Restructuring the traditional fermentation industry into viable biorefineries for the production of fuels, chemicals and plastics is essential in order to replace (petro)chemical processing. This work presents engineering aspects of Aspergillus awamori submerged fermentation for on-site production of an enzymatic consortium that contains glucoamylase, protease and phosphatase. The crude broth filtrate was used for the production of wheat flour hydrolysates. Improvements on traditional starch hydrolysis carried out in two stages (liquefaction and saccharification) were attempted through integration of unit operations and reduction of processing temperature and reaction duration. An initial increase of temperature to 68 degrees C and a subsequent decrease to 60 degrees C for the rest of the enzymatic hydrolysis resulted in a starch to glucose conversion yield of 94 and 92% when a wheat flour concentration and commercial starch concentration of 225 g L(-1) was used, respectively. The use of crude broth filtrates resulted in the simultaneous hydrolysis of wheat protein and phytic acid, as was indicated by the increase in free amino nitrogen and phosphorus concentration, respectively.
A novel design of a wheat-based biorefinery for bioethanol production, including wheat milling, gluten extraction as byproduct, fungal submerged fermentation for enzyme production, starch hydrolysis, fungal biomass autolysis for nutrient regeneration, yeast fermentation with recycling integrated with a pervaporation membrane for ethanol concentration, and fuel-grade ethanol purification by pressure swing distillation (PSD), was optimized in continuous mode using the equation-based software General Algebraic Modelling System (GAMS). The novel wheat biorefining strategy could result in a production cost within the range of dollars 0.96-0.50 gal(-1) ethanol (dollars 0.25-0.13 L(-1) ethanol) when the production capacity of the plant is within the range of 10-33.5 million gal y(-1) (37.85-126.8 million L y(-1)). The production of value-added byproducts (e.g., bran-rich pearlings, gluten, pure yeast cells) was identified as a crucial factor for improving the economics of fuel ethanol production from wheat. Integration of yeast fermentation with pervaporation membrane could result in the concentration of ethanol in the fermentation outlet stream (up to 40 mol %). The application of a PSD system that consisted of a low-pressure and a high-pressure column and employing heat integration between the high- and low-pressure columns resulted in reduced operating cost (up to 44%) for fuel-grade ethanol production.
A wheat-based continuous process for the production of a nutrient-complete feedstock for bioethanol production by yeast fermentation has been cost-optimized. This process could substitute for the current wheat dry milling process employed in industry for bioethanol production. Each major wheat component (bran, gluten, starch) is extracted and processed for different end-uses. The separate stages, liquefaction and saccharification, used currently in industry for starch hydrolysis have been integrated into a simplified continuous process by exploiting the complex enzymatic consortium produced by on-site fungal bioconversions. A process producing 120 m3 h-1 nutrient-complete feedstock for bioethanol production containing 250 g L-1 glucose and 0.85 g L-1 free amino nitrogen would result in a production cost of $0.126/kg glucose.
A wheat-based continuous process for the production of a nutrient-complete feedstock for bioethanol production by yeast fermentation has been cost-optimized. This process could substitute for the current wheat dry milling process employed in industry for bioethanol production. Each major wheat component (bran, gluten, starch) is extracted and processed for different end-uses. The separate stages, liquefaction and saccharification, used currently in industry for starch hydrolysis have been integrated into a simplified continuous process by exploiting the complex enzymatic consortium produced by on-site fungal bioconversions. A process producing 120 m3 h-1 nutrient-complete feedstock for bioethanol production containing 250 g L-1 glucose and 0.85 g L-1 free amino nitrogen would result in a production cost of $0.126/kg glucose.
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