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C H A P T E R

19
Novel bioethanol production processes
and purification technology using
membranes
Alessandro Senatorea, Francesco Dalenab, Angelo Basilec,*
a
Chemistry and Chemical Technologies Dpt., University of Calabria, Rende, Cosenza, Italy; bDepartment
of Environmental and Chemical Engineering Dpt., University of Calabria, Rende, Cosenza, Italy; cITM-
CNR, c/o University of Calabria, Rende, Cosenza, Italy
* Corresponding author. e-mail address: a.zarli@nextchem.it

1. Introduction The development of new technologies to pro-


duce biofuels with low environmental impact is
Increasing of oil prices and polluting emis- one of the greatest scientific efforts of this cen-
sions, as well as the Security Act and the U.S. En- tury. Based on the raw material and on the work-
ergy Independence of 2007, led the American ing process carried out on it, biofuels can be
scientific society, and immediately after the classified as primary (natural gases) or second-
entire scientific community, to search for a new ary biofuels (ethanol, biodiesel, biooil, biogas,
kind of fuel with low environmental impact, or charcoal), and these, as a result, can be subse-
which could meet the needs of the world from quently classified into first, second, or third gen-
both an energetic and a renewable point of eration (Fig. 19.1).
view [1]. At the moment, primary biofuels are easily
The massive use of this nonrenewable fuel, converted into energy thanks to industrial plants
due to the rapid industrial development is that operate on a wide range of scales, from few
strictly connected to the prediction that by kilowatts to hundreds of megawatts [7]. The sec-
2040e50 the fuel demand in the world will ondary biofuels can be instead mainly converted
exceed the availability [2]; in addition, fossil through three different processes: (i) chemical
fuels are primarily responsible for the emission (biomass into liquid fuels), (ii) thermochemical
of CH4, N2O, and CO2 (the so-called greenhouse (combustion, gasification, and pyrolysis), and
gases (GHG)), which contribute to the global (iii) biochemical process (fermentation) [7,8],
warming [3e6]. through which various type of biofuels such as

Catalysis, Green Chemistry and Sustainable Energy


https://doi.org/10.1016/B978-0-444-64337-7.00019-7 359 Copyright © 2020 Elsevier B.V. All rights reserved.
360 19. Novel bioethanol production processes and purification technology using membranes

FIGURE 19.1 Schematic representation of the division class of biofuels.

hydrogen, ethanol, methanol, diesel, and many compression-ignition engine) to be used alone
others can be obtained. Among the many, from or in mixtures with gasoline or diesel, where
both an economic and a productive point of the slowdown in its development on a global
view, ethanol has been chosen as a possible alter- scale is mainly due to the production costs
native candidate, to satisfy the global energy de- ([2a]; [6b]; [9]; [9a]).
mand of the transport sector [8a]. One liter of ethanol affords 66% of the energy
Usually, one of the most important methods provided by the same amount of gasoline;
of industrial ethanol production is carried out moreover, being an alcohol, ethanol is an inter-
by a process that comes from the oil industry esting oxygenated molecule with a high latent
that foresees the acid-catalyzed hydration of heat of vaporization (840e855 kJ/kg), a low ce-
ethylene [2], as shown in the following chemical tane number (5e20), and a high octane number
reaction: (99e107), which allows it to not take part in the
H3 PO4 preignition process of the engine and to be
C2 H4 þ H2 O ! CH3 CH2 OH
burned with a shorter time and a higher
But today, ethanol, also known as bioethanol compression ratio if compared to a fossil fuel
and concurrently produced from plantations ([4e6,9]; [6b]; [2a]). A typical gasoline fuel has
rich in easily fermentable sugars such as sugar- a heat of vaporization of about 380e400 kJ/kg,
cane, corn, wheat, and sugar beet [2a], is a very a cetane number of 8, and an octane number
interesting molecule from both a chemical and of about 82e92 ([9b]). Furthermore, ethanol
physical point of view [4e6]. has a higher evaporation enthalpy (1177 kJ/
From a chemical point of view, ethanol is a kg, at 60 C) compared to gasoline (348 kJ/kg,
molecule (with a molecular weight of 46.07 g/ at 60 C) [9]; Lynd, 1996). All these data are sum-
mol and a density of 0.789 g/cm3) with an ethyl marized in Table 19.1, while Table 19.2 summa-
group linked to a hydroxyl group, which makes rizes the main advantages and disadvantages of
it a polar molecule really versatile to be mixed this molecule as a fuel.
both with water and many organic solvents Due to the chemical structure of the molecule,
([6a]) [4e6]. Moreover, for its physicochemical which contains a hydrophilic head and allows
properties, ethanol has been widely studied as miscibility with water, ethanol could be used in
a good fuel substitute for internal combustion vehicles in the pure form or in a mixture with
(IC) engines (i.e., the spark-ignition or the gasoline, where the advantages of this mixtures

IV. Selected examples and case history


1. Introduction 361
TABLE 19.1 Ethanol combustion characteristics compared to fossil fuels.

Property Unit Ethanol Gasoline Diesel

Density (at 20 C) g/cm 3


0.79 0.75 0.82
Octane number e 99e107 82e92 e
Cetane number e 5e20 8 48

Latent heat of vaporization kJ/kg 840e920 380e400 375


a
Type of motor e e SI engine CIa engine
References e Kukoyi et al., 2015; [9b]; [9b] [10]
Gangult et al., 2011
a
CI, compression ignition; SI, spark ignition.

are the substantial lowering of hydrocarbons, ni- solution show how density, octane number,
trogen oxides (NOx), and carbon monoxide (CO) and latent heat of vaporization increase with
emissions with respect to the gasoline fuel alone the ethanol concentration, while the heating
[9b]. Moreover, also if a high amount of water value decreases [9b]. The E85 blend also in-
must be avoided due to engine problems, hy- creases thermal efficiency, while there is
drous ethanol with a water content of about observed a decrease in hydrocarbons, CO, and
6.8% has been tested with good results in a NOx emissions. The reduction of NOx, in par-
four-stroke engine ([9c]). Today, different blends ticular, has been attributed to a reduction in
of ethanol with gasoline called “E” blends are flame temperature, confirmed by a reduction in
used in SI engines as well as flex-fuel vehicles. exhaust temperature ([9b]; [9c]). With pure
The code used to identify a mixture of this kind ethanol or oxygenated fuel, NOx slightly in-
consists of a letter “E”, followed by a number creases again, due probably to the advanced
that identifies the percentage of ethanol in the combustion that leads to a higher temperature
mixture [4e6,11]. Studies on different blends and inecylinder pressure ([9b]; [9c]). The perfor-
from E5 to E85 up to a 100% pure ethanol mances of the engine are mainly observed in

TABLE 19.2 Schematization of advantages and disadvantages of ethanol as a biofuel.

