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Membrane separation of xylose and glucose can be accomplished via oxidation of glucose to gluconic acid by enzymatic glucose oxidase catalysis. Oxygen for this reaction can be supplied via decomposition of hydrogen peroxide by enzymatic catalase catalysis. In order to maximize the biocatalytic productivity of glucose oxidase and catalase (gluconic acid yield per total amount of enzyme) the following system set-ups were compared: immobilization of glucose oxidase alone; co-immobilization of glucose oxidase and catalase; glucose oxidase and catalase free in the membrane bioreactor. Fouling-induced enzyme immobilization in the porous support of an ultrafiltration membrane was used as strategy for entrapment of glucose oxidase and catalase. The biocatalytic productivity of the membrane reactor was found to be highly related to the oxygen availability, which in turn depended on the reactor configuration, hydrogen peroxide concentration and catalase origin. When glucose oxidase and catalase (from Aspergillus niger ) were free in the membrane bioreactor a total biocatalytic productivity of 122 mg gluconic acid/mg enzyme was obtained after five consecutive reaction cycles. The free enzymes showed superior performance compared to the immobilized systems as a result of limited substrate and product diffusion in the latter case.

Commercial production of ethanol from lignocellulosic biomass is becoming a reality, but the next step is to diversify the process and produce chemicals and materials. These lignocellulosic biorefineries will in many cases rely on hydrolysis of biomass carbohydrates into monosaccharides – the sugar platform. Cellulases are the most important enzymes required in this process, but the complex nature of lignocellulose requires several other enzymes (hemicellulases and auxiliary enzymes) for efficient hydrolysis. Enzyme recycling increases the catalytic productivity of the enzymes by reusing them for several batches of hydrolysis, and thereby reduces the overall cost associated with the hydrolysis. Research on this subject has been ongoing for many years and several promising technologies and methods have been developed and demonstrated. But only in a very few cases have these technologies been upscaled and tested in industrial settings, mainly because of many difficulties with recycling of enzymes from the complex lignocellulose hydrolyzate at industrially relevant conditions, i.e., high solids loadings. The challenges are associated with the large number of different enzymes required for efficient hydrolysis, enzyme stability, and the detrimental interaction between enzyme and lignin. This review provides a comprehensive overview of the various methods for enzyme recovery and recycling, for example recycling of free enzymes, readsorption to fresh material, recycling of solids, membrane filtration, and immobilization. Lignin is a major obstacle for successful hydrolysis and enzyme recycling. A thorough understanding of this subject and possibilities to minimize adsorption or methods to desorb the enzymes are important in order to develop the technology. © 2016 Society of Chemical Industry and John Wiley & Sons, Ltd

The activity and substrate degradation pattern of a novel Aspergillus nidulans GH26 endo-β-mannanase (AnMan26A) was investigated using two galactomannan substrates with varying amounts of galactopyranosyl residues. The AnMan26A was characterized in parallel with the GH26 endomannanase from Podospora anserina (PaMan26A) and three GH5 endomannanases from A. nidulans and Trichoderma reesei (AnMan5A, AnMan5C and TrMan5A). The initial rates and the maximal degree of enzymatically catalyzed conversion of locust bean gum and guar gum galactomannans were determined. The hydrolysis product profile at maximal degree of conversion was determined using DNA sequencer-Assisted Saccharide analysis in High throughput (DASH). This is the first reported use of this method for analyzing galactomannooligosaccharides. AnMan26A and PaMan26A were found to have a novel substrate degradation pattern on the two galactomannan substrates. On the highly substituted guar gum AnMan26A and PaMan26A reached 35-40% as their maximal degree of conversion whereas the three tested GH5 endomannanases only reached 8-10% as their maximal degree of conversion. α-Galactosyl-mannose was identified as the dominant degradation product resulting from AnMan26A and PaMan26A action on guar gum, strongly indicating that these two enzymes can accommodate galactopyranosyl residues in the -1 and in the +1 subsite. The degradation of α-6(4)-6(3)-di-galactosyl-mannopentaose by AnMan26A revealed accommodation of galactopyranosyl residues in the -2, -1 and +1 subsite of the enzyme. Accommodation of galactopyranosyl residues in subsites -2 and +1 has not been observed for other characterized endomannanases to date. Docking analysis of galactomannooligosaccharides in available crystal structures and homology models supported the conclusions drawn from the experimental results. This newly discovered diversity of substrate degradation patterns demonstrates an expanded functionality of fungal endomannanases, than hitherto reported.

