CHAPTER I

THE PROBLEM AND ITS BACKGROUND

INTRODUCTION

Fuels and energy sources that are made from organic by-products or

naturally occurring, living organisms are known as biomass fuels or simply

biofuels. According to Republic Act No. 9367, also known as the Philippines’s

“Biofuels Act of 2006”, the State should develop and utilize indigenous

renewable and sustainably-sourced clean energy sources to reduce

dependence on imported oil; and ensure the availability of alternative and

renewable clean energy without any detriment to the natural ecosystem,

biodiversity and food reserves of the country. The Philippines embraced the

development of biofuels hoping to achieve future energy security, augment

farmers' income, and generate rural employment. The member economy also

hoped to position itself as a leading biofuels producer in the region. The main

challenge facing the industry is the availability of feedstock and the processing

facilities to meet the demand of the government's National Biofuels Program

(Biofuels Philippines, 2007).

As the country sought to end its dependence on oil, alternative sources of

fuel were being examined. Bioethanol has been developed as both an additive

and an alternative to fuel. It can be produced either from petroleum bases or from

sources known as biomass which include wood, grass, grains, or indigestible

plants. Sugarcane and corn both contain readily assessable sugars are popular
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fuel sources because very little processing needs to be done in order to prepare

the feed for fermentation. Another alternative source for biofuel is from cellulosic

biomass. Crops like switch grass, poplar trees, and straw as well as waste from

paper mills or livestock such as cattle can be converted into ethanol (M.L.

Maurice, 2011).

In an effort to improve the process of ethanol conversion, industry created

a process called Simultaneous Saccharification and Fermentation (SSF). SSF

combines the hydrolysis step and the fermentation step in order to make the

conversion process more efficient. Simultaneous Saccharification and

Fermentation process also results in decrease of enzymatic end-product

inhibition (M.L. Maurice, 2011). However, hydrolysis and fermentation both

required specific temperature and pH ranges for optimal operation. Any sudden

change of temperature and pH during the process could kill or retard the

reaction. Those factors affecting the so-called process were hard to maintain.

Thus, a need of a bioreactor was highly recommended by most studies. A

bioreactor is an apparatus, like a large fermentation chamber, for growing

organisms such as bacteria or yeast under controlled conditions. Bioreactors are

used in the biotechnological production of substances such as pharmaceuticals,

antibodies, or vaccines, or for the bioconversion of organic waste (American

Heritage Science Dictionary, 2005).

A lot of countries boasted of their own bioreactors. Each contained almost

the same principles but differ in the process equipment used. That was because

of the diverse advancement of electronics and technology. Here in the

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Philippines, there existed so many studies about biomass conversion to

bioethanol, but still its modern technology could not suffice the completion of

such bioreactors.

This study aimed for the design and development of prototype

Simultaneous Saccharification Fermentation (SSF) apparatus for the production

of bioethanol. The proponents wanted an apparatus, which would be easy to use

and with the capacity to measure and control all the important parameters of the

process. Also, the proponents tried to resolve a variety of problems regarding

specific temperature ranges during saccharification and fermentation process in

order to improve both yield and process efficiency. Furthermore, the proponents

wanted to overcome the main challenge facing the industry regarding feedstock

and processing facilities and to meet the demand of the government's National

Biofuels Program.

OBJECTIVES OF THE STUDY

The primary objective of the study was to design and develop a

Simultaneous Saccharification Fermentation (SSF) apparatus for the production

of bioethanol. Specifically this study aimed to:

1. Present the system design of the SSF apparatus taking into

considerations the following:

1.1 Apparatus specifications and dimensions

1.2 System components and controls

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1.2.1 Temperature control

1.2.2 pH measurement and control

1.2.3 O2/CO2 regulation

1.2.4 Distillation set up

1.3 Material requirements

2. Test the performance of the developed equipment in terms of:

2.1 % ethanol yield

3. Compare the % ethanol obtained from SSF apparatus with the

laboratory process.

4. Present the cost estimate of the developed SSF apparatus.

5. Provide an instruction manual for the SSF apparatus.

NULL HYPOTHESIS

The % bioethanol obtained from SSF apparatus did not differ significantly

with that of manual operation process.

SIGNIFICANCE OF THE STUDY

Since the main objective of this study was to design and develop a SSF

apparatus for the production of bioethanol, the researchers believed that this

study was of great importance to the society especially to industries. This study

would open doors of opportunity to government and private sectors to explore

more input indigenous materials to get the desired results. This development

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would help in further evaluation of different feed stocks locally available for its

conversion to bioethanol with further emphasis on maximizing the yield.

Also, the SSF developed in a small scale could serve as a reference in

upgrading the equipment which could be utilized in the chemical plants but this

time producing bioethanol in a large scale.