Advantages Disadvantages

Oxygenated molecule Miscibility with water


High latent heat of vaporization (840 kJ/kg) Lower vapor pressure
Low cetane number (8)
High octane number (100)

Effects
Preventing self-ignition in IC Initiation in engines at cold temperatures is difficult
Burning at high compression ratio
Burning almost completely

IV. Selected examples and case history


362 19. Novel bioethanol production processes and purification technology using membranes

torque experiments that show how it increases used in industrial plants, but membrane separa-
with increasing the compression ratio [11a]. tion technologies are gradually catching on in
There is a lot of literature on ethanol blends biorefining and bioenergy production, due to
that, based on a search done on ScienceDirect the low energy consumption, greater separation
with the keywords “ethanol fuel blends,” shows efficiency, reduced number of processing steps,
an increase of about 9.5% from 2000 until 2018 and high quality of the final product [11c]. In
(Fig. 19.2). In the same period, another inter- the second part of this chapter, various aspects
esting search with the keywords “bioethanol of membrane reactor (MR) technology will be
fuel” shows how the scientific interest and the considered and discussed by referring to both
term bioethanol as a fuel are slowly taking the the ethanol and bioethanol reforming reactions
upper hand over ethanol (Fig. 19.2). to produce pure hydrogen.
At the moment, data updated to 2017 reveal
that the United States and Brazil represent the
major countries involved in bioethanol pro-
duction mainly from corn and sugarcane 2. The bioethanol production process
(Table 19.3), with, respectively, 58% (15.8 billions
of gallons) and 26% (7.06 billions of gallons) of Based on the chemical composition of the
the global ethanol production (Fig. 19.3), fol- initial feedstock, the pretreatment, technology,
lowed by Europe and China [11b]. and cost-effectiveness of processes vary widely.
Several efforts are being carried out to opti- In any case, it is really important that the fermen-
mize the process of conversion of ethanol, and tation processes have a good suitability for pro-
today, an appropriate separation technology is ducing bioethanol.
required. At the moment, distillation, the pro- The costs and yields of the final product are
cess which separates liquid compounds of a mainly affected by (i) content of lignin in the
mixture exploiting the different volatility of biomass; (ii) type and variety of sugars to be fer-
each component through selective boiling and mented; (iii) costs for the collection and storage
condensation points, is the main technique of low density lignocellulose materials [12].

FIGURE 19.2 Scientific articles on ScienceDirect found with the keywords “ethanol fuel blends” and “bioethanol Fuel,”
from 2000 to 2018.

IV. Selected examples and case history


2. The bioethanol production process 363
TABLE 19.3 Bioethanol production costs.

Ethanol from corn Ethanol from sugarcane

Type of process Dry grind Melle-Boinot

Feedstock costs ($/L) 0.21 0.012


Costs on the plant ($/L) 0.109 0.048
Gain from by-products ($/L) 0.068 0
Total production costs ($/L) 0.25 0.06

Ethanol yield (L/tons of feedstock) 403.66 100


Ethanol price ($/L) 0.40 0.20
References [11], [2a] [11e], [2a]

The main steps involved in the bioethanol the so-called cellulases that are also respon-
production process are the pretreatments, hy- sible for the hydrolysis of cellulose [13]; these
drolysis, fermentation, and purification, where enzymes are able to convert only pentose and
the fermentative processes are a common point hexoses sugars [14,15]. The problem with
among all the three generations of feedstock feedstock that contains a lot of lignin is the
(Fig. 19.4). expense of pretreatments, which serve to elimi-
The whole process involves the biochem- nate its structure and free the sugars that will
ical conversion of simple sugars into ethanol be fermented by the enzymatic treatment. This
through enzymes produced by microorganisms: removal improves significantly the effect

FIGURE 19.3 AFDC data of global ethanol production, from 2007 to 2017.

IV. Selected examples and case history


364 19. Novel bioethanol production processes and purification technology using membranes

FIGURE 19.4 Schematic repre-


sentation of the various steps of
fermentative process.

of enzymatic hydrolysis, improving process i Physical pretreatment. The main techniques


yield. that take into account physical principles are
Experimental data show that hydrolysis car- mechanical chipping, grinding, milling, or
ried out without pretreatment lowers the yield uncatalyzed steam explosion
by about 20%, whereas yields after pretreat- (autohydrolysis) and liquid hot water
ment often exceed 90% [16]. The simple sugars pressure (Table 19.4) [23,24]. In any case, the
produced during hydrolysis are subsequently main purpose of this treatment is to reduce
transformed into ethanol during enzymatic the particle size of the cellulosic/
fermentation. The limiting aspect of the fermen- lignocellulosic raw material, to obtain smaller
tation process is the self-by-product inhibition, particles having a larger surface area, which
which is the inhibition of yeast cell enzymes makes sugars easily accessible for other
from its product, bioethanol, at high concentra- industrial steps [24,25]. Usually, the
tions [17]. This problem is usually overcome by maximum particle size obtained after a
the removal and recovery of ethanol during its chipping treatment is about 10e30 mm, while
production through distillation process, also if it is of about 0.2e2 mm after a milling or
genetic techniques are trying to produce yeasts grinding process [4e6,20,22]. The optimal
that are increasingly resistant to this type of particle size range seems to be about
self-inhibition [13]; [13a]. 4e8 mm, which increases the subsequent
extraction yield up to 7.5% ([22a];[3]). So at
the end of this process, the cellulose degree of
2.1 Pretreatment polymerization decreases with a partial break
Pretreatment is one of the key steps involved in of the chains of both lignin and cellulose
bioethanol production processes, capable of [25,26].
altering the size, structure, and chemical composi- ii Chemical pretreatment. Taking advantage of
tion of the starting biomass; it is really crucial to different acidic, basic, or oxidizing chemicals,
make the polysaccharides to be fermented easily different effects can be obtained on the
accessible by chemicals and enzymes of other steps lignocellulosic materials. The most common
and to guide the yield and the cost-effectiveness of and useful methods toward feedstock with a
the whole process (indeed, it represents about 18% high lignin content are alkaline, ozonolysis,
of the total cost of the whole transformation pro- peroxide, and wet oxidation treatments,
cess) [18,19]; [19a]; [20]. The choice of pretreat- while to improve the solubilization of
ments is linked to a number of important criteria, hemicelluloses, treatments with diluted
such as (i) ethanol yield; (ii) best lignin removal acids such as H2SO4, are preferred
treatment; (iii) limitation in the production of prod- for their efficiency [26a].
ucts that inhibit the fermentation enzymes; (iv) iii Physicochemical pretreatment. A series of
minimization of GHG; and (v) minimization of physicochemical reaction conditions such as
toxic by-products [18,21,22]. According to these humidity, temperature, and pH deeply affect
criteria, pretreatment can be divided into the solubilization of lignocellulosic
(i) physical, (ii) chemical, (iii) physicochemical, compounds, since it is the most sensitive
and (iv) biologic (Fig. 19.5). fraction. Hemicelluloses, for instance, become

