fact, along with a lower starch content than corn, makes ethanol production at the commercial scale a real challenge.ResultsA new fermentation process for ethanol production from Thoroughbred, a winter barley variety with a high starch content, was developed. The new process was designated the EDGE (enhanced dry grind enzymatic) process. In this process, in addition to the normal starch-converting enzymes, two accessory enzymes were used to solve the β-glucan problem. First, β-glucanases were used to hydrolyze the β-glucans to oligomeric fractions, thus significantly reducing the viscosity to allow good mixing for the distribution of the yeast and nutrients. Next, β-glucosidase was used to complete the β-glucan hydrolysis and to generate glucose, which was subsequently fermented in order to produce additional ethanol. While β-glucanases have been previously used to improve barley ethanol production by lowering viscosity, this is the first full report on the benefits of adding β-glucosidases to increase the ethanol yield.ConclusionsIn the EDGE process, 30% of total dry solids could be used to produce 15% v/v ethanol. Under optimum conditions an ethanol yield of 402 L/MT (dry basis) or 2.17 gallons/53 lb bushel of barley with 15% moisture was achieved. The distillers dried grains with solubles (DDGS) co-product had extremely low β-glucan (below 0.2%) making it suitable for use in both ruminant and mono-gastric animal feeds.

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The effects of pressure, temperature, residence time, and mass of skim milk on some characteristics of casein, prepared by precipitation with high pressure CO2, were examined in a batch reactor. For a 500-g milk sample, precipitation occurred at pressures > 2760 kPa and temperatures > 32 degrees C. Residence time was not significant and was held at 5 min. Yields were maximum at 2750 to 5520 kPa and at 38 to 49 degrees C for a 500-g milk sample. The resulting whey had a pH of 6.0. The casein product had an acceptable appearance and had greater solids, ash, and Ca contents than commercial acid caseins. Particle size distribution studies showed that the mean particle size was sensitive to precipitation pressure and temperature and was similar to that of acid caseins produced under laboratory conditions. The HPLC studies of the casein and whey fractions showed that precipitation by CO2 did not result in fractionation of casein or whey proteins to their component proteins.

Conversion of a high-solids saccharified corn mash to ethanol by continuous fermentation and stripping was successfully demonstrated in a pilot plant consuming 25 kg of corn per day. A mathematical model based on previous pilot plant results accurately predicts the specific growth rate obtained from these latest results. This model was incorporated into a simulation of a complete dry-grind corn-to-ethanol plant, and the cost of ethanol production was compared with that of a conventional process. The results indicate a savings of $0.03 per gallon of ethanol produced by the stripping process. The savings with stripping result from the capacity to ferment a more concentrated corn mash so there is less water to remove downstream.

The operation of a pilot plant consisting of a 14-1 fermentor, 10-cm packed column and condenser for continuous fermentation and stripping of ethanol was stable for more than 100 days. The feed consisted of a non-sterile solution of 560 g/l glucose with 100 g/l corn steep water. Fouling of the packing in the column with attached growth of yeast cells was controlled by in situ washing at intervals of 3-6 days. A computer simulation of the pilot plant was developed and used to analyze the data. The productivity of the continuous fermentor varied from 14 g ethanol to 17 g ethanol l-1 h-1. The yield was equal to the maximum theoretically possible: 0.51 g ethanol/g glucose consumed. Results are fit to linear models for the effects of ethanol concentration on specific growth rate and cell yield, and for the effect of stripping temperature on specific growth rate.