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Bioresource Technology 220 (2016) 609–614

Contents lists available at ScienceDirect

Bioresource Technology
journal homepage: www.elsevier.com/locate/biortech

Ethanol fermentation characteristics of recycled water by Saccharomyces


cerevisiae in an integrated ethanol-methane fermentation process
Xinchao Yang a,b, Ke Wang a, Huijun Wang a, Jianhua Zhang a, Zhonggui Mao a,⇑
a
Key Laboratory of Industrial Biotechnology, Ministry of Education, School of Biotechnology, Jiangnan University, Wuxi 214122, China
b
School of Biological Science and Technology, University of Jinan, Jinan 250022, China

h i g h l i g h t s

 Fermentation time was shortened by 40% when mixed water was used as process water.
 The maximal ethanol production rate increased from 1.07 g/L/h to 2.01 g/L/h.
 The intracellular trehalose per DCW in mixed water was higher than that of in tap water.
 This process could minimize wastewater discharge and water consumption.

a r t i c l e i n f o a b s t r a c t

Article history: An process of integrated ethanol-methane fermentation with improved economics has been studied
Received 4 June 2016 extensively in recent years, where the process water used for a subsequent fermentation of carbohydrate
Received in revised form 9 August 2016 biomass is recycled. This paper presents a systematic study of the ethanol fermentation characteristics of
Accepted 10 August 2016
recycled process water. Compared with tap water, fermentation time was shortened by 40% when mixed
Available online 12 August 2016
water was employed. However, while the maximal ethanol production rate increased from 1.07 g/L/h to
2.01 g/L/h, ethanol production was not enhanced. Cell number rose from 0.6  108 per mL in tap water to
Keywords:
1.6  108 per mL in mixed water but although biomass increased, cell morphology was not affected.
Ethanol
Saccharomyces cerevisiae
Furthermore, the use of mixed water increased the glycerol yield but decreased that of acetic acid, and
Recycled water the final pH with mixed water was higher than when using tap water.
Anaerobic digestion Ó 2016 Elsevier Ltd. All rights reserved.
Thin stillage

1. Introduction (Saha et al., 2005). Therefore substantial increases in ethanol pro-


duction will also require effective solutions for stillage
The growing need to expand the use of renewable energy management.
sources in a sustainable manner has boosted the production of bio- In the conventional ethanol fermentation process, distillery
fuels worldwide (Moraes et al., 2015). However, biofuel production waste is usually treated by solid-liquid separation followed by
processes generate large volumes of wastewater, especially stil- anaerobic-aerobic digestion, and the effluent from this is further
lage, which is the aqueous by-product from the distillation of etha- treated using physical or chemical methods to achieve the national
nol following fermentation of carbohydrates (Wilkie et al., 2000). discharge standard (Jördening and Winter, 2005; Kim et al., 1997).
The production of ethanol from biomass, whether from sugar Anaerobic digestion of corn-ethanol thin stillage and its biogas
crops, starch crops, dairy products, or cellulosic materials, results generation potential have been evaluated in laboratory studies
in the concurrent production of stillage which has a considerable since the 1980s, as an alternative approach to recover more energy
pollution potential. Among the available feedstocks, cassava is of from the corn as well as treating the stillage (Lee et al., 2011). After
particular interest due to its low cost, high productivity, and lack anaerobic digestion, the treated stillage could potentially be reused
of competition for arable land. In the conventional cassava ethanol within the plant as process water. Recycling of digested thin stil-
fermentation process, massive amounts of freshwater are con- lage would not only eliminate the energy-intensive evaporator
sumed and 8–15 L of distillery waste is produced per L ethanol but also reduce the fresh water requirements for ethanol produc-
tion (Alkan-Ozkaynak and Karthikeyan, 2011). Anaerobic digestion
of thin stillage offers not only the benefit of reduced energy input
⇑ Corresponding author. for co-product drying, but also enables energy recovery through
E-mail address: maozg@jiangnan.edu.cn (Z. Mao).

