Process scale-up simulation and techno-economic assessment of ethanol fermentation from cheese whey

IF 6.1 1区 工程技术 Q1 BIOTECHNOLOGY & APPLIED MICROBIOLOGY
Mattia Colacicco, Claudia De Micco, Stefano Macrelli, Gennaro Agrimi, Matty Janssen, Maurizio Bettiga, Isabella Pisano
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引用次数: 0

Abstract

Background

Production of cheese whey in the EU exceeded 55 million tons in 2022, resulting in lactose-rich effluents that pose significant environmental challenges. To address this issue, the present study investigated cheese-whey treatment via membrane filtration and the utilization of its components as fermentation feedstock. A simulation model was developed for an industrial-scale facility located in Italy’s Apulia region, designed to process 539 m3/day of untreated cheese-whey. The model integrated experimental data from ethanolic fermentation using a selected strain of Kluyveromyces marxianus in lactose-supplemented media, along with relevant published data.

Results

The simulation was divided into three different sections. The first section focused on cheese-whey pretreatment through membrane filtration, enabling the recovery of 56%w/w whey protein concentrate, process water recirculation, and lactose concentration. In the second section, the recovered lactose was directed towards fermentation and downstream anhydrous ethanol production. The third section encompassed anaerobic digestion of organic residue, sludge handling, and combined heat and power production. Moreover, three different scenarios were produced based on ethanol yield on lactose (YE/L), biomass yield on lactose, and final lactose concentration in the medium. A techno-economic assessment based on the collected data was performed as well as a sensitivity analysis focused on economic parameters, encompassing considerations on cheese-whey by assessing its economical impact as a credit for the simulated facility, dictated by a gate fee, or as a cost by considering it a raw material. The techno-economic analysis revealed different minimum ethanol selling prices across the three scenarios. The best performance was obtained in the scenario presenting a YE/L = 0.45 g/g, with a minimum selling price of 1.43 €/kg. Finally, sensitivity analysis highlighted the model’s dependence on the price or credit associated with cheese-whey handling.

Conclusions

This work highlighted the importance of policy implementation in this kind of study, demonstrating how a gate fee approach applied to cheese-whey procurement positively impacted the final minimum selling price for ethanol across all scenarios. Additionally, considerations should be made about the implementation of the simulated process as a plug-in addition in to existing processes dealing with dairy products or handling multiple biomasses to produce ethanol.

奶酪乳清乙醇发酵的工艺放大模拟和技术经济评估
背景欧盟的奶酪乳清产量在 2022 年超过了 5500 万吨,由此产生的富含乳糖的污水对环境构成了巨大挑战。为解决这一问题,本研究调查了通过膜过滤处理奶酪乳清以及利用其成分作为发酵原料的情况。为位于意大利阿普利亚地区的一个工业规模设施开发了一个模拟模型,该设施设计为每天处理 539 立方米未经处理的奶酪乳清。该模型综合了在添加乳糖的培养基中使用选定的 Kluyveromyces marxianus 菌株进行乙醇发酵的实验数据,以及相关的公开数据。第一部分的重点是通过膜过滤对奶酪乳清进行预处理,从而回收 56%w/w 的乳清浓缩蛋白、工艺水再循环和乳糖浓缩。在第二部分,回收的乳糖用于发酵和下游无水乙醇生产。第三部分包括有机残渣的厌氧消化、污泥处理以及热电联产。此外,还根据乳糖的乙醇产量(YE/L)、乳糖的生物量产量和培养基中最终的乳糖浓度提出了三种不同的方案。根据收集到的数据进行了技术经济评估,并对经济参数进行了敏感性分析,其中包括对干酪乳清的考虑,评估其经济影响,将其作为模拟设施的信用额度(由入场费决定),或作为成本(将其视为原材料)。技术经济分析表明,三种方案的最低乙醇销售价格各不相同。在 YE/L = 0.45 g/g 的方案中,表现最好,最低销售价格为 1.43 欧元/公斤。最后,敏感性分析强调了该模型对干酪-羊毛处理相关价格或信贷的依赖性。结论这项工作强调了政策实施在此类研究中的重要性,证明了对干酪-羊毛采购采用的入门费方法如何对所有方案中乙醇的最终最低销售价格产生积极影响。此外,还应考虑将模拟流程作为现有乳制品加工流程或处理多种生物质生产乙醇流程的插件。
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来源期刊
Biotechnology for Biofuels
Biotechnology for Biofuels 工程技术-生物工程与应用微生物
自引率
0.00%
发文量
0
审稿时长
2.7 months
期刊介绍: Biotechnology for Biofuels is an open access peer-reviewed journal featuring high-quality studies describing technological and operational advances in the production of biofuels, chemicals and other bioproducts. The journal emphasizes understanding and advancing the application of biotechnology and synergistic operations to improve plants and biological conversion systems for the biological production of these products from biomass, intermediates derived from biomass, or CO2, as well as upstream or downstream operations that are integral to biological conversion of biomass. Biotechnology for Biofuels focuses on the following areas: • Development of terrestrial plant feedstocks • Development of algal feedstocks • Biomass pretreatment, fractionation and extraction for biological conversion • Enzyme engineering, production and analysis • Bacterial genetics, physiology and metabolic engineering • Fungal/yeast genetics, physiology and metabolic engineering • Fermentation, biocatalytic conversion and reaction dynamics • Biological production of chemicals and bioproducts from biomass • Anaerobic digestion, biohydrogen and bioelectricity • Bioprocess integration, techno-economic analysis, modelling and policy • Life cycle assessment and environmental impact analysis
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