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EthanolfromSyngasMicrobialConversion
Theproductionofbiofuelsfrombiomassgeneratedsyngasisanemergingtechnology
thatcanutilizeawidevarietyofbiomassresources.Theprocess,asoutlinedinFigure
1,involvesfirstconvertingbiomass(e.g.prairiegrasses,woodchips,paperwastes,
agriculturalwastes,etc.)tosyngas(amixtureofcarbonmonoxide,carbondioxide,and
hydrogen)viaaprocesscalledgasification.Gasificationisthepartialoxidationof
biomassathightemperatures.Thesyngascanthenbeconvertedtobiofuelssuchas
methanol,ethanolandhydrogenusingeitherametalcatalystoramicrobialcatalyst
(e.g.bacteria).Inadditiontobiomass,anumberofotherfeedstockscanbeusedto
producesyngasincludingnaturalgas(methane),coal,andacombinationofcoaland
biomassdenotedascofiring(Dayton,2003).Thoughmanyoftheseprocessesarewell
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established,interestinproducingsyngasfrombiomassisincreasingduetoits
abundantavailabilityandrenewablenature.

Theuseofmetalcatalystsisareliabletechnologyandcurrentlyisusedinindustryto
produceavarietyofbiofuelsandchemicals.However,thismethodislimitedbythe
needforextremereactionconditions(highpressuresandtemperatures)whichrequire
highenergyinputs.Theselectivityofconversionislow,andsomecatalystsarevery
sensitivetocontaminantsinthesyngasandareeasilypoisoned.Additionally,the
reactionsgeneratesubstantialquantitiesofheatwhichmustberemovedforthe
reactionstoproceed.Thesechallengescontributetothehighcostofproducingbiofuels
andchemicalsfromsyngasusingmetalcatalysts.Analternativemethodistouse
microbialcatalyststoconvertsyngastoethanol.

Currentcommercialproductionoffuelethanolprimarilyinvolvesfermentationof
sugars,ratherthansyngas,thataretypicallyderivedfromcorngrainorsugarcane.
Interesthasgreatlyexpandedtoobtainingthesugarsfromthebreakdownofcellulosic
materialsalthoughnotallcellulosiccomponentsarecomposedofsugars.The
gasificationprocesscanpotentiallyutilizetheentirebiomassfeedstock,boththesugar
containingcomponentsofcelluloseandhemicelluloseandthenonsugarcontaining
componentsoflignin,whichprovidesagreaterconversionefficiencyofbiomassto
energyorchemicals(McKendry,2002a).
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Atypicalprocessfortheconversionofsyngastoethanolinvolves(1)productionofthe
syngas,(2)removalofcontaminantsfromthesyngasbeforeenteringthemicrobial
conversionprocess,(3)ifneeded,adjustmentofthesyngasH 2/COratio(whichdiffer
byfeedstockandgasifierconditions)tofitthemicrobialprocess,(4)passageofthe
syngasthroughthemicrobialreactorattheappropriatetemperature,and(5)collection
andpurificationoftheproductsastheyexitthereactor.
Inthegasificationprocess,steamoroxygen(intheformofairorpureoxygeninlower
thanstoichiometricamounts)arefedtoagasifierathightemperatures(greaterthan
700C)toconvertcarbonaceousbiomassintoCO,CO2andH 2whichformthebuilding
blocksforethanolproductionviafermentation.

Gasificationofbiomasstoproducesyngasinvolvesthreemainstepsinitialheatingto
dryoutanymoistureembeddedinthefeedstockpyrolysis(heatingthefeedstockupto
300500oCintheabsenceofoxidizingagents)toproducegas,tars,oilsandsolidchar
residueandgasificationofthesolidchar,tarsandgastoyieldtheprimarycomponents
ofsyngas(Bridgwater,2003).

Thegasificationofcarbonaceousbiomassoccursviathreemainreactionspartial
oxidation(equation1),completeoxidation(equation2),andthewatergasreaction
(equation3)(McKendry,2002b).

C+O2COH 298K=268KJ/mol(1)
C+O2CO2H 298K=406KJ/mol(2)
C+H 2OCO+H 2H 298K=118KJ/mol(3)

Inaddition,thewatergasshiftreactionplaysanimportantroleinthecompositionof
theCO,CO2,andH 2(equation4).