http://dx.doi.org/10.1016/j.biortech.2016.08.040
0960-8524/Ó 2016 Elsevier Ltd. All rights reserved.
610 X. Yang et al. / Bioresource Technology 220 (2016) 609–614

the production of methane, with a prospective improvement in recycle of 50% may be possible (Bothast and Schlicher, 2004;
net-energy balance for ethanol production. Wilkie et al., 2000).
In recent years, many researchers have studied the potential for The integrated method of ethanol-methane fermentation has
the use of thin stillage as dilution water to minimize the use of been studied in recent years. As shown in Fig. 1, some of the
fresh water for substrate suspension during fermentation. Sho- organic matter within thin stillage is converted to methane by
jaosadati and coworkers studied modifications of the conventional anaerobic digestion. After further treatment the digestate is reused
ethanol fermentation process using biomass and stillage recycle, as part of the process water for ethanol fermentation, forming a
where recycle of 15–70% of stillage from a previous fermentation closed-circuit circulation process. The overall technology reduced
was tested successfully, permitting a 13–47% decrease in water energy consumption and water consumption, reducing waste
consumption and 13–47% reduction of stillage volume water emissions. Zhang and co-works (2010b) studied a full recy-
(Shojaosadati et al., 1996). For the corn-ethanol process, up to half cling process incorporating two-stage anaerobic treatment of dis-
of the thin stillage is directly recycled as process water, and the tillery wastewater from bioethanol production from cassava.
remainder is evaporated to produce a condensed, soluble, syrup Furthermore, Zhang et al. (2010a) studied the effect on ethanol
containing 30% solids, requiring a substantial proportion of plant production of utilizing waste anaerobic digestion distillate effluent
energy inputs (van Leeuwen et al., 2012). It would be much more in an integrated ethanol-methane fermentation process. Wang and
advantageous to use the nutrients in thin stillage for the cultiva- co-workers (2013) established and assessed a novel cleaner pro-
tion of beneficial microbes or microbial products (Rasmussen duction process for corn-grain fuel ethanol. Subsequently, Wang
et al., 2014). A portion of thin stillage may be used as make-up et al. (2014a) studied the reuse of a mixture of anaerobic digestion
water for upstream processes (cooking and fermentation), which effluent and thin stillage for cassava ethanol production. In this
will further help to reduce the volume of stillage produced, as well novel integrated process, a portion of thin stillage is mixed with
as reduce consumption of water, steam and some chemicals. How- the effluent from anaerobic digestion of residual thin stillage, pro-
ever, stillage strength will actually rise with its increased use in ducing a ‘mixed’ water which is then reused as process water for
backset water, as the chemical oxygen demand produced will not the following ethanol fermentation batch (Wang et al., 2014a). This
change, while accumulation of fermentation products and non- novel integrated process reduced both energy consumption and
fermentable sugars can inhibit the fermentation process (Sun wastewater production.
et al., 2013). Typically, between 15 and 30% of the thin stillage is However, the ethanol fermentation characteristics of mixed
recycled as backset for upstream processes, although a maximum water were not studied systematically. The major goal of this study

Fig. 1. Flowchart of the integrated ethanol–methane fermentation process.


X. Yang et al. / Bioresource Technology 220 (2016) 609–614 611

was to determine the ethanol fermentation characteristics of 2.5. Ethanol fermentation


