1. ERT 211 BIOCHEMICAL ENGINEERING

2. Week 15: Bioconversion Technologies

3. Introduction: BIOCONVERSION
Sugarcane residue
ABUNDANCE OF BIOMASS WHOLE OVER THE WORLD
Impose environmental
problems

4. What is Biomass
Living and dead biological material that can be used for biofuel or industrial production.
Focus on biomass produced from agriculture activities.

5. How to use the biomass? Convert to useful products. Convert to energy.
What method can we use?
Physically?
Chemically?
Biologically?

6. Energy from biomass Biofuels
Bioethanol – made from crops eg sugarcane, corn, potato, kenaf
Biodiesel – made from oils/fats using
transesterification process
Biogas (methane, CO2, N2) – produce by the biological breakdown of organic matters in the absence of O2

7. Products from bioconversion
Industrial chemicals (organic acids, acetic acids, giberellic acids, biopolymers)
Food additives (amino acids, nucleosides, vitamins, fats and oils)
Health care products (antibiotics, steroid, vaccines, monoclonal antibodies)
Industrial enzymes (amylases, proteases, diastases).

8. Physical Method
Mechanical processes; pelletization of wood waste, paddy straw.
Extraction process

9. Thermo chemical methods
A process where heat is the dominant mechanism to convert biomass into another chemical form
Three different classes of thermo chemical:
Combustion/burning
Gasification – convert carbonaceous materials into carbon monoxide&hydrogen (syngas)
Liquefaction

10. Biological methods
use of the enzymes of bacteria and other micro-organisms to break down biomass.
micro-organisms are used to perform the conversion process: anaerobic digestion, fermentation and composting.
The importance group of bacteria in bioconversion are:
Lactic acid bacteria
Acetic acid bacteria
Bacteria of alkaline fermentation

11. What is bioconversion
Bioconversion is the conversion of organic materials, such as plant or animal waste, into usable products or energy sources by biological processes or agents, such as certain microorganisms or enzymes.
Things to consider:
What to convert
what to use
What to get

12. What bioconversion can do
Bioconversion can be carried out physically, thermochemically and biologically.
This process has been applied in the production of foodstuffs, organic chemicals and energy.
Biological methods for bioconversion has given priority with the use of microorganisms as less expensive yet effective agents.
This process is also known as fermentation.

13. \

14. BIOCONVERSION TECHNOLOGY ACETIC ACID PRODUCTION
FOR
ACETIC ACID PRODUCTION

15. Acetic acid Usage : CH3COOH, also known as ethanoic acid
is an organic acid that gives vinegar its sour taste and pungent smell.
Acetic acid is one of the simplest carboxylic acids.
Usage :
- in vinegar making (4%-18% acetic acid)
- solvent
- cellulose acetate used in photographic film

16. Acetic acid production
Microorganism used : Acetobacter
is a genus of acetic acid bacteria
have the ability to convert ethanol to acetic acid in the presence of oxygen
They are Gram-negative,
aerobic
rod-shaped bacteria.

17. Type of culture : highly aerated fermentation
Raw material : diluted purified ethanol from grape juice, apple juice, barley malt etc.
Acetic acid fermentation :
- Acetobacter convert alcohol to acetic acid in the presence of excess oxygen.
- The oxidation of one mole of ethanol yields one mole each of acetic acid and water;
- C2H5OH + O2 → CH3COOH + H2O

19. Factors influence acetic acid production
Factors influence - Oxygen supply and the concentration gradients of ethanol and acetate.
1. Lack of oxygen
lack of O2 will killed the bacteria because they are extremely sensitive.
to overcome this problem, has to use efficient aeration
efficient aeration can be achieved with the used of compressed air and proper mechanical device.
for efficient aeration also have to consider shear stress imparted by the fluid and the microorganisms itself.

20. the efficiency depends on the ratio between the energy input necessary per unit weight of O2 transferred to the culture.
2. Over-oxidation
when there is over-oxidation, acetic acid will convert to CO2 and H2O.
will decrease acetic acid production.
have to maintain acetic acid concentrations above 6% of the total culture.
and avoid the total depletion of ethanol.