Production of ethanol from lignocellulosic materials has a promising market potential, but the process is still only at pilot/demonstration scale due to the technical and economical difficulties of the process. Operating the process at very high solids concentrations (above 20% dry matter-DM) has proven essential for economic feasibility at industrial scale. Historically, simultaneous saccharification and fermentation (SSF) was found to give better ethanol yields compared to separate hydrolysis and fermentation (SHF), but data in literature are typically based on operating the process at low dry matter conditions. In this work the impact of selected enzyme preparation and processing strategy (SHF, presaccharification and simultaneous saccharification and fermentation-PSSF, and SSF) on final ethanol yield and overall performance was investigated with pretreated wheat straw up to 30% DM. The experiments revealed that an SSF strategy was indeed better than SHF when applying an older generation enzyme cocktail (Celluclast-Novozym 188). In case of the newer product Cellic CTec 2, SHF resulted in 20% higher final ethanol yield compared to SSF. It was possible to close the mass balance around cellulose to around 94%, revealing that the most relevant products could be accounted for. One observation was the presence of oxidized sugar (gluconic acid) upon enzymatic hydrolysis with the latest enzyme preparation. Experiments showed gluconic acid formation by recently discovered enzymatic class of lytic polysaccharides monoxygenases (LPMO's) to be depending on the processing strategy. The lowest concentration was achieved in SSF, which could be correlated with less available oxygen due to simultaneous oxygen consumption by the yeast. Quantity of glycerol and cell mass was also depending on the selected processing strategy.

Measurement of the protein content in samples from production of lignocellulosic bioethanol is an important tool when studying the adsorption of cellulases. Several methods have been used for this, and after reviewing the literature, we concluded that one of the most promising assays for simple and fast protein measurement on this type of samples was the ninhydrin assay. This method has also been used widely for this purpose, but with two different methods for protein hydrolysis prior to the assay-alkaline or acidic hydrolysis. In samples containing glucose or ethanol, there was significant interference from these compounds when using acid hydrolysis, which was not the case when using the alkaline hydrolysis. We evaluated the interference from glucose, cellulose, xylose, xylan, lignin and ethanol on protein determination of BSA, Accellerase(®) 1500 and Cellic(®) CTec2. The experiments demonstrated that the presence of cellulose, lignin and glucose (above 50 g/kg) could significantly affect the results of the assay. Comparison of analyses performed with the ninhydrin assay and with a CN analyser revealed that there was good agreement between these two analytical methods, but care has to be taken when applying the ninhydrin assay. If used correctly, the ninhydrin assay can be used as a fast method to evaluate the adsorption of cellulases to lignin.

Bioethanol production would benefit from a rapid screening method to determine the ability of feedstock to be processed into fermentable sugars. The aim of this study was to relate near infrared (NIR) spectra of straw to the release of sugars for ethanol production from cultivars of winter wheat, and to establish a calibration model to quickly determine the content of structural carbohydrates, lignin, and ash. We applied a high-throughput pretreatment and enzymatic hydrolysis (HTPPH) assay, involving hydrothermal pretreatment (180 � C for 17.6 min) and enzymatic hydrolysis, to establish the release of glucose and xylose from 20 cultivars grown in two replicates at two sites; in total 79 samples were measured. The NIR spectra could explain 56% of the variance in sugar release with a root mean square error of cross-validation (RMSECV) of 0.014 g g −1 dm. NIR calibrations predicting content of structural carbohydrates and lignin could explain only about 25% of total variance, whereas calibrations predicting ash content could explain 94% of total variance. The relatively low percentage of explained variance of sugar release was due mainly to uniformity of samples, which rendered the uncertainty of HTPPH method to be large compared with variance between samples. NIR spectroscopy, therefore, has potential to assess sugar release of wheat straw. Improved prediction of carbohydrates and lignin require better compositional analysis for homogeneous material. Despite successful prediction of ash content, site-specific cross-validation indicated that there might be problems with model transferability from site to site.