mixed water to test its suitability for reuse and assess any eco-
nomic benefits arising. Triplicate fermentations were carried out in 250 mL flasks con-
taining 135 mL of medium. Urea was added before inoculating. A
2. Materials and methods 10% (v/v) inoculum of seed medium was added to each flask. All
fermentations were carried out at 30 °C without shaking.
2.1. Microorganism
2.6. Analysis
A commercial strain of S. cerevisiae TG1348 for ethanol produc-
tion was obtained from Henan Tian Guan Co., Ltd., (Henan, Glucose, ethanol, glycerol and acetic acid concentrations in fer-
Nanyang, China). mentation media were determined by high-performance liquid
chromatography (HPLC). Samples were centrifuged (10,000g for
2.2. Seed medium 10 min) and the supernatant passed through a 0.20 lm filter prior
to analysis. Standards and prepared samples (20 lL) were injected
One loopful of S. cerevisiae was inoculated into a 500 mL into a Bio-Rad HPX-87H Aminex ion exclusion column. The column
Erlenmeyer flask holding 200 mL of a solution containing (g/L): was operated at 65 °C and sulfuric acid (0.005 mol/L) was used as
glucose 20, yeast extract 8.5, (NH4)2SO4 1.3, MgSO47H2O 0.1 and mobile phase at a flow rate of 0.6 mL/min. A refractive index detec-
CaCl22H2O 0.06. The flask was incubated on a shaker (200 rpm) tor (Shodex RI-101, Shodex, Tokyo, Japan) was employed. Data
at 30 °C for 18 h to produce seed medium. were processed using Chromeleon software (Dionex, CA, USA).
For mixed water, yeast cells were counted using a hemocytometer.
2.3. Operation of the process Cell number was converted to dry cell weight (DCW) using a factor
of 2.5  1011 g dry mass per cell (Devantier et al., 2005). For tap
Tap water was used for the first ethanol fermentation batch. At water (control), cell growth was determined by absorbance at
the end of the fermentation the resulting ‘beer’ was distilled. Part 600 nm. Note that, lmax ¼ dx  1 . X (X: mass concentration of cells,
dt X
of the residual liquor was centrifuged (4000g for 30 min) to t: time).
obtain the ‘thin stillage’ supernatant which was stored at 20 °C
before use. The residual liquor was fed into a two-stage anaerobic 2.7. Trehalose content
digester. Digestate (60%) was combined with thin stillage (40%)
and employed as ‘mixed’ process water for the following ethanol Trehalose was extracted from cells that were chilled and
fermentation batch. Table 1 shows the characteristics of the differ- washed with cold 0.5 M trichloroacetic acid, and the trehalose con-
ent process waters (thin stillage, digestate, mixed water, tap centration estimated using the anthrone method (Wang et al.,
water). 2014b). Samples for dry weight analysis were washed with dis-
tilled water and dried at 80 °C for 12 h.
2.4. Fermentation medium
3. Results and discussion
Fermentation medium was composed of (g/L): glucose 100,
MgSO47H2O 0.1, CaCl22H2O 0.06, and urea 0.5, dissolved in the 3.1. Characteristics of different process water
appropriate process water. Urea was sterilized separately to avoid
Maillard reaction. The pH was adjusted to 5.0 using 30% (w/w) Before fermentation, there was an initial content of glycerol,
H2SO4 or 10% (w/v) NaOH. Thin stillage and digestate were pro- acetic acid and lactic acid in the mixed process water, as shown
vided by Wujiang Yongxiang Alcohol Manufacturing Co. Ltd. in Table 1. Compared with tap water, mixed water is rich in amino
(Wujiang, Jiangsu, China). Tap water was used as a process water acids. Its total metal ion content was a maximum of 119.3 mmol/L,
control. whereas tap water contained negligible amounts.

Table 1
Comparison of different process water in terms of pH, glycerol, acetic acid, lactic acid, metal ion and amino acid.