21. CITRIC ACID PRODUCTION

22. Citric acid is a weak organic acid C6H8O7
exists in greater than trace amounts in a variety of fruits and vegetables, most notably citrus fruits
commercial citric acid is produced by fermentation of carbohydrates or citrus juices
Usage :
- to add an acidic or sour taste to foods and soft drinks.
- general additive in the confectionery industry.
- pharmaceutical industries

23. Citric acid production
Microorganism used : Aspergillus niger or Candida sp. (yeast)
Culture method : submerged fermentation system and surface fermentation
Raw materials : Molasses, sugarcane syrup, sucrose

24. Biochemistry of production (Involves few steps)
Breakdown of hexoses (sugar) to pyruvate and acetyl CoA.
The anaplerotic formation of oxaloacetate from pyruvate and CO2
The accumulation of citrate within the tricarboxylic acid cycle
- The key enzyme is pyruvate carboxylase, constitutively produced in Aspergillus species.

26. Factor influence citric acid production using submerged culture method.
sensitive to iron. Medium used must be iron-deficient. Fermentor must be stainless steel to prevent leaching of iron frm fermentor wall
Oxygen supply
pH should maintain below 2.0. At higher values, A.niger accumulates gluconic acid rather than citrate.

27. Ethanol production

28. Bioconversion technology for ethanol production
Ethanol or ethyl alcohol (C2H5OH) is a clear colourless liquid, it is biodegradable, low in toxicity and causes little environmental pollution if spilt.
Ethanol burns to produce carbon dioxide and water.
Ethanol is widely used in Brazil and in the United States.
Most cars on the road today in the U.S. can run on blends of up to 10% ethanol and 90% petrol
Application of ethanol : raw material, solvent, used in fuel and in chemical, pharmaceutical & food industries.

29. Bioethanol, unlike petroleum, is a form of renewable energy that can be produced from agricultural feedstocks.
It can be made from very common crops such as sugar cane, potato, manioc and maize.

30. Basic biology and technological method
biologically, alcohol was formed when there is an action of microorganisms in the form of yeast anaerobs on sugar or carbon containing solution.
sugar yeast ethanol carbon dioxide
C6H12O yeast C2H5OH CO2
For commercialization of ethanol production, two different types of substrates are available for fermentation.
Both substrates need different type of pre-treatment.
Sugar containing biomass
Starch containing biomass

32. Bioethanol production Substrate : Sugar containing biomass

33. Sugar containing biomass : sugar cane, molasses, sugar beet
Production steps :
1. milling/grinding (extract juices)
2. fermentation of juices (sugar)
with yeast
sugar yeast ethanol carbon dioxide
C6H12O6 + yeast C2H5OH CO2
3. Distillation
4. Dehydration

35. Bioethanol production Substrate : Starch containing biomass

36. Starch containing biomass : maize, cassava, grain, potato
Production steps :
1.Slurry preparation
The starch-containing substrate
(Cassava powder) is mixed with water
to form slurry.
2.Gelatinization
The slurry is then gelatinized with
steam (68-74°C). Gelatinization is the formation of starch paste.

37. 3.Dextrinization
Dextrinization is the breakdown of gelatinized starch into smaller fragments or dextrins by means of α- or Β-amylase. The action of α-amylase on gelatinized starch results in dramatic reduction of viscosity.
4.Saccharification
Saccharification is the complete conversion of dextrins into glucose (sugar) through the action of glucoamylase.
5.Fermentation
The resulting sugar is cooled and transferred to a fermentor where yeast is added. It is catalyzed by the action of enzymes present in microorganisms like yeasts with ethyl alcohol as the end product.
sugar yeast ethanol carbon dioxide
C6H12O6 + yeast C2H5OH CO2

38. 6.Distillation
After fermentation, the fermented liquor is transferred to a distillation process where the ethanol is separated from the remaining stillage (residue non-fermentable solids and water). Distillation is the process in which a liquid or vapor mixture of two or more substances is separated into its component fractions of desired purity by the application or removal of heat. This process can usually produce a 95.6% by volume ethanol product.
7.Dehydration
Ethanol from distillation process is sent to the molecular sieves column for further dehydration to produce 99.7% v/v ethanol.