CO+H 2OCO2+H 2(4)

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Syngascanalsocontainanumberofothercompoundssuchasmethane(CH 4),
acetylene,ethylene,ethane,nitricoxide(NO),sulfurdioxide(SO2),tars,andashwhich
canhavecomplexeffectsonthemetalcatalystormicroorganismsused.Equations5
through10showsomeofthesereactions(Kuo,2005).

Theimpuritiesdifferbyfeedstockandgasificationprocess.Coalgasificationproduces
moreNOxandSOximpurities,whereasbiomassgasificationproducesmorehydrocarbon
impurities(Kuo,2005McIlveenWright,2006).Impuritiesaretypicallydealtwithby
includingagascleanupprocessdownstreamofthegasifierorbymodifyingthedesign
ofthegasifiertoproducelowerlevelsofimpurities(e.g.,lowertarproduction).The
additionofcatalysts(suchasCaO)canalsobeusedtoreducetar(Corella,2006).
Researchisneededtobetterunderstandhowimpuritiesaffectmicroorganismsand
theirassociatedenzymaticfunctions.

Themixofgasescontainedinthesyngasvariesasaresultofthefeedstocktypeand
oxidizingagentused(air,pureO2orsteam).

Air(becauseofthehighinertN2content)increasesthevolumeofnitrogeninthe
syngaswhichincreasesthedownstreamcostofcleaningandstoringsyngas.However,
theaddedcostoftheairprocessmustbebalancedwiththeextracostofusingpureO2
orsteamastheoxidizingagent.SteamproducesahigherH 2contentbecauseofthe
watergasshiftreaction(equation4),butrequiresmoreenergytocreate(Bridgewater,
2006).Thedifferencesinthemixtureofgasesusingairsteamandaircatalysts(i.e.,
2030wt%silicasandanddolomite)foravarietyofdifferentfeedstocksareshownin
tables1and2respectively(McIlveenWright,2006).Theaircatalystprocessproduces
lessmethaneandhasalowerhydrocarbonvolumepercentagethanoccurswiththeair
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steamprocess.

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GasificationReactors.Severaldifferenttypesofgasifierscanbeusedtoproduce
syngasfrombiomass.

Countercurrentfixedbed(updraft)gasifiersconsistofafixedbedofbiomasswitha
countercurrentflowofsteam,oxygenand/orairflowingupwardthroughthefuelbed.
Inordertoformafixedbedthatispermeabletotheflowoftheoxygensource,the
biomassfuelmusthavehighmechanicalstrengthandnotcakeintoanimpermeable
mass.Gasexittemperaturesarelow,whichimprovesthermalefficiency,butincreases
tarandmethaneimpuritiesinthegas(McKendry,2002bBridgwater,2006).
Cocurrentfixedbed(downdraft)gasifiersaresimilartoupdraftgasifiersexceptthat
thesteam,oxygenorairflowscocurrentlydownwardwiththefuel.Becausethegas
passesthroughthehotcharatthebottomofthebedbeforeexiting,someimpurities
suchastarsaretrappedinthecharandthefinalproducthasahigherpurity.Theexit
temperatureofthegasishigher,resultinginaloweroverallefficiency(McKendry,
2002bBridgwater,2006).
Thefuelinafluidizedbedgasifierisgasifiedinanoxygen/airandsteammixture.The
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ashisoftenremovedusingacyclone.Fuelthroughputishigherthanforfixedbed
gasifiers,andhastheadvantageofuniformtemperaturedistributionachievedinthe
gasificationzoneresultingincleanerreactions.However,conversionratesarelower,
requiringtherecyclingofpartoftheexitgasbacktothegasifier.Fluidizedbedswork
particularlywellforbiomass,asbiomassresourcescontainhigherlevelsofcorrosive
ashesthatcanharmfixedbedreactors(McKendry,2002bBridgwater,2006).
Inentrainedflowgasifiers,thefuelisfedeitherasadrypulverizedsolidorafuelslurry
intandemwithoxygen(orsometimesair).Gasificationtakesplaceinadensecloudof
fineparticlesandisparticularlyusefulforcoalswhichcanbeeasilypulverizedintofine
particles.Thisgasifierhasthehighestoperatingtemperatureandpressure,which
decreasestheamountoftarsandmethaneformedduringgasification(McKendry,
2002bBridgwater,2006).