IV. Selected examples and case history


2. The bioethanol production process 365

FIGURE 19.5 Schematic representation of types of pretreatment processes and some examples.

more soluble in water at temperature higher fermentation inhibitors during the process
than 150 C, favoring the extraction of xylan [29]. However, some improvements must be
[13,27]. The most used pretreatment of this made before they can be used in industrial
type is the CO2 explosion, which is able to processes, such as faster growth times and
separate the hemicelluloses, reducing the removal of natural competitors, making it a
length of the polymer chains of glucosidic very expensive and precarious balance [29a].
fractions into simpler sugars. These Other disadvantages are the low rate of
treatments, often used with recovery of hydrolysis and the long pretreatment times
chemical solvent, can improve the yield on (between 4 and 8 weeks) compared to other
lignocellulosic raw material [28]. pretreatment technologies [30,31]. Table 19.4
iv Biologic pretreatment. Biologic pretreatment is a presents various types of pretreatments, both
treatment that has a great potential in the with the advantages and disadvantages for
industrial processes of the future, for its high each of them.
yield and low environmental impact. In this
Currently, the combination among the biologic
process, microorganisms such as fungi
pretreatment (usually in the form of ready-made
(white-, brown-, and soft-rot fungi) and
enzymes) and the other methods seems to be the
bacteria, or enzymes extracted from them, are
best choice to reduce the whole process time and
mainly used to degrade the lignin structure of
to improve ethanol yield [36]. An example can
the plant, which results in (i) a very low
be made coupling the enzymatic hydrolysis
energy requirement; (ii) no release of toxic
with ozonolysis, where the rate of enzymatic
compounds; and (iii) no generation of

IV. Selected examples and case history


366 19. Novel bioethanol production processes and purification technology using membranes

TABLE 19.4 Some examples of various types of pretreatment according to the starting feedstock (LCB) and the
advantages and disadvantages for each of them.

Pretreatment
Category Method Advantages Disadvantages Ref.

Physical Milling Cost effective High energy input, inability to remove lignin [21,32]
that restricts the access of the enzymes to
cellulose and inhibits cellulases
Extrusion Operate at high solids loadings, High energy consumption, effect is limited [21,32]
low production of inhibitory when no chemical agents are used, mostly
compounds, short time effective on herbaceous type biomass
Chemical Acid Short retention time, lignin and Concentrated acid process is corrosive and [21,32]
hydrolysis hemicellulose are removed dangerous. Requires specialized nonmetallic
constructions, formation of inhibitors at low
pH
Alkaline Removes lignin and a part of the Low digestibility in softwoods, large [21,32,33]
hydrolysis hemicellulose, decrease in the amounts of water requires for washing
polymerization degree
Organosolv Produces low residual lignin High capital investment, handling of harsh [21,32,34]
substrates that reduce unwanted organic solvents, formation of inhibitors
adsorption of enzymes and
allows their recycling and reuse
Ionic liquid Low vapor pressure designer Costly, complexity of synthesis and [21,32,35]
solvent, working under mild purification, toxicity, poor biodegradability,
reaction conditions and inhibitory effects on enzyme activity
Oxidation Lower production of by- Cellulose is partly degraded, high cost [21,32]
products
Physicochemical Steam Less expensive than other pre- Excessive degradation of the physical and [21,32]
explosion treatment methods and chemical properties of cellulose and release
chemical-free of inhibitors
Liquid hot High recovery and lower High energy input, removes mainly [21,32]
water formation of inhibitory hemicellulose
pretreatment components
Ammonia Reduces the lignin fraction, short Costly, does not significantly solubilize [21,32]
fiber retention time, no formation of hemicellulose, ammonia must be recycled
expansion some inhibitory by-products after the pretreatment to reduce the cost and
protect the environment; much less effective
for softwood
Biologic Microbial Lignin degradation, low energy Slow reaction time [21,32]
treatment requirement, chemical-free, mild
conditions

