On-farm solid state simultaneous saccharification and fermentation of whole crop forage rice in wrapped round bale for ethanol production.

Yasuhiro Tachibana,Mitsuo Horita,Tetsuo Kawaide,Hiroko Kitamoto,Yukiko Shinozaki

doi:10.1186/s13068-014-0192-9

Abstract

BackgroundIn an attempt to reduce environmental loading during ethanol production from cellulosic plant biomass, we have previously proposed an on-site solid state fermentation (SSF) method for producing ethanol from whole crops, which at the same time provides cattle feed without producing wastes. During the ensiling of freshly harvested plant biomass with cellulase and glucoamylase, the added yeast and lactic acid bacteria induced simultaneous saccharification and production of ethanol and lactic acid in hermetically sealed containers on-farm. In a previous study, laboratory-scale SSF (using 250 g of fresh rice crop biomass) yielded 16.9 weight % ethanol in dry matter (DM) after 20 days of incubation. In this study, the fermentation volume was scaled up to a normal-sized round bale and the fermentation process (ethanol concentrations of the products) was monitored. The ethanol produced was recovered and the recovery efficiency was evaluated.ResultsSSF tests with forage rice round bales using polyethylene-wrapped whole plant materials (cultivar Leaf Star, average of 125.2 kg dry weight) were monitored in the field without temperature control. They yielded 14.0 weight % ethanol and 2.9 weight % lactic acid in DM after six months of incubation, and the ethanol ratio in the bale remained stable for 14 months after processing. SSF tests with three different rice cultivars were conducted for three years. Ethanol recovery from a fermented whole bale (244 kg fresh matter (FM) containing about 12.4 kg ethanol) by one-step distillation using vacuum distillation equipment yielded 86.3% ethanol collected from distilled solution (107 kg of 10.0 weight % ethanol). In addition, an average of 1.65 kg ethanol in 40.8 kg effluent per bale was recovered. Relative nitrogen content was higher