Gasifiermanufacturersindicatethatofthecommercialgasifiersinuse,75%areco
current,20%arefluidizedbeds,2.5%arecountercurrent,and2.5%areotherdesigns
(VanLoo,2003).
Thecommercialproductionofchemicalsfromsyngastypicallyusesmetalcatalysts,but
analternativeroutetoproduceethanolfromsyngasusesmicrobialcatalysts(e.g.
bacteria).Severalgeneraofmicroorganismsarecapableofconsumingsyngasaspartof
theirmetabolismandproducingchemicalssuchasethanolandotherproducts(e.g.
aceticacid).Theoverallstoichiometryfortheformationofethanolusingsyngas
substratesareshowninequations1113(Vega,1989).
6CO+3H 2OCH 3CH 2OH+4CO2(11)
2CO2+6H 2CH 3CH 2OH+3H 2O(12)
6CO+6H 22CH 3CH 2OH+2CO2(13)

ClostridiumljungdahliiandClostridiumautoethanogenumwereamongthefirst
organismsidentifiedthatconvertCO,CO2andH 2(syngas)toethanolandaceticacid
(Abrini,1994Vega,1990).C.ljungdahlii,firstisolatedin1987,isagrampositive,
rodshapedanaerobecapableoffermentingsugarssuchasxyloseandfructosein
additiontosyngas(Klasson,1992).Thisorganismfavorstheproductionofacetate
duringitsactivegrowthphasewhileethanolisproducedprimarilyasanongrowth
relatedproduct(Klasson,1992).TheproductionofacetateisfavoredathigherpH(5
7),whereastheproductionofethanolisfavoredatlowervalues(pH4to4.5).

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Clostridiumautoethanogenumisastrictlyanaerobic,grampositive,sporeforming,rod
like,motilebacteriumwhichmetabolizesCOtoformethanol,acetateandCO2asend
products.ItisalsocapableofusingCO2andH 2,pyruvate,xylose,arabinose,fructose,
rhamnoseandLglutamateassubstrates(Abrini,1994).

Eubacteriumlimosumhasbeenisolatedfromvarioushabitatsincludingthehuman
intestine,rumen,sewageandsoil.IthasahighgrowthrateunderhighCO
concentrationsandcanfermentsyngastoproduceacetate,ethanol,butyrateand
isobutyrate(Chang1998,1999,2001).

Peptostreptococcusproductusisagrampositiveanaerobiccoccus,foundinthehuman
bowel,andcapableofmetabolizingCO2,H 2orCOtoproduceacetate(Lorowitz,1984).
Studieshaveshownthatalthoughacetateisoneoftheprimaryendproductsofits
metabolism,P.productuscanalsoformadditionalproductsinresponsetoCO2
limitations(Misoph,1996).

ClostridiumcarboxidivoransP7Tisanovelsolventproducinganaerobicmicrobewhich
wasisolatedfromthesedimentofanagriculturalsettlinglagoon.Itismotile,gram
positive,andsporeformingandformsacetate,ethanol,butyrate,andbutanolasend
products.TheoptimumpHrangeforthisstrainis5.07.0andtheoptimum
temperaturerangeis3740C(Liou,2005).

Allofthesemicroorganismsareacetogens.Acetogensareaversatilegroupof
microorganismsthatcanusegaseslikeCO2,H 2andCO,aswellassugarsandother
substrates(Drake,1994Wood,1986b,c).Theyalsoareanaerobicmicroorganismsthat
utilizetheacetylCoApathwayastheirpredominantmechanismtoproduceacetylCoA
fromCO2.AcetylCoAissubsequentlyaprecursortotheproductionofothercompounds
suchaslipids,aminoacids,nucleotidesandcarbohydrates(Ljungdahl,1986).

TheacetylCoApathway(WoodLjungdahlpathway)consistsoftwocomponentsthe
methylbranchandthecarbonylbranch(figure2).Asacetogensareanaerobic,CO2
ratherthanoxygenservesastheelectronacceptorandH 2usuallyservesastheelectron
donor.ThesynthesisofacetylCoAfromCO2andH 2requiresthereductionofCO2and
involves(1)theformationofthecarbonylprecursorofacetylCoAbytheenzymeacetyl
CoAsynthase,alsoknownascarbonmonoxidedehydrogenase(CODH),(2)the
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formationofthemethylprecursorofacetylCoA,and(3)condensationoftheabovetwo
precursorstoformacetylCoA(Wood,1986a).AcetylCoAcanthenbeusedtomake
productssuchasethanol,aceticacid,butanol,butyricacid,and/orcellmass(figures2
and3).