IV. Selected examples and case history


2. The bioethanol production process 367
hydrolysis increased by a factor of five following of cellulase enzymes suitable for the hydrolysis
a 60% removal of the lignin from wheat straw. process: endo-1,4-b-glucanase (EDG; EC 3.2.1.4),
Enzymatic hydrolysis yield increased from 0% cellobiohydrolase (CBH; EC 3.3.1.91), and
to 57% as lignin decreased from 29% to 8% after b-glucosidase (BGL; EC 3.2.1.21).
ozonolysis pretreatment [12,37]. The cellulose reduction in glucose occurs in
three steps: (i) at first, EDG begins the break by
2.2 Hydrolysis attacking the amorphous regions of the polymer,
forming a new lower molecular weight chain,
In the hydrolysis step that follows the pre- more accessible for cellobiohydrases (cello-
treatment phase, a depolymerization reaction is drexin); (ii) CBHs are the enzymes responsible
carried out in water by enzymes or acids, to for the breaking of b-1,4-glycosidic linkages start-
break down the long cellulosic and hemicellulo- ing from the ends of the chain and leading to the
sic chains that are reduced to smaller units (a formation of the cellobiose; (iii) BGL hydrolyzes
mixture of pentose and hexose monomers) [38]. the cellobiose units into glucose [42a]; [27,43].
This hydrolysis process is critical to obtain a The enzymatic hydrolysis reaction of the cellu-
good yield in ethanol, since the quality of the hy- lose is schematized in Fig. 19.6.
drolyzate drastically affects the fermentation Several microorganisms can produce cellulose
process [39]. The yield of this step is also closely enzymes such as Clostridium, Cellulomonas, Erwi-
related to the previous pretreatment step that nia, Thermonospora, Bacteriodes, Bacillus, Ruminococ-
produces the hydrolysable substrate of a given cus, Acetovibrio, and Streptomyces. Also, several
purity that is important for both the final yield fungi are involved in the production of cellulases
and price. In the second-generation feedstock, such as Trichoderma, Penicillium, Fusarium, Phaner-
for instance, can be obtained up to five sugars ochaete, Humicola, and Schizophillum sp. [42].
(glucose, galactose, mannose, xylose, and arabi- These aforementioned species are enzymes that
nose) that are much more complex to hydrolyze specifically hydrolyze cellulose, but in a good
than that obtained from the first-generation feed- fermentation process of lignocellulose substrates,
stock (i.e., glucose) [38]. other enzymes are added. In fact, Xylanase, Glucu-
In the acid hydrolysis treatment, the sub- ronidase, Acetylesterase, and b-xylosidase attack spe-
strates are treated with mineral acids (i.e., cifically hemicellulose to reduce it into glucose,
H2SO4 and HCl) for a period of time at a specific galactose, mannose, xylose, and arabinose [27].
temperatures, to break down the cellulose and The enzymatic hydrolysis is influenced by
hemicelluloses chain into more easily ferment- various experimental conditions. Temperature
able sugars, as described in the equation [3]: and pH are the main factors, but also the concen-
ðC6 H10 O5 Þn þ H3 Oþ þ H2 O/ nC6 H12 O6 tration of the substrate or the load of the cellu-
lase. It has been reported [27a] that the optimal
(19.1) conditions in which cellulase enzymes act are
Disposal cost and control of acid concentra- at a temperature of 40e50 C and pH of 4e5.
tion are the main problems deriving from acid
hydrolysis [39]. On the other hand, the enzy-
matic treatment, carried out by cellulose and 2.3 Fermentation process
hemicellulase enzymes, appears to be more se- The fermentation step has a key role in the con-
lective, without inhibitory by-products and version of monomeric units of sugars into ethanol
applicable to milder experimental conditions, through a yeast, as in the following reaction:
but too expensive to be used in industrial pro-
cesses [39e42]. There are mainly three kinds C6 H12 O6þyeast / 2 C2 H5 OH þ 2 CO2 (19.2)

IV. Selected examples and case history


368 19. Novel bioethanol production processes and purification technology using membranes

FIGURE 19.6 The enzymatic hydrolysis reaction of cellulose.

Saccharomyces cerevisiae is the most used yeast Hemicellulose is instead converted into xylose,
for this process, which for the conversion uses via the pentose-phosphate pathway (PPP), which
glucose, mannose, and fructose processed produces fructose-6-phosphate, which through
through the EmbdeneMeyerhof pathway the EMP pathway is converted into pyruvate.
(EM) of glycolysis, and galactose through the
Xylose / PPP pathway/Fructose6
Leloir pathway (LP) [27b]. Several experi-
ments have been tried over the years, to be phosphate/EMP pathway /Pyruvate (19.4)
able to convert another of the most common
Although yeasts are the main microorganisms
sugars in plants: xylan that has been recently
used in the fermentation process, there are other
fermented by new interesting genetically
types of organisms capable of fermenting
modified yeasts [10].
pentose and hexose both separately and simulta-
The fermentation process requires glucose or
neously: bacteria and fungi [44a] [11].
other simple sugars that are phosphorylated to
For example, some of the bacteria capable
glucose-6-phosphate, and subsequently con-
of fermenting xylose in ethanol are Bacillus, Kleb-
verted into pyruvate (3C) via the Embdene
siella, Thermoanerobacter, Aeromonas and Escheri-
MeyerhofeParnas (EMP) pathway through
chia Coli while some fungi are Neurospora
some intermediates. Anyway, to be fermented,
Zygosaccharomyces, Monilia, and Rhizopusfor
cellulose must first be hydrolyzed [44].
[44a] [4e6]. Table 19.5 shows some examples of
Glucose / Glucose 6phosphate/Pyruvate microorganisms and the optimal experimental
(19.3) conditions for the maximization of the yield of
ethanol.

IV. Selected examples and case history


2. The bioethanol production process 369
TABLE 19.5 Different yields of ethanol in some of main yeasts, bacteria, and fungi.

Sugar Ethanol
Temperature Fermentation concentration yield
Microorganism ( C) pH time (h) (g/L) (g/L) Reference

Yeasts Saccharomyces Cerevisiae 30 5.5 65 280 130.12 [45]


3013
Saccharomyces cerevisiae 35 5.0 96 80 39 [21]
BY4742
Bacteria Zymomonas Mobilis 30 6.5 18 117 30.4 [46]
NRRL 806
Zymomonas Mobilis 30 4.0 44 200 99.78 [47,48]
ZMA7-2
Fungi Aspergillus oryzae 694 First aerobic 5.0 24 50 24.4 [48a]
step)
30
Second 5.0 144
anaerobic step)
30
Rhizobium javanicus First aerobic 5.0 24 100 33 [48a]
2871 step)
30
Second 5.0 72
anaerobic step)
30

As can be seen from the results shown in the ta- production processes (hydrolysis and fermenta-
ble, a great look is given to Saccharomyces cerevisiae tion) to increase their yield and reduce their costs
and the bacterium Zymomonas mobilis (respec- are SHF (where enzymatic hydrolysis and
tively, 130.12 and 99.78 g/L in ethanol yield). fermentation occur separately) and simulta-
Moreover, these two strains both give good re- neous saccharification and fermentation (SSF)
sults for high ethanol yield (90%e97% of the (where both of the steps occur simultaneously).
theoretical one) and high ethanol tolerance, up In both the cases, one of the most expensive
to about 10% (w/v) in fermentation medium [49]. but profitable processes in terms of yield, the
enzymatic hydrolysis is performed by cellulase
that breaks down cellulose chains into two
2.4 Integrated processes
glucose molecules [50]. In the first separate pro-
In addition to pretreatment, the other two cess (SHF) the hydrolysis is carried out before
steps that require economic sources are hydroly- the fermentation process, which in turn is
sis and fermentation; in these cases, both the con- divided into two phases, one in which the
centration of initial products and ethanol yield simplest hexose sugars are fermented to ethanol
are economically feasible when the final yield ex- and a second phase for the fermentation of xy-
ceeds at least 40 g/L of bioproduct [49a]. The loses [12]. The advantage of this technique is to
two methodologies that integrate these two control separately the two processes, each with