Parameter and unit Thin stillage Digestate Mixed watera Tap water
pH 4.30 7.90 6.46 7.42
Glycerol (g/l) 5.36 NDb 2.14 ND
Acetic acid (g/l) 0.51 0.19 0.32 ND
Lactic acid (g/L) 5.62 ND 2.25 ND
Na+ (mmol/L) 55.89 94.35 78.97 1.42
K+ (mmol/L) 33.27 21.14 26.00 0.09
Mg2+ (mmol/L) 7.24 8.24 7.84 0.44
Ca2+ (mmol/L) 3.87 1.13 2.23 0.54
Al3+ (mmol/L) 3.85 2.11 2.81 N.D.
Fe3+ (mmol/L) 1.40 0.11 0.63 0.13
Cu2+ (mmol/L) 0.30 0.01 0.13 0.03
Zn2+ (mmol/L) 0.04 0.01 0.02 N.D.
Mn2+ (mmol/L) 0.15 0.01 0.07 0.005
Li+ (mmol/L) 0.98 0.32 0.58 0.23
Phe (mg/L) ND 74.2 (Wang et al., 2013) 44.52 ND
Asp (mg/L) 0.02 28.20 (Wang et al., 2013) 16.93 ND
Gly (mg/L) 0.02 17.00 (Wang et al., 2013) 10.21 ND
Pro (mg/L) 0.05 12.7 (Wang et al., 2013) 7.64 ND
Glu (mg/L) 0.09 4.51 (Wang et al., 2013) 2.74 ND
a
Mixed water of thin stillage (40%) and digestion (60%).
b
ND: not detectable.
612 X. Yang et al. / Bioresource Technology 220 (2016) 609–614

3.2. Performance of ethanol fermentation of nutrients, although it is now recognized that some components
of complex media play non-nutritional roles in promoting the
A shorter fermentation time was achieved when mixed water growth and survival of yeast (Thomas et al., 2002). Buffering capac-
was used as the process water (Fig. 2); glucose was depleted after ity was created during the anaerobic digestion process in mixed
30 h and 50 h respectively with mixed water and tap water water: the main source is proteins, which when hydrolyzed release
(Fig. 2a). Thus fermentation time was reduced by 40% when using ammonia and salts of weak organic acids (Foxon et al., 2010),
mixed water compared with tap water. Although mixed water resulting in a small increase in pH at the end of fermentation com-
increased the fermentation rate, ethanol production was not pared with tap water.
increased (Fig. 2a, b). In addition, using mixed water gave rise to Yeast cells have evolved defense strategies against several types
raised glycerol levels (Fig. 2c), but reduced acetic acid production of stress damage. Factors such as trehalose and heat shock pro-
(Fig. 2d). teins, which stabilize or repair denatured proteins, were increased
The results shown in Fig. 2 suggest that other components of in stressed yeast cells (Zhao and Bai, 2009). Trehalose is a non-
mixed water could accelerate the depletion of glucose. This obser- reducing disaccharide consisting of two glucose monomers (a-D-
vation can readily be explained. Growth of yeast is faster and the glucopyranosyl-1,1-a-D-glucopyranoside; Gibney et al., 2015).
biomass produced is greater in media containing complex ingredi- Because trehalose is relatively inert and very stable, it is thought
ents when compared to minimal medium (Narendranath et al., to act as a protectant for subcellular structures against osmotic
2001). During ethanol fermentation in the integrated process, and other stress (Eleutherio et al., 2014; Jain and Roy, 2009). Mixed
methanogenic bacteria present in the digestate component of process water contains complex constituents, which result in
mixed water are decomposed and release intracellular substances. osmotic and other stress for cells. This is the most likely explana-
Nitrogenous compounds including protein give rise to ammonium tion for the increase in intracellular trehalose when mixed water
ion which has previously been found at a relatively high concentra- was employed.
tion in the two-stage anaerobic digestate derived from thin stillage Acetic acid is another factor promoting ethanol fermentation in
(759 mg/L on average; Wang et al., 2014a). mixed water, stimulating ethanol production in some circum-
Ammonium ion in mixed water could promote yeast growth stances (Mohammad J. Taherzadeh, 1997; Thomas et al., 2002;
and hence increase the fermentation rate (Wang et al., 2012). In Zhao et al., 2009). It was found that acetic acid production was
our study, mixed water contained high levels of phenylalanine, lower when using mixed water (which itself contains acetic acid)
aspartic acid and glycine (Table 1). Trace amounts of amino acids as process water (Table 2). However, the mechanism whereby
were found by other workers in all stillages tested (Wilkie et al., acetic acid is converted into ethanol requires clarification. Under
2000). These amino acids may promote rapid yeast growth during anaerobic conditions, glycerol generated by yeast reoxidizes
the log phase. Improved growth in complex media has been NADH, produced as a secondary fermentation product, to NAD+
thought to be entirely due to the availability of greater amounts (Guo et al., 2009) and therefore glycerol production increases with