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AcetylCoAisaversatileintermediatechemicalinthemetabolicpathwayofacetogenic
microorganismsandisaprecursortotheproductionoflipids,aminoacids,nucleotides
andcarbohydrates(Ljungdahl,1986).Itisthesourceforcellularcarbonaswellas
cellularenergy(figure3).

Inthemethylbranch,CO2(orCO2formedfromCOviaCODH)isreducedtoformate
(HCOO)whichissubsequentlyconvertedtoamethylcorrinoidprotein(Ljungdahl,
1986Ragsdale,1991).Inthecarbonylbranch,CO2isreducedtoformaboundCO
complexwithCODH.AcetylCoAisproducedfromthecombinationofthemethyl
corrinoidproteinandtheCOcomplex(Diekert,1994).
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Electronsarerequiredduringseveralstepsofthemetabolicprocess.

Inconjunctionwithotherenzymes,hydrogenaseenzymesutilizehydrogentoproduce
electronsrequiredfortheformationofethanol,aceticacid,and/orcellmass.Inthe
absenceofhydrogen,electronscanbegeneratedthroughtheoxidationofCOtoCO2
viatheCODHenzyme.Oftenmicroorganismscontainseveraldifferenthydrogenases,
andinmanycasesthefunctionsoftheseenzymesaredifficulttodetermine.Inhibition
ofhydrogenaseisofparticularinterestasitreducestheabilityofthemicroorganismto
consumehydrogen,whichcausesthemicroorganismtouseCOasasourceofelectrons
attheexpenseofusingtheCOforethanol.GasessuchasO2,acetylene,CO,andnitric
oxide(NO)areknowninhibitorsofhydrogenase(Seefeldt,1989Acosta,2003Byung
HongKim,1984Krasna,1954Tibelius,1984Girbal,1995aMeyer,1985,1986
Hyman,1988,1991).

AcetylCoAgoesthroughthecatabolicpathway(figure3)inordertomakeATP
(adenosinetriphosphate)whichprovidesthemicroorganismwithenergy.Itisalsoby
thisroutethattheacetylCoAisconvertedtoacetate,andisthepathwayfavoredby
themicroorganismduringitsrapidgrowthphase.Thisphaseofmetabolismisknownas
theacidogenicphaseduetotheincreasedacidityofthegrowthmediumfromthe
productionofacids(Rao,1989).Thesolventogenicphaseiswhereethanolisproduced.
Thisphaseischaracterizedbyslowergrowthofthemicroorganismwithlittleorno
productionofATP.Butanolandbutyricacidcanalsobeproducedbycombiningtwo
moleculesofacetylCoAtoformbutyrylCoA.

SeveralfactorsaffecttheswitchfromacidogenesistosolventogenesisincludingpH,ATP
demand,availabilityofnutrients,availabilityofreducingequivalents,andenzyme
activities(Meyer,1989Girbal,1995a,bGrube,2002Kashket,1995Kutzenok,
1952).Duetotheuncertaintyintheswitchfromacidogenesistosolventogenesis,
severalresearchteamshavestudiedmethodsofinducingsolventogenesisincludingthe
additionofacetateandbutyrate(Gottschal,1981)oryeastextractandreducingagents
(Klasson,1992)totheculturemedium,aswellasalteringtheavailabilityofnutrients
(nitrogen,sugar,iron)(Girbal,1995a,bMeyer,1985ByungHongKim,1984).
Additionofartificialelectroncarriers(e.g.,methylviologen,benzylviologen,and
neutralred)hasbeenshowntopromotealcoholproduction(Girbal,1995a,bKlasson,
1992).
Severalreactordesignscanbeusedforthefermentationprocess.Tricklebedreactors
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(TBR)consistofaverticaltubularreactor,packedwithsolidmaterialthatthe
microorganismscanattachto.Thedirectionoffluidflowisnormallycountercurrent,
withtheliquidtricklingdownwardsasthegasesflowupwards(Amos,2004Wolfrum,
2002).