IV. Selected examples and case history


370 19. Novel bioethanol production processes and purification technology using membranes

its own temperature, which in the case of Saccha- Another integrated process based on SSF tech-
romyces cerevisiae and cellulases are, respectively, nology is the consolidate bioprocessing (CBP).
32 and 50 C [12a]; [12]. Temperatures above Which integrate the two processes, producing
32 C would lose yeast vitality, while the best cel- also the enzyme required for the whole process
lulases activities are usually between 45 and [12b] (Fig. 19.8).
55 C [12] (Zhao et al., 2012; [12c]). An implemen- Another excellent example of integrated pro-
tation of this method is called SHCF (separate cess is introduced and discussed in the next
hydrolysis and cofermentation), where both section.
pentose and hexose sugars are fermented simul-
taneously in a single-step process (Zhao et al.,
2012). A disadvantage of the enzymatic hydroly-
3. MR concept and technology
sis is the inhibition of the same cellulosic en-
zymes from high concentrations of glucose; this
A very important example of an integrated
problem is usually solved by increasing enzyme
process is the membrane reactor (MR). It is an en-
concentration, but a new method has been devel-
gineering device in which both reaction and sep-
oped with the SSF patented by Gauss et al., in
aration of one or more products occur
1976 [12,51]; [51a]. This method is used to
simultaneously. The separation is performed by
convert cellulose into ethanol, allowing simulta-
a membrane that is integrated with the reactor,
neous hydrolysis and fermentation into a single
in which the reaction takes place. There are
reactor (Fig. 19.7) where glucose is rapidly con-
different configurations of MRs. For example, a
verted into ethanol without leading to the afore-
simple configuration of MR is shown in
mentioned accumulation problems.
Fig. 19.9 with two concentric tubes: the catalyst
This process requires a compromise between
is allocated in the inner part of the tube contain-
the functionality of the enzyme and the vitality
ing the membrane (generally, it is the membrane
of the yeast, so temperatures of 37 C and pH
itself), whereas the membrane works as a selec-
above 5 are mainly used [50]. As an example,
tive barrier for the chemical species considered.
the final ethanol concentration in an SSF process,
The main application of the product removal
which uses wheat straw as raw material, gives a
from the reaction zone as it is produced is in
yield of 40 g/L starting from a concentration
reversible reaction. This is due to Le Chatelier-
of hexose and pentose sugars greater than
Braun principle (“If an external force leads to the
70% [12].
separation as a specified component from a system

FIGURE 19.7 From LCB to ethanol in SHF and SSF fermentation process.

IV. Selected examples and case history


3. MR concept and technology 371

FIGURE 19.8 Differences among SSF, SSCF, and CBP processes.

at equilibrium, this system adjusts so as to minimize The thermodynamic equilibrium constant is


the effect of the applied force”), for which a product as follows:
removal leads to an enhancement of the reaction
½Cc ½Dd
efficiency. Keq ¼ (19.6)
From a chemical point of view, in an MR, ½Aa ½Bb
removing a species produced during the reaction and determines the maximum conversion of the
from the reaction zone reduces the reverse reac- reaction.
tion rate, which improves the overall conversion In particular, if the compound C is considered
rate of reactants [52]. to be the hydrogen molecule, the concept is well
If we consider a generic reversible reaction: shown in Fig. 19.10A, with Fig. 19.10B for a
aA þ bB ¼ cC þ dD (19.5) generic reversible and exothermic reaction.

FIGURE 19.9 Conceptual scheme of a membrane reactor configuration.

IV. Selected examples and case history


372 19. Novel bioethanol production processes and purification technology using membranes

FIGURE 19.10 Conceptual difference of a traditional reactor (A, left side) and a membrane reactor (B, right side).

In the case of a traditional (or conventional) conversion of a traditional reactor (see X2eX4).
reactor, TR (Fig. 19.10A), the maximum limit of Generally a compromise is chosen, so the
the thermodynamic conversion, represented by temperature is a bit reduced with a higher
the red curve in both figures, makes it impossible reaction conversion with respect to a TR.
to have a chemical conversion higher than the
one suggested by the thermodynamic equilib-
rium. In the case of MRs, Fig. 19.10B, this limit
does not exist because the system is different
3.1 Main application opportunities of
and thermodynamics is not applicable in the using an MR
same way like in a TR. In fact, the thermody- To extend the concept, there are also other
namic equilibrium does not take place because great opportunities in using MRs. Some of
something is escaping from the system. So, in them are resumed in Fig. 19.11, where four
the case of MRs, the system is an open structure different cases are considered. Two are related
because part of the material (for example, to (1) the chemical conversion enhancement by
hydrogen, a product of the reaction) is escaping selective separation of a product of an equilib-
through the membrane, and the maximum con- rium limited reaction and (2) conversion
version obtainable is higher than the previous enhancement by coupling of reactions. The other
case, because of the Le Chatelier principle. In two are related to (3) the reaction selectivity (to
other words, the reversible reaction is trans- be not confused with the selectivity of the mem-
formed into an irreversible one. For example, brane), selectivity enhancement by selective
in Fig. 19.10A the maximum conversion at the permeation of an intermediate product; and (4)
temperature X1 is around 50% (see X2 in the selectivity enhancement by dosing a reactant
thermodynamic curve); vice versa, at the same through the membrane.
temperature (X1) in Fig. 19.10B, the maximum The first case is also called extractor mode: an
conversion is around 90% (see X3; see the curve example is hydrogen selectively removed using
named “dynamic equilibrium”). dense Pd-based membranes. Examples of chem-
Anyway, from the figure, it is also clear that, ical reactions are water gas shift (WGS), steam
instead of working at the same temperature X1 reforming of methane, steam reforming of alco-
to increase the conversion, an MR can work at hols (methanol, ethanol, etc.), decomposition of
lower temperatures maintaining the same H2S and HI, alkane dehydrogenation, etc.