Lastly, the SSF apparatus would be of great significance to students in

their laboratory experiments. The apparatus would be easy to use with the

capacity to measure and control all the important parameters of the biological

culture. The design offered challenges to accommodate the demands of the

saccharification and fermentation process resolving variety of problems regarding

specific temperature ranges in order to improve both yield and process efficiency.

This study was expected to improve the process of ethanol conversion combining

the hydrolysis step and the fermentation step in order to make the conversion

process more efficient.

SCOPE AND LIMITATION

The study was focused mainly on the development of a SSF apparatus

suitable for the controlled environment of a pure culture or of a defined mixture of

organisms and substrate for the production of bioethanol. The factors that were

considered in the design are the cost, capacity, and economic viability and

supply of the materials. An instruction manual was also provided.

The SSF apparatus covered the saccharification and fermentation of corn

starch and provided an aeration system for the substrate and enzymes. It

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included a distillation set-up for the extraction of bioethanol. The analysis of the

bioethanol produced was considered.

This study was limited with the use of corn starch for bioethanol

production and it was conducted at Batangas State University Laboratory. It

covered the pre-treatment of corn starch using alpha-amylase, conversion of

corn starch to reducing sugars using glucoamylase, and fermentation of sugars

to bioethanol. Saccharomyces cerevisiae was used as fermenting yeast. All the

enzymes and yeast used in the SSF process were obtained from National

Institute of Microbiology and Biotechnology (BIOTECH), University of the

Philippines, Los Baños. The analysis of the % bioethanol produced was done by

the Department of Energy.

Recovery of the enzymes was not included in the study. It was not

economical to recover the enzyme.

CONCEPTUAL FRAMEWORK

The development of the prototype considered the selection of materials

that were economical and suited for the production, and as well as the fabrication

of the equipment.

The layout of this study was illustrated for the better understanding of the

concept of this research.

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Figure 1: Conceptual Paradigm in the Design and Development of SSF apparatus

INPUT PROCESS OUTPUT

Technical Process Development Stage

Requirements:
 Saccharification Fabrication SSF Apparatus
Process Preliminary Testing and Bioethanol (% ethanol)
 Fermentation Process Modification Instruction Manual
Bioethanol Production
 Distillation Process
 Saccharification
 Properties of
Bioethanol  Fermentation
 Corn flour  Distillation
Performance Testing
Prototype Requirements:  Percentage
 Material Selection Bioethanol
 Specification of Parts
 Design Layout

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DEFINITION OF TERMS

The following terms used in the study are hereby defined:

Alpha-amylase. A form of amylase in humans and other mammals that cuts alpha-

bonds of large sugar molecules. α-amylase randomly cleaves the α (1-4) glycosidic

linkages of amylose to yield dextrin, maltose or maltotriose (www.biology-online.org).

Bioethanol. A biofuel produced by fermenting the sugars in biomass materials such as

corn and agricultural residues. It is used in internal-combustion engines either in pure

form or more often as a gasoline additive (The American Heritage Science Dictionary,

2005).

Distillation. It is the separation of a volatile liquid from a non-volatile substance or,

more frequently, the separation of two or more liquids of different volatility (S. Young,

2003).

Enzymes. Are any of a group of complex proteins or conjugated proteins that are

produced by living cells and act as catalysts in specific biochemical reactions (Collins

English Dictionary, 2003).

Fermentation. The process by which complex organic compounds, such as glucose,

are broken down by the action of enzymes into simpler compounds without the use of

oxygen. It results in the production of energy in the form of two ATP molecules, and

produces less energy than the aerobic process of cellular respiration. In yeast and most

plant cells, fermentation produces ethyl alcohol, carbon dioxide, and water (The

American Heritage Science Dictionary, 2005)

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Gluco-amylase. An amylase that cleaves the last alpha-1,4-glycosidic linkages at the

non-reducing end of amylase and amylopectin to yield glucose (www.biology-

online.org).

Hydrolysis. This process breaks down the cellulosic molecules exposed during

pretreatment into glucose molecules and short chains. It can be carried out chemically

via acid washes or biologically via enzymatic reactions (M. Maurice, 2011).

Saccharification. Is the process of converting complex carbohydrate (e.g. starch) into

simple monosaccharide components (e.g. glucose) through hydrolysis (www.biology-

online.org).

Temperature control. The use of various temperature monitoring devices and cooling

methods, such as forced air flow, within a processor or FPGA-based system, to control

overall temperature of ICs and internal cabinet temperatures (www.maxim-ic.com).

pH control. a pH control system measures the pH of the solution and controls the

addition of a neutralizing agent (on demand) to maintain the solution at the pH of

neutrality, or within certain acceptable limits (Emerson Process Management, 2011).

% ethanol. The ethanol content in the product produced in the fermentation process.