Palm kernel press cake (PKC) is a residue of palm oil extraction, which was found to contain 48.5% of total carbohydrates of which 35.2% was mannan. The present study examines enzymatic hydrolysis of polysaccharides from the cell-wall material present in PKC to obtain monosaccharides that can be substrate in various fermentation processes such as ethanol production. The requirements for pretreatment were investigated and it was found that mannan in PKC was readily hydrolysed without any pretreatment. Several enzyme preparations were tested and Mannaway 25L was found as the best for releasing mannose, and Gammanase 1.0L worked well in degrading cellulose and mannose. Binary mixtures of enzymes were tested to increase the conversion, and 1:1 mixture of Mannaway 25L and Gammanase 1.0L showed good synergistic effect releasing 30% more mannose than the sum obtained using these enzymes individually. Using an enzyme loading of 2.3 mg protein/g PKC resulted in 63% of mannan in PKC being hydrolysed to mannose in 24 h, and in 96 h a total of 365 g mannose and glucose could be produced per kg PKC. Finally, PKC was hydrolysed and fermented using Saccharomyces cerevisiae with an ethanol yield of 125 g/kg PKC.

Wheat straw hydrolysate produced by enzymatic hydrolysis of hydrothermal pretreated wheat straw at a very high solids concentration of 30% dry matter (w/w) was used for testing the effect of nutrients on their ability to improve fermentation performance of Saccharomyces cerevisiae. The nutrients tested were MgSO4 and nitrogen sources; (NH4)2SO4, urea, yeast extract, peptone and corn steep liquor. The fermentation was tested in a separate hydrolysis and fermentation process using a low amount of inoculum (0.33 g kg(-1)) and a non-adapted baker's yeast strain. A factorial screening design revealed that yeast extract, peptone, corn steep liquor and MgSO4 were the most significant factors in obtaining a high fermentation rate, high ethanol yield and low glycerol formation. The highest volumetric ethanol productivity was 1.16 g kg(-1) h(-1) and with an ethanol yield close to maximum theoretical. The use of urea or (NH4)2SO4 separately, together or in combination with MgSO4 or vitamins did not improve fermentation rate and resulted in increased glycerol formation compared to the use of yeast extract. Yeast extract was the single best component in improving fermentation performance and a concentration of 3.5 g kg(-1) resulted in high ethanol yield and a volumetric productivity of 0.6 g kg(-1) h(-1).

The economic dependency on fossil fuels and the resulting effects on climate and environment have put tremendous focus on utilizing fermentable sugars from lignocellulose, the largest known renewable carbohydrate source. The fermentable sugars in lignocellulose are derived from cellulose and hemicelluloses but these are not readily accessible to enzymatic hydrolysis and require a pretreatment, which causes an extensive modification of the lignocellulosic structure. A number of pretreatment technologies are under development and being tested in pilot scale. Hydrolysis of lignocellulose carbohydrates into fermentable sugars requires a number of different cellulases and hemicellulases. The hydrolysis of cellulose is a sequential breakdown of the linear glucose chains, whereas hemicellulases must be capable of hydrolysing branched chains containing different sugars and functional groups. The technology for pretreatment and hydrolysis has been developed to an extent that is close to a commercially viable level. It has become possible to process lignocellulose at high substrate levels and the enzyme performance has been improved. Also the cost of enzymes has been reduced. Still a number of technical and scientific issues within pretreatment and hydrolysis remain to be solved. However, significant improvements in yield and cost reductions are expected, thus making large-scale fermentation of lignocellulosic substrates possible. © 2007 Society of Chemical Industry and John Wiley & Sons, Ltd

Monocot residues such as corn stover and straw are often not fully exploited and constitute a potential substrate for bioethanol production. However, a number of factors such as high enzyme loadings make large-scale utilization economically difficult. Addition of non-ionic surfactants and poly(ethylene glycol) to enzymatic hydrolysis of various lignocellulosic substrates has been found to increase the conversion of cellulose into soluble, fermentable sugars. We have shown that surfactants are able to increase cellulose conversion with up to 70%. This provides an opportunity of decreasing enzyme loading while retaining the same degree of hydrolysis. Investigations of five wheat straw substrates produced with different pretreatment methods revealed that surfactants have a more pronounced effect on acid and steam treated straw than, e.g. ammonia and hydrogen peroxide treated straw. Thus, lignin content is not directly proportional with the potential surfactant effect. Studies of adsorption of cellulases support the theory that the main mechanism behind the surfactant effect is prevention of unspecific adsorption of enzyme on the substrate lignin. This is believed to be due to hydrophobic interaction between lignin and the surfactant, causing steric repulsion of enzyme from the lignin surface. More research is needed to reveal which factors influence enzyme and surfactant adsorption.