IV. Selected examples and case history


3. MR concept and technology 373

FIGURE 19.11 Main application opportunities of inorganic MRs: (1) conversion enhancement by selective permeation; (2)
conversion enhancement by coupling of reactions; (3) selectivity enhancement by selective permeation; (4) selective enhance-
ment by dosing of reactant.

The second case considers the coupling of undesirable reactions [53,54]. Examples of reac-
two different reactions in the two different tions are partial oxidation, oxy-
zones of the reactor: in one, for example, dehydrogenation of hydrocarbons, oxidative
hydrogen is produced and selectively trans- coupling of methane, etc.
ferred through the membrane to the other zone. There is also another case, called contactor
For example the WGS reaction in carried out mode, where the membrane is the diffusion
one side and the hydrogenation of benzene on barrier and is also catalytically active
the other side. In this configuration, two (or intrinsically active). In this case, in the reac-
different reactions take place in the same reactor, tion zone, the residence time is controlled by
so energy can be transferred through the mem- tuning the pressure difference applied to the
brane, if the two reactions are one endothermic membrane. Two cases can be distinguished:
and the other one exothermic.
- forced flow-mode, used with enzyme-
The third and the fourth cases related to the
catalyzed reactions and oxidation of volatile
selectivity enhancement of the reaction are
organic compounds;
generally called distributor mode: it is impor-
- opposing reactant mode, used with partial
tant for avoiding hot spots by dosing the
oxidations reactions.
amount of a reactant; it also helps to extend
catalyst life. The reactant that could lead to un- To resume the main advantages of the inor-
desirable or side reactions is added in a ganic MR technology, considering for example
controlled manner to the reaction zone. By its a pure hydrogen production, the main benefits
gradual or distributed addition into the reactor, are as follows:
its concentration in the reaction zone can be
- chemical reaction and hydrogen separation
kept at a low value along the reactor, and this
performed in only one system with a
helps to prevent from its participation in the
consequent reduction of the capital costs;

IV. Selected examples and case history


374 19. Novel bioethanol production processes and purification technology using membranes

- conversion enhancement of equilibrium the ability of anticipating the reticular expan-


limited reactions; sion from hydrogen [60].
- higher conversions than TRs operating at the The behavior of dense Pd-based and porous
same experimental conditions of MRs or, on membranes has been studied since the 1960s,
the contrary, the same conversion, but the when involved in MR applications for hydrogen
operatives are milder; production, because the higher performance of
- improvement of both H2 yield and H2 Pd membranes overcomes all the other materials.
selectivity; This is due to both the high solubility of hydrogen
- direct production of H2 with a very high and the full perm-selectivity to hydrogen perme-
purity (in the case of dense Pd-based MRs). ation with respect to all the other gases.

3.2 Type of membrane used for inorganic


MRs 4. MRs for bioethanol reactions to
produce pure hydrogen
There exist many kinds of inorganic mem-
branes. Among them, particular attention is Currently, most of the worldwide demand
paid to the dense Pd-based membranes because for hydrogen comes from natural gas, which is
of their full hydrogen perm-selectivity [55]. As it processed in TRs mainly via steam reforming
is well-known, the hydrogen permeation reaction, as well as partial oxidation and auto-
through dense Pd-based membranes follows a thermal reforming reactions. Today, 50% of
solution-diffusion transport mechanism [56]. the global hydrogen is produced by natural
In the case of dense palladium (Pd) membrane, gas steam reforming reaction: although its
it must be carefully stressed that at impact on the climate is considered quite nega-
T < 300 C the metal is exposed to a hydrogen tive due to the production of greenhouse gases,
flow, so the embrittlement phenomenon takes it represents the most common process for the
place in the metallic lattice after a few cycles production of hydrogen. The entire conven-
of a$b transitions of pure Pd [57e59]. These tional process to transform natural gas into
transitions do not take place as a change of the hydrogen involves four different systems:
lattice structure: they only produce a dilatation one TR, two WGS TRs (high and low tempera-
in the lattice. As a solution of this problem, tures), and a successive stage for the hydrogen
generally by alloying palladium with elements separation and purification, such as pressure
such as silver, copper, or other metals, PdeH swing adsorption, preferential oxidation reac-
phases show an increased reticular step and tors, membrane separation, etc. (Fig. 19.12).

FIGURE 19.12 Conventional multistage process for natural gas steam reforming and hydrogen separation/purification.