40. Bioethanol production Substrate : cellulose containing biomass

41. cellulose containing biomass : paddy straw, wood, coconut husk, paper waste
Production steps :
1. biomass harvested
2. biomass pretreatment with heat or chemicals (NaOH, HCL) - Cellulose is a polymer of glucose. Hemicellulose is a copolymer of different C5 and C6 sugars including e.g. xylose, mannose and glucose, depending on the type of biomass. Lignin is a branched polymer of aromatic compounds.

42. 3. Hydrolysis of cellulose with enzyme nto produce sugar
4. Fermentation of sugar with yeast
sugar yeast ethanol carbon dioxide
C6H12O6 + yeast C2H5OH CO2
5. Distillation
After fermentation, the fermented liquor is transferred to a distillation process where the ethanol is separated from the remaining stillage (residue non-fermentable solids and water).

44. Biodiesel production

45. Biodiesel
Biodiesel refers to a vegetable oil- or animal fat-based diesel fuel consisting of long-chain alkyl (methyl, propyl or ethyl) esters.
Biodiesel is typically made by chemically reacting lipids (e.g., vegetable oil, animal fat, soybean, palm oil, jathropa, sunflower oil, canola) with an alcohol.
Biodiesel can be used in pure form or may be blended with petroleum diesel at any concentration in most injection pump diesel engines.

46. Biodiesel is a light to dark yellow liquid.
It is practically immiscible with water, has a high boiling point and low vapor pressure.
Biodiesel is a renewable fuel that can be manufactured from algae, vegetable oils, animal fats or recycled restaurant greases; it can be produced locally in most countries.
It is safe, biodegradable and reduces air pollutants, such as particulates, carbon monoxide and hydrocarbons.
Blends of 20 percent biodiesel with 80 percent petroleum diesel (B20) can generally be used in unmodified diesel engines.
Biodiesel can also be used in its pure form (B100), but may require certain engine modifications to avoid maintenance and performance problems.

47. Biodiesel production
Biodiesel production is the act of producing the biodiesel, through either transesterification or alcoholysis. The process involves reacting vegetable oils or animal fats catalytically with a short-chain aliphatic alcohols (typically methanol or ethanol).

48. Production steps : biodiesel from soybean seeds
1. Raw materials screening
Remove impurities/dirts from raw materials
2. Oil extraction
Extract oil by pressing or using solvent extraction
3. Purification
Remove impurities from the oil (centrifuge)
4. transesterification
Reaction of oil with methanol+catalyst (NaOH, HCl,
lipase)+heat. Will produce methyl ester and Glycerol

49. Transesterification

50. 5. Purification
a) Separation of methyl ester with glycerine.
Glycerine more dense than methyl ester. So
glycerine will settle at the bottom.
b)Wash biodiesel with water to remove contaminants.
Water is heavier than biodiesel and absorb excess
methanol+NaOH

52. Advantages of bioconversion
Increase recycling
-generate money from waste
Generation of renewable energy
-bioethanol..biodiesel..biogas
-not too dependent on fossil fuel
Reduce landfill effect
- It saves space in landfills.
Offset to fossil fuel usage
-expand energy freedom of choice.
Reduce carbon emission
-reduce greenhouse gasses by using bioenergy

53. Remediate ecological disaster
-Municipal solid wastes – is getting out of control necessitating bigger landfills that are further away from our urban centers. This excess waste contributes to land, water, and air pollution

55. Convert solar energy into liquid fuels

56. Reduce Greenhouse Gases
Please read article entitle “Carbon’s New Math” to get full picture on this
Advantages.

57. Remediate ecological disaster
Municipal solid wastes – is getting out of control necessitating bigger landfills that are further away from our urban centers. This excess waste contributes to land, water, and air pollution
Rural agricultural residues and damaged crops could have a higher value as soil amendments and biomass feedstock