The fungus Penicillium brasilianum IBT 20888 was cultivated on three different carbon sources to investigate the effect of the carbon source on the enzyme production. The carbon sources used were Sigmacell cellulose (SC), steam pretreated spruce (SPS) and a mixture of SC, oat spelts xylan and birchwood xylan (SCXX). Enzymatic assays and capillary electrophoresis revealed clear differences among three enzyme preparations produced—both in activity levels and in the distribution between enzymes within the same class. The hydrolysis efficiency of the resulting enzyme preparations was studied on SC and SPS. The three enzyme preparations performed equally well on SPS using an enzyme loading of 25 FPU (g cellulose) −1 . The enzyme preparation produced on SCXX resulted in 15% less glucose released from SC compared to the two other enzyme preparations. A lower total cellobiohydrolase level could in part explain this difference. Adsorption studies revealed that three-fold more protein was adsorbed onto SPS compared to SC due to the presence of lignin in SPS. The binding onto lignin was demonstrated to be non-specific as most proteins in the enzyme preparations were adsorbed. It was also demonstrated by the use of CE that some degradation of the enzymes occurred during the hydrolysis.

The production of cellulases and hemicellulases by Penicillium pinophilum IBT 4186, P. persicinum IBT 13226 and P. brasilianum IBT 20888 was studied during well-controlled batch cultivations using various polysaccharides as carbon source. Generally, the use of cellulose as carbon source resulted in production of cellulases whereas xylan resulted in production of xylanases, but the enzyme production by P. pinophilum IBT 4186 was less strictly regulated by the carbon source compared to the two other species. Capillary electrophoresis (CE) was used to quantify the main five cellulases produced by P. brasilianum IBT 20888 during cultivations on cellulose. It was found that the concentration of cellulases possessing a cellulose-binding module (CBM) was unaltered by an increased cellulose concentration in the cultivations, whereas the concentration of some cellulases without the cellulose-binding module was increased. The lack of correlation between initial cellulose concentration and final filter paper activity in the medium could therefore be assigned to adsorption of a fraction of the cellulases produced by P. brasilianum IBT 20888 onto remaining cellulose.

For enzymatic hydrolysis of lignocellulosic material, cellulolytic enzymes from Trichoderma reesei are most commenly used, but, there is a need for more efficient enzyme cocktails. In this study, the production of cellulolytic and xylanolytic enzymes was investigated in 12 filamentous fungi from genus Penicillium and compared with that of T. reesei. Either Solka-Floc cellulose or oat spelt xylan was used as carbon source in shake flask cultivations. All the fungi investigated showed coinduction of cellulolytic and xylanolytic enzymes during growth on cellulose as well as on xylan. The highest filter paper activity was measured after cultivation of Penicillium brasilianum IBT 20888 on cellulose.

The filamentous fungus Penicillium brasilianum IBT 20888 was cultivated on a mixture of 30 g l−1 cellulose and 10 g l−1 xylan for 111 h and the resulting culture filtrate was used for protein purification. From the cultivation broth, five cellulases and one xylanase were purified. Hydrolysis studies revealed that two of the cellulases were acting as cellobiohydrolases by being active on only microcrystalline cellulose (Avicel). Three of the cellulases were active on both Avicel and carboxymethyl cellulose indicating endoglucanase activity. Two of these showed furthermore mannanase activity by being able to hydrolyze galactomannan (locust bean gum). Adsorption studies revealed that the smaller of the two enzymes was not able to bind to cellulose. Similarity in molecular mass, pI and hydrolytic properties suggested that these two enzymes were identical, but the smaller one was lacking the cellulose-binding domain or an essential part of it. The basic xylanase (pI>9) was only active towards xylan. Two of the purified cellulases with endoglucanase activity were partly sequenced and based on sequence homology with known enzymes they were classified as belonging to families 5 and 12 of the glycosyl hydrolases.