IV. Selected examples and case history


4. MRs for bioethanol reactions to produce pure hydrogen 375
From the point of view of the process intensifi- influence of the feed molar ratio at low reaction
cation strategy, a large number of scientific temperatures (400e450 C), using both porous
works in this field evaluate the benefits in using stainless-steel supported Pd-based and dense
alternative solutions to the conventional pro- self-supported PdeAg MRs.
cesses, such as the MRs for both producing In both types of supported and self-supported
and simultaneously purifying hydrogen in inorganic membranes, the researchers pointed
only one stage. In fact, using an MR, the four out that higher pressures are able to favor the
systems reported in Fig. 19.12 are reduced to so-called “shift effect” due to an increase of the
only one. hydrogen permeation driving force. This results
During the last decades, MR technology has in a greater removal of hydrogen from the reac-
been developed with the intention of producing tion zone to the permeate zone, as a COx-free
hydrogen based on ethanol as a renewable hydrogen stream.
source. As reported by Ref. [61] the number of To cite only a few examples [68,69] ESR reac-
scientific studies per year focusing on hydrogen tion was carried out with a steam-to-carbon molar
production via ethanol steam reforming (ESR) ratio in the range 3/1e12/1, using a supported
reaction combined with MR technology, with PdeAg MR packed with a RheLaAl2O3 catalyst.
respect to the total number of publications on At 700 C and 6.9 bar, this MR gives around 75%
this field, with both TR and MR applications, is hydrogen yield, while at 69 bar, it drops to 42%
dramatically increasing from time to time. The due to an increase of methane yield.
same work also shows the various catalysts Moreover, a PdeAg deposited on a porous
and the percentage distribution of the principal stainless-steel (PSS) membrane was studied by
catalysts for ESR reactions in MRs. Among Ref. [70] for performing the ESR reaction in the
others, Rh-, Ru-, Pd-, Pt-, Ni-, Co-, and Cu- MR. The membrane, prepared by the electroless
based ones are used in TRs and, in particular, plating technique, was experimentally tested at
Ni and Ru-based catalysts are mainly used, 450 C, in the pressure range of 2.0e11.0 bar, us-
probably because they are cheaper than other ing a CueZn/Al2O3 catalyst. A sweep gas
catalysts. improved the H2 permeation driving force and
The catalysts performance evaluation has increased the H2 recovery.
been based on various parameters, such as H2 In the field of oxidative ESR reaction [71], a
selectivity, ethanol conversion, and catalyst sta- self-supported PdeAg MR was used. They
bility versus time. For example, following [51] increased the oxygen content on the reaction
the catalysts used in ESR show, with respect to side (O2 over ethanol feed ratio > 1.3/1) and
the H2 selectivity on alumina supports, the order confirmed that both H2 yield and H2 recovery
of Co > Ni > Rh > Pt > Ru > Cu. Vice versa, are reduced due to the fast oxidation reaction
other researchers connecting the catalytic activ- of the hydrogen produced during the reaction.
ity to the resistance of coke formation show At O2 on ethanol feed ratio equal to 0.6/1,
that the activity of metal-based catalysts has 400 C, and 2.5 bar, w18% H2 yield and 30% H2
the order of Rh > Co > Ni > Pd [62]. recovery is obtained.
Anyway, also other chemical reactions, such as The reaction of oxygen addition to ethanol
preferential oxidation and autothermal reforming dehydrogenation was carried out by Ref. [72].
of ethanol, are extensively used for hydrogen pro- They used a laminated 25 mm PdAg membrane
duction in MRs (see the recent [63]). foil and carried out the ethanol dehydrogenation
In fact, apart from the various kinds of cata- reaction at 350 C. It was observed that hydrogen
lysts, recent papers [11,52,64e67] focused the production decreases with increasing the oxy-
attention on ESR mainly considering the gen content in the feed. The researchers observed

IV. Selected examples and case history


376 19. Novel bioethanol production processes and purification technology using membranes

that, when oxygen is not supplied, the carbo- palladium and gold were doubled on a PSS
naceous layer reduces drastically or does not support.
allow at all the hydrogen permeation. At oxy- Yun et al. [75] were able to prepare an ultra-
gen/ethanol feed ratio >1, the hydrogen perme- thin supported Pd membrane (thickness 2 mm)
ation is lowered by the oxidation reaction of to be used in an MR for performing the ESR reac-
hydrogen, while at oxygen/ethanol feed tion. In their work, high feed molar ratio, at mod-
ratio <0.7, the carbonaceous layer is not fully erate experimental conditions (at 360 C; and
oxidized, but a constant hydrogen permeation 1 atm) resulted in a 70% ethanol conversion.
(and recovery) is obtained. Around 40% is the Other interesting experimental results were ob-
best H2 yield. tained by Ref. [76] using a very thin PdeAg layer
Instead of using the highly expensive Pd- (4 mm) deposited on PSS to obtain a composite
based MR, other works on the ESR reaction membrane. With this membrane allocated in an
focused on the use of nonpalladium-based MR MR, packed with a cobased catalyst, at 500 C,
to reduce the cost of palladium. As an example, a 100% conversion and 70% H2 recovery were
[73] carried out the ESR reaction at 350 C using obtained. At milder temperature conditions
a silica-alumina composite MR, with a water/ (400 C), Ref. [77] reached a conversion of 98%
ethanol feed ratio ranging between 3/1 and and an H2 recovery of 65%, even though its pu-
13/1. Their membrane, prepared by chemical va- rity was around 95% (this was probably due to
por deposition technique, is not fully selective the presence of pin-holes and microcracks on
to hydrogen permeation. In fact, it shows, at the Pd layer formed under experimental
350 C, a H2/CH4 selectivity ¼ 350, with an H2 operations).
permeance ¼ 108 mol/m2/s1/Pa1. At water/ Lin et al. [78,79] used two kinds of supported
ethanol feed ratio ¼ 3/1, H2 yield is more than membranes, NiePdeAg (8 mm thick) and Pde
20%. This yield is improved as 10%e20% more Ag (20 mm thick) in an MR. The best result in
than that of a TR working at the same operating terms of ethanol conversion is 80% using the Nie
conditions of an MR. PdeAg MR operated at 450 C and 3.0 bar.
An important contribution to hydrogen pro- To resume, part of the specialized literature
duction carrying out the ESR reaction in an MR about ESR and/or Bio-ESR reactions in MRs in-
technology is the one of [74], where a volves dense unsupported Pd-based MRs. For
nonpalladium-based MR for collecting hydrogen example, Basile and coworkers used various
with very low CO content (molar full hydrogen perm-selective unsupported Pde
concentration < 1%) is used. The membrane is Ag membranes (50 mm thick) [52,64,65,71,80e82]
composed of SiO2 supported onto PSS and the in MRs for pure hydrogen production from ESR
catalyst is RueSiO2. As a result, the stream or Bio-ESR reactions, and they obtained various
permeated through the membrane is rich in experimental results, depending on both the cata-
hydrogen and CO, further converted via WGS lysts and the operating conditions. Their best
reaction to decrease the CO content under 1% experimental result was achieved using a syn-
in the permeate side. At water/ethanol feed thetic bioethanol mixture, using a cobased
ratio ¼ 5/1 and 600 C, the H2 recovery and the catalyst at 400 C, which consisted of a
H2 yield are 85% and 50%, respectively. complete (100%) ethanol conversion and 90% of
Concerning again the supported Pd-based H2 100% pure recovered in the permeate zone
MRs, [47,48] obtained a complete ESR conver- of the MR.
sion at 500 C, recovering a hydrogen stream Recently, various researchers started to
with a purity of 99.9%. These researchers used consider the need for coupling green processes
a supported membrane in which a first layer of and bio-derived sources, so a growing attention