Continuousstirredtankreactors(CSTR)arecommonlyusedinsyngasfermentation.A
CSTRhasacontinuousflowofgasbubblingthroughtheliquidwhichtypicallyconsists
ofadilutesolutionofessentialnutrientsforthemicroorganismtogrowandsurviveon.
Theliquidiscontinuouslyaddedandremovedfromthereactor.Highagitationis
neededtoenhancethetransferrateoftheCO,CO2,andH 2fromthesyngastothe
organisms(Klasson,1992).Ifthetransferisnotfastenough,theproductionofcellular
productswillbelimitedtohowfastthegasistransferredtotheorganism.Microbialcell
recyclesystemscanbeusedinconjunctionwiththeCSTRtoincreasecelldensitywithin
thereactor.Insuchasystem,thefermentationbrothispumpedthrougharecyclefilter
andtheretentatecontainingthemicrobialcellsisseparatedfromthepermeate(cell
freemedia)andrecycledbacktothebioreactor.Thisprocesspreventslossofcellmass
fromthebioreactorduringcontinuousoperationandalsoallowstheCSTRtobe
operatedatdilutionratesgreaterthanthemaximumgrowthrateofthemicrobial
catalyst.Recyclinghasbeenshowntoprovidea2.6foldincreaseincellconcentration
(Klasson,1993a,b).

Packedbedreactors(immobilizedcellreactors)arecolumnspackedwithbiocatalyst
particlestowhichthemicroorganismsareimmobilized(Bailey,1986).Thesereactors
areusuallyoperatedconcurrentlywheretheliquidandgasflowinthesamedirection
(Klasson,1992).Advantagesofthisreactorincludehighdensityofthemicroorganisms
andeasyseparationofthemicrobialcellsfromthefermentationbroth.However,the
rateatwhichsyngascomponentsaretransferredtotheorganismisusuallyslow.

CommercialProductionofEthanolViaMicrobialConversionofSyngas.Ethanolisnot
currentlyproducedonacommercialbasisusingmicrobialfermentationofsyngas.This
isanewtechnologystillintheresearchphase,withmostresearchconductedata
laboratoryscaleusingsyntheticsyngas(mixedfromcommercialgases).Assummarized
intable3,anumberofresearchgroupshavereportedproductyieldsfortheconversion
ofsyngastoethanolusingmicroorganisms.

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Comparedwithmetalcatalyticprocesses,microbialethanolfromsyngasprocessescan
beoperatedatrelativelylowpressuresandtemperatures.Mostbiologicalenzymes
operateatclosetoambienttemperatureswhichreducecosts(Wolfrum,2002)and
occurinthedark,enablingtheuseofclosedreactorswhichusesimplerreactordesigns
andhavelowercosts.Microbialenzymeshaveahighertoleranceforsyngas
contaminantsthanmetalcatalysts(whichareverysusceptibletopoisoning),andare
evencapableofadaptingtocontaminantsliketarwithincertainlimits(Ahmed,2006
Ragauskas,2006).Theproductionofethanolfrombiomassderivedsyngascircumvents
problemssuchassolidshandlinganddisposaloftheunconvertedligninthatoccurin
conventionallignocellulosicfermentationprocesses.

Disadvantagesofmicrobialprocessesincludethelongreactiontimeofthewatergas
shiftreactionduetotheslowcellgrowthofthemicroorganisms.Sincethereactionis
anaerobic,itdoesnotprovideasmuchenergyforcellularmetabolismasdo
photosyntheticandaerobicreactions.Syngasfermentationisoftenlimitedbylow
productivityandtherateatwhichsyngascantransfertotheliquid(Worden,1997),
whichplacesapremiumongoodbioreactordesignandhighcelldensitiesofthe
microorganismtomaketheprocesseconomicallyfeasible.Athighpartialpressures,
nitricoxide(NO)andcarbonmonoxide(CO)contaminantsinthesyngascaninhibitthe
hydrogenaseenzymethatisinvolvedintheconversionofsyngastoethanol(Krasna,
1954Tibelius,1984).
Abrini,J.,Naveau,H.,&Nyns,E.J.(1994).Clostridiumautoethanogenum,SpNov,an
AnaerobicBacteriumThatProducesEthanolfromCarbonMonoxide.Archivesof
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