The production of cellulose and hemicellulose-degrading enzymes by cultivation of Aspergillus niger ATCC 9029, Botrytis cinerea ATCC 28466, Penicillium brasilianum IBT 20888, Schizophyllum commune ATCC 38548, and Trichoderma reesei Rut-C30 was studied. Wet-oxidised wheat straw suspension supplemented with NH4NO3, MgSO4, and KH2PO4 was used as cultivation medium aiming to obtain an enzyme mixture optimal for enzymatic hydrolysis of wet-oxidised wheat straw. The cultivations with B. cinerea and P. brasilianum gave the highest endoglucanase (EC 3.2.1.4) and β-glucosidase (EC 3.2.1.21) activities, in contrast to the other fungi where lower activities were found. The culture filtrates were concentrated by ammonium sulphate precipitation. After enzyme concentration, the highest enzyme activities (1.34 FPU/ml) were found in the culture broth originating from P. brasilianum. Enzymatic hydrolysis of filter cake from wet-oxidised wheat straw for 48 h with an enzyme loading of 5 FPU/g biomass resulted in glucose yields from cellulose of 58% (w/w) and 39% (w/w) using enzymes produced by P. brasilianum and a commercial enzyme mixture, respectively. At higher enzyme loading (25 FPU/g biomass) using either enzyme mixtures the glucose yield from cellulose was in the range of 77–79% (w/w).

Biofuel production processes at high gravity are currently under development. Most of these processes however use sugars or first generation feedstocks as substrate. This paper presents the results of a life cycle assessment (LCA) of the production of bio-ethanol at high gravity conditions from a second generation feedstock, namely, wheat straw. The LCA used lab results of a set of 36 process configurations in which dry matter content, enzyme preparation and loading, and process strategy were varied. The LCA results show that higher dry matter content leads to a higher environmental impact of the ethanol production, but this can be compensated by reducing the impact of enzyme production and use, and by polyethylene glycol addition at high dry matter content. The results also show that the renewable and non-renewable energy use resulting from the different process configurations ultimately determine their environmental impact.

Recycling of enzymes has a potential interest during cellulosic bioethanol production as purchasing enzymes is one of the largest expenses in the process. By recycling enzymes after distillation, loss of sugars and ethanol are avoided, but depending on the distillation temperature, there is a potential risk of enzyme degradation. Studies of the rate of enzyme denaturation based on estimation of the denaturation constant K D was performed using a novel distillation setup allowing stripping of ethanol at 50–65 °C. Experiments were performed in a pilot-scale stripper, where the effect of temperature (55–65 °C) and exposure to gas–liquid and liquid–heat transmission interfaces were tested on a mesophilic and thermostable enzyme mixture in fiber beer and buffer. Lab-scale tests were included in addition to the pilot-scale experiments to study the effect of shear, ethanol concentration, and PEG on enzyme stability. When increasing the temperature (up to 65 °C) or ethanol content (up to 7.5 % w/v), the denaturation rate of the enzymes increased. Enzyme denaturation occurred slower when the experiments were performed in fiber beer compared to buffer only, which could be due to PEG or other stabilizing substances in fiber beer. However, at extreme conditions with high temperature (65 °C) and ethanol content (7.5 % w/v), PEG had no enzyme stabilizing effect. The novel distillation setup proved to be useful for maintaining enzyme activity during ethanol extraction.

Different versions of two commercial cellulases were tested for their recyclability of enzymatic activity at high dry matter processes (12% or 25% DM). Recyclability was assessed by measuring remaining enzyme activity in fermentation broth and the ability of enzymes to hydrolyse fresh, pretreated wheat straw. Industrial conditions were used to study the impact of hydrolysis temperature (40 or 50 °C) and residence time on recyclability. Enzyme recycling at 12% DM indicated that hydrolysis at 50 °C, though ideal for ethanol yield, should be kept short or carried out at lower temperature to preserve enzymatic activity. Best results for enzyme recycling at 25% DM was 59% and 41% of original enzyme load for a Celluclast:Novozyme188 mixture and a modern cellulase preparation, respectively. However, issues with stability of enzymes and their strong adsorption to residual solids still pose a challenge for applicable methods in enzyme recycling.

Lignocellulolytic enzymes are among the most costly part in production of bioethanol. Therefore, recycling of enzymes is interesting as a concept for reduction of process costs. However, stability of the enzymes during the process is critical. In this work, focus has been on investigating the influence of temperature and ethanol on enzyme activity and stability in the distillation step, where most enzymes are inactivated due to high temperatures. Two enzyme mixtures, a mesophilic and a thermostable mixture, were exposed to typical process conditions [temperatures from 55 to 65 °C and up to 5 % ethanol (w/v)] followed by specific enzyme activity analyses and SDS-PAGE. The thermostable and mesophilic mixture remained active at up to 65 and 55 °C, respectively. When the enzyme mixtures reached their maximum temperature limit, ethanol had a remarkable influence on enzyme activity, e.g., the more ethanol, the faster the inactivation. The reason could be the hydrophobic interaction of ethanol on the tertiary structure of the enzyme protein. The thermostable mixture was more tolerant to temperature and ethanol and could therefore be a potential candidate for recycling after distillation.

A recent development in waste management and engineering has shown that the cellulase can be used for the liquefaction of organic fractions in household waste. The focus of this study was to optimize the enzyme hydrolysis of thermally treated municipal solid waste (MSW) by the addition of surfactant. Concurrently, the enzyme performance was analysed on pure cellulose in a solution of MSW wastewater. Results showed no effect of surfactant addition to the hydrolysis media as measured by viscosity and particle size distribution. MSW treatment wastewater was found to contain a high amount of calcium, potassium, sodium, chloride and others that may affect cellulolytic enzymes. Cellulase performance showed no effect of adding the metal ion-chelating agent EDTA to the solution. The cellulases were stable, tolerated and functioned in the presence of several contaminants.

Wheat straw is a potential feedstock for bioethanol production. This paper investigates tissues from whole internode sections subjected to hydrothermal pretreatment at 185 °C and subsequent enzymatic hydrolysis up to 144 h. Analyses revealed an increase in surface lignin as hydrolysis progressed, which could be coupled to the gradual decrease in hydrolysis rate over time. The data support the hypothesis of lignin extraction from the cell wall matrix during pretreatment and deposition as droplets upon cooling. These droplets are assumed to accumulate during enzymatic hydrolysis. Additionally, after 144 h of enzymatic hydrolysis the cortex had vanished, exposing the heavier lignified vascular tissue. Accumulation of lignin droplets and exposure of residual lignin could be part of the explanation for the decreasing hydrolysis rate. Flattening of macrofibrils after pretreatment together with more indentations on the surfaces was also observed, possibly caused by a proposed synergistic effect of cellobiohydrolases and endoglucanases.

Lignocellulosic plant material is potentially a sustainable source of fermentable sugars for bioethanol production. However, a barrier to this is the high resistance or recalcitrance of plant cell walls to be hydrolyzed. Therefore, a detailed knowledge of the structural features of plant cell walls that contribute to recalcitrance is important for improving the efficiency of bioethanol production. In this work we have used a technique known as Comprehensive Microarray Polymer Profiling (CoMPP) to analyze wheat straw before and after being subjected to hydrothermal pre-treatments at four different temperatures. The CoMPP technique combines the specificity of monoclonal antibodies with the high-throughput capacity of microarrays. Changes in the relative abundance of cell wall polysaccharides could be tracked during processing, and a reduction in xylan, arabinoxylans, xyloglucan, and mixed-linked glucan epitopes was detected at the two highest temperatures of pre-treatment used. This work demonstrates the potential of CoMPP as a complementally technique to conventional methods for analyzing biomass composition.

Palm kernel press cake (PKC) is a residue from palm oil extraction presently only used as a low protein feed supplement. PKC contains 50% fermentable hexose sugars present in the form of glucan and mainly galactomannan. This makes PKC an interesting feedstock for processing into bioethanol or in other biorefinery processes. Using a combination of mannanase, beta-mannosidase, and cellulases, it was possible without any pretreatment to hydrolyze PKC at solid concentrations of 35% dry matter with mannose yields up to 88% of theoretical. Fermentation was tested using Saccharomyces cerevisiae in both a separate hydrolysis and fermentation (SHF) and simultaneous saccharification and fermentation (SSF) setup. The hydrolysates could readily be fermented without addition of nutrients and with average fermentation yields of 0.43 +/- 0.02 g/g based on consumed mannose and glucose. Employing SSF, final ethanol concentrations of 70 g/kg was achieved in 216 h, corresponding to an ethanol yield of 70% of theoretical or 200 g ethanol/kg PKC. Testing various enzyme mixtures revealed that including cellulases in combination with mannanases significantly improved ethanol yields. Processing PKC to ethanol resulted in a solid residue enriched in protein from 17% to 28%, a 70% increase, thereby potentially making a high-protein containing feed supplement.