IV. Selected examples and case history


4. MRs for bioethanol reactions to produce pure hydrogen 377
was paid to the hydrogen generation using biogas high separation efficiency, a reduced number of
[83]. As a versatile raw feedstock, biogas could be processing steps, and high quality of the final
considered an alternative to natural gas exploita- product.
tion, thereby helping to reduce the greenhouse Among the specific membrane processes that
gas emissions. Its composition depends on the ty- are of particular interest for biorefining and bio-
pology of residual biomass (sewage treatment energy production, these can be cited: diafiltra-
plants, industrial wastewater, among animal tion (DF), membrane distillation (MD),
waste, and so on) used during the various anaer- microfiltration (MF), nanofiltration (NF), perva-
obic digestion processes. Nevertheless, biogas poration (PV), and ultrafiltration (UF).
has main components of methane and carbon di- In particular, MF, UF, and NF use porous
oxide, including traces of H2S, NH3, hydrogen, ni- membranes driven by hydrostatic pressure,
trogen, oxygen, and steam. whereas PV uses nonporous membranes driven
Regarding the integration of biogas reform- by a chemical potential gradient, while MD
ing with MR technology, at this moment (year uses porous hydrophobic membranes driven
2019), unfortunately, only a few works are pub- by a thermal gradient.
lished in the specialized literature. For example, Examples of specific applications can be cited:
Ref. [63] report the performance of a limited
- Acetic acid production (MF, UF)
number of applications in this interesting and
- Biodiesel production (MF, UF, NF)
new research field. In their book chapter, the
- Bioethanol production (PV, MD)
authors show that only [84] used a supported
- Biogas production (MF, UF)
Pd/Al2O3 membrane (Pd layer of 7 mm) for car-
- Biooil production (MF)
rying out the biogas steam reforming reaction
- Dehydration of bioethanol (PV)
in an MR. These authors obtained at quite mod-
- Enzyme recovery (MF, UF)
erate experimental conditions (450 C and
- Fermentation inhibitor removal (NF)
3.5 bar) a CH4 conversion around 30%, an H2
- Lignin and hemicellulose recovery (MF,
recovery of 70%, 96% in concentration. In
UF, UF)
all the other cases, thick unsupported Pd or
PdeAg dense membranes were used, favoring The recent excellent review of [10] discusses in
a recovery of a high-grade hydrogen stream detail and in-depth the current knowledge
(nearly 100% in purity) with conversions regarding application of many of the cited mem-
around 90% [85], but using high temperatures brane technologies to biorefining and bioenergy
(700 C). production. This paper also introduces pervapo-
The other recent literature in this field is more ration membrane bioreactors (PVMBR) and mem-
concentrated on biogas steam reforming in TRs brane distillation bioreactors (MDBR) as potential
[86e89] and, concerning the MRs development, integrated technologies for bioethanol produc-
on methane/natural gas steam reforming reac- tion. Among the various membrane techniques
tion [63]. to improve the operation of the ethanol-water
Bioethanol is also produced using a large separation include MF of the broth before the
number of other membrane technologies. In distillation (and PV, in a hybrid system) and MD.
fact, compared to other separation techniques, Anyway, whereas the benefits of introducing
the main attractions of membrane separation these techniques are well recognized, extensive
processes in biorefining and bioenergy produc- research is still needed to scientifically and
tion are a very low energy consumption, a very economically justify their applications. A

IV. Selected examples and case history


378 19. Novel bioethanol production processes and purification technology using membranes

tentative economic assessment demonstrates biomass effectively in the bioreactor with the
that the application of process improvements potential benefits for the bioprocesses where
can lead to production cost savings of w11% product formation separation is desired simulta-
[10]. So, further research of the different alterna- neously in a compact system.
tives, preferably on pilot or large scale, appears An excellent review of these aspects was
economically and technically justified [2]. recently proposed by Ref. [90] where recent
In particular, the distillation through mem- advances and emerging issues associated with
branes allows selective mass transport of specific biohydrogen generation using MBR technology
components from a mixture, making this tech- are deeply and critically discussed. Several tech-
nique useful in wastewater treatment, desalina- niques aimed at overcoming these barriers are
tion of seawater, dairy processing, and highlighted. Moreover, environmental and
separating volatile components. The paper of economical potentials along with future research
[39] is an excellent review that concentrates on perspectives are addressed to better drive bio-
the discussion on the various aspects related hydrogen technology toward the necessary prac-
the bioethanol production. They consider criti- ticality and economical-feasibility aspects. The
cally the existing variance of second-generation main conclusion of the authors is “Considering
bioethanol production methodology. In the pa- the practicality and economic feasibility of bio-
per, a section is entirely dedicated to MD tech- hydrogen generation with AnMBRs, technology
nique, which holds several benefits: it works at breakthrough must be sought to refine better perfor-
lower experimental conditions (T and P), perfect mances in terms of reduced energy consumption
theoretical separation, and fewer mechanical and fouling; extract most of hydrogen from substrate
property requirements. As drawbacks, MD is and scaling up of the long-term steady state
impractical once it is installed on a commercial operation.”
scale, which is namely due to the heat loss and
module design that further expand the cost
inefficiency. 5. Conclusion and future trends
The biohydrogen can also be obtained using
an anaerobic membrane bioreactor (AnMBR). As seen in this chapter, the choice of the right
In fact, another important field of hydrogen pro- raw material combined with the right produc-
duction is the use of bioreactors. In this case, sci- tion process is a key objective of all researchers
entists speak about “biohydrogen.” in the sector.
Biohydrogen can be produced by several bio- Process optimization means obtaining bio-
logic ways, for example, photodecomposition ethanol productivity optimization reducing
of organic compounds by photosynthetic bacte- costs. Currently the most used raw materials
ria (photofermentation), biophotolysis of water for the production of bioethanol are the first-
using algae and cyanobacteria, and fermentative generation feedstocks, but new technologies are
hydrogen production from organic waste pushing toward a new direction: agricultural
streams. and urban wastes. Production costs remain un-
Anyway, in all these cases, there is not com- competitive compared to those of the first gener-
plete conversion, and there are low yield and ation, but bioethanol produced from wastes has
low generation rates. To bypass these drawbacks the great advantage of being independent of the
the concept of a bioreactor combined with the costs of the raw materials market. Furthermore,
use of membranes seems to be the most prom- the use of this type of raw materials will be one
ising solution. In this integrated system, mem- of the resolutions of the problem of disposal of
branes separate liquid from biomass and retain urban waste. Looking further still, marine

IV. Selected examples and case history


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(1986) 149e152. a review, International Journal of Molecular Sciences 9
[3] D. Groleau, P. Chevalier, T.T.H. Yuen, Production (9) (2008) 1621e1651.
of polyols and ethanol by the osmophilic

IV. Selected examples and case history

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