Comparison of acetone–butanol–ethanol fermentation and ethanol catalytic upgrading as pathways for butanol production: A techno-economic and environmental assessment

Butanol is an important compound used as a building block for producing value-added products and an energy carrier. The main butanol production pathways are conventional acetone–butanol–ethanol (ABE) fermentation and catalytic upgrading of ethanol. On the other hand, the application of biomass as a promising substrate for biofuel production has been widely considered recently. However, few studies have compared different butanol production pathways using biomass as raw material. In light of that, the present work aims (i) to provide a short review of the catalytic ethanol upgrading and (ii) to compare conventional ABE fermentation and catalytic ethanol upgrading processes from the economic and environmental perspectives. Aspen Plus v9.0 was used to simulate both processes. The economic and environmental assessments were carried out considering the Colombian economic context, a gate-to-gate approach, and single impact categories. Considering a processing scale of 1000 ton/d, the conventional ABE fermentation process presented a more favorable technical, economic, and environmental performance for butanol production from biomass. It also offered lower net energy consumption (i.e., 57.9 GJ/ton of butanol) and higher butanol production (i.e., 2.59 ton/h). Nevertheless, the proposed processing scale was insufficient to reach economic feasibility for both processes. To overcome this challenge, the minimum processing scale had to be higher than 1584 ton/d and 1920 ton/d for conventional ABE fermentation and catalytic ethanol upgrading, respectively. Another critical factor in enhancing the economic feasibility of both butanol production pathways was the minimum selling price of butanol. More specifically, prices higher than 1.56 USD/kg and 1.80 USD/kg would be required for conventional ABE fermentation and catalytic ethanol upgrading, respectively. From the environmental impact point of view, the conventional ABE fermentation process led to a lower potential environmental impact than catalytic ethanol upgrading (0.12 PEI/kg vs. 0.18 PEI/kg, respectively).

Process Engineering of the Acetone-Ethanol-Butanol (ABE) Fermentation in a Linear and Feedback Loop Cascade of Continuous Stirred Tank Reactors: Experiments, Modeling and Optimization

The production of butanol, acetone and ethanol by Clostridium acetobutylicum is a biphasic fermentation process. In the first phase the carbohydrate substrate is metabolized to acetic and butyric acid, in the following second phase the product spectrum is shifted towards the economically interesting solvents. Here we present a cascade of six continuous stirred tank reactors (CCSTR), which allows performing the time dependent metabolic phases of an acetone-butanol-ethanol (ABE) batch fermentation in a spatial domain. Experimental data of steady states under four operating conditions—with variations of the pH in the first bioreactor between 4.3 and 5.6 as well as the total dilution rate between 0.042 h−1 and 0.092 h−1—were used to optimize and validate a corresponding mathematical model. Beyond a residence time distribution representation and substrate, biomass and product kinetics this model also includes the differentiation of cells between the metabolic states. Model simulations predict a final product concentration of 8.2 g butanol L−1 and a productivity of 0.75 g butanol L−1 h−1 in the CCSTR operated at pHbr1 of 4.3 and D = 0.092 h−1, while 31% of the cells are differentiated to the solventogenic state. Aiming at an enrichment of solvent-producing cells, a feedback loop was introduced into the cascade, sending cells from a later state of the process (bioreactor 4) back to an early stage of the process (bioreactor 2). In agreement with the experimental observations, the model accurately predicted an increase in butanol formation rate in bioreactor stages 2 and 3, resulting in an overall butanol productivity of 0.76 g L−1 h−1 for the feedback loop cascade. The here presented CCSTR and the validated model will serve to investigate further ABE fermentation strategies for a controlled metabolic switch.

Process Engineering of the Acetone-Ethanol-Butanol (ABE) Fermentation in a Linear and Feedback Loop Cascade of Continuous Stirred Tank Reactors: Experiments, Modeling and Optimization

The production of butanol, acetone and ethanol by Clostridium acetobutylicum is a biphasic fer-mentation process. In the first phase the carbohydrate substrate is metabolized to acetic and bu-tyric acid, in the following second phase the product spectrum is shifted towards the economi-cally interesting solvents. Here we present a cascade of six continuous stirred tank reactors (CCSTR), which allows performing the time dependent metabolic phases of an ace-tone-butanol-ethanol (ABE) batch fermentation in a spatial domain. Experimental data of steady states under four operating conditions - with variations of the pH in the first bioreactor between 4.3 and 5.6 as well as the total dilution rate between 0.042 1/h and 0.092 1/h - were used to optimize and validate a corresponding mathematical model. Beyond a residence time distribution representation and substrate, biomass and product kinetics this model also includes the differen-tiation of cells between the metabolic states. Model simulations predict a final butanol product concentration of 8.2 g/L and a butanol productivity of 0.75 g/(L h) in the CCSTR operated at a pH in bioreactor 1 of 4.3 and D = 0.092 1/h, while 31 % of the cells are differentiated to the solventogenic state. Aiming at an enrichment of solvent-producing cells, a feedback loop was introduced into the cascade - sending cells from a later state of the process (bioreactor 4) back to an early stage of the process (bioreactor 2). In agreement with the experimental observations, the model accurately predicted an increase of butanol formation rate in bioreactor stages 2 and 3, resulting in an overall butanol productivity of 0.76 g/(L h) for the feedback loop cascade. The here presented CCSTR and the validated model will serve to investigate further ABE fermentation strategies for a controlled metabolic switch.

Energy-efficient butanol production by Clostridium acetobutylicum with histidine kinase knockouts to improve strain tolerance and process robustness

Under stress, Clostridium acetobutylicum sporulates and halts its metabolism, which limits its use in industrial acetone-butanol-ethanol (ABE) fermentation. It is challenging to manipulate the highly regulated sporulation program used by...