Fig. 2. Representative profiles of metabolism of S. cerevisiae with mixed water (d) or tap water (j). Data presented are the average of three independent cultivations and
error bars represent standard deviations.
X. Yang et al. / Bioresource Technology 220 (2016) 609–614 613

Table 2 increased the glycerol yield but decreased acetic acid yield, while
Growth rates and product yields for anaerobic growth of S. cerevisiae on glucose with the maximal ethanol production rate of 2.01 g/L/h was higher than
different water. Data presented are the average of three independent cultivations.
the 1.07 g/L/h found in tap water, reflecting faster glucose
Parameter and unit Mixed watera Tap water metabolism.
1
Maximal specific growth rate (h ) 0.77 0.45 In traditional fermentation processes, the whole stillage is cen-
Ethanol yield (mol/mol of glucose) 1.82 1.89 trifuged to separate the liquid fraction, or thin stillage, from the
Glycerol yield (mmol/mol of glucose) 97.78 65.29 solid fraction, or the wet distillers’ grains. It has been reported that
Acetic acid yield (mmol/mol of glucose) 8.72 13.85
Maximal ethanol production rate (g/L/h) 2.01 1.07
acetic acid increased the levels of ethanol production and acceler-
Maximal trehalose yield (g/g of DCW) 0.15 0.02 ated the fermentation rate (Abbott and Ingledew, 2004). Our
a
results also suggest that acetic acid could promote the production
Mixture of thin stillage (40%) and digestion (60%).
of ethanol.

biomass. Thus the accelerated glucose depletion in mixed water 3.3. Microscopic images of mixed water fermentation
shown in Fig. 2c could be explained by the enhanced rate of cell
production seen in Fig. 3a. Fig. 4 (Supplementary Data) shows electron microscopy images
Cell number in mixed water increased up to 1.6  108 per mL at of S. cerevisiae in the middle of logarithmic phase growing on the
the end of log phase, whereas the value was 0.6  108 per mL in tap medium prepared with either tap water or mixed water. Fig. 4a
water (Fig. 3a). The difference in biomass reflected different glyc- shows the normal cell morphological structure when grown in
erol yield production. For both process waters, the final pH was tap water. Fig. 4b showed the cells morphological structure when
reached after 18 h of fermentation and remained unchanged there- grown in mixed water. Compared with tap water, cell number
after. However, the final pH with mixed water was higher than increased, as counted using a hemocytometer, when mixed water
with tap water (Fig. 3b). Lactic acid production was higher when was used as process water. In addition, cellular morphology and
using mixed water as process water (Fig. 3c). Intracellular tre- germination capacity were not affected when mixed water was
halose increased gradually over 40 h for mixed water, while in employed.
mixed water intracellular trehalose per DCW was 4–6-fold higher Our results show that cell grown is faster in mixed water than
than in tap water (Fig. 3d). in tap water. Greater amount of nutrients are present in mixed
The higher rate of conversion of glucose (Fig. 2) was also water. Appreciable amounts of amino acids were present in the
reflected in the higher maximum specific growth rate (lmax) thin stillage. These amino acids provide rich nutrition for the
(Table 2) in mixed water, with a lmax of 0.77 h1 compared to growth of yeast, resulting in an increased cell number when mixed
0.45 h1 in tap water. When glucose was depleted, ethanol and water was used as process water compared to tap water. In this
glycerol yields per glucose molecule were consistent with the etha- process, ethanol is the required end product of fermentation by
nol and glycerol production observed. The use of mixed water Saccharomyces cerevisiae. During fermentation some weak acids

Fig. 3. Representative profiles of metabolism of S. cerevisiae with mixed water (d) or tap water (j). Data presented are the average of three independent cultivations and
error bars represent standard deviations.
614 X. Yang et al. / Bioresource Technology 220 (2016) 609–614

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1. Shandong Province Natural Science Foundation of University
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