As technologies for utilizing biomass for fuel and chemical production continue to improve, enzymatic hydrolysis can be run at still higher solids concentrations. For hydrolyses that initially contain little or no free water (10–40% total solids, w/w), the saccharification of insoluble polymers into soluble sugars involves changes of volume, density, and proportion of insoluble solids. This poses a new challenge when determining the degree of hydrolysis (conversion yield). Experiments have shown that calculating the yield from the resulting sugar concentration in the supernatant of the slurry and using the assumed initial volume leads to significant overestimations of the yield. By measuring the proportion of insoluble solids in the slurry as well as the sugar concentration and specific gravity of the aqueous phase, it is possible to precisely calculate the degree of conversion. The discrepancies between the different ways of calculating yields are demonstrated along with a nonlaborious method for approximating yields in high solids hydrolysis.

To improve process economics of the lignocellulose to ethanol process a reactor system for enzymatic liquefaction and saccharification at high-solids concentrations was developed. The technology is based on free fall mixing employing a horizontally placed drum with a horizontal rotating shaft mounted with paddlers for mixing. Enzymatic liquefaction and saccharification of pretreated wheat straw was tested with up to 40% (w/w) initial DM. In less than 10 h, the structure of the material was changed from intact straw particles (length 1-5 cm) into a paste/liquid that could be pumped. Tests revealed no significant effect of mixing speed in the range 3.3-11.5 rpm on the glucose conversion after 24 h and ethanol yield after subsequent fermentation for 48 h. Low-power inputs for mixing are therefore possible. Liquefaction and saccharification for 96 h using an enzyme loading of 7 FPU/g.DM and 40% DM resulted in a glucose concentration of 86 g/kg. Experiments conducted at 2%-40% (w/w) initial DM revealed that cellulose and hemicellulose conversion decreased almost linearly with increasing DM. Performing the experiments as simultaneous saccharification and fermentation also revealed a decrease in ethanol yield at increasing initial DM. Saccharomyces cerevisiae was capable of fermenting hydrolysates up to 40% DM. The highest ethanol concentration, 48 g/kg, was obtained using 35% (w/w) DM. Liquefaction of biomass with this reactor system unlocks the possibility of 10% (w/w) ethanol in the fermentation broth in future lignocellulose to ethanol plants.

The growth and preference for utilisation of various sugar by the Penicillium species Penicillium pinophilum IBT 4186, Penicillium persicinum IBT 13226 and Penicillium brasilianum IBT 20888 was studied in batch cultivations using various monosaccharides as carbon source, either alone or in mixtures. P. pinophilum IBT 4186 and P. persicinum IBT 13226 had a μ max around 0.08–0.09 h −1 using either glucose or xylose as carbon source. The μ max of P. brasilianum IBT 20888 was 0.16 and 0.14 h −1 on glucose and xylose, respectively. Glucose was found to exert repression on the catabolism of mannose, galactose, xylose and arabinose. The three species were able to utilise all the tested monosaccharides, but arabinose was only slowly metabolised. Glucose was also found to repress the production of endoglucanases, endoxylanases and β-xylosidases. After glucose depletion, the fungi started producing β-glucosidase and endoglucanases. Xylose did not repress the enzyme production and it induced the production of endoxylanases and β-xylosidases.

The overall objective in this European Union-project is to develop cost and energy effective production systems for coproduction of bioethanol and electricity based on integrated biomass utilization. A pilot plan reactor for hydrothermal pretreatment (including weak acid hydrolysis, wet oxidation, and steam pretreatment) with a capacity of 100 kg/h was constructed and tested for pretreatment of wheat straw for ethanol production. Highest hemicellulose (C5 sugar) recovery and extraction of hemicellulose sugars was obtained at 190 degrees C whereas highest C6 sugar yield was obtained at 200 degrees C. Lowest toxicity of hydrolysates was observed at 190 degrees C; however, addition of H2O2 improved the fermentability and sugar recoveries at the higher temperatures. The estimated total ethanol production was 223 kg/t straw assuming utilisation of both C6 and C5 during fermentation, and 0.5 g ethanol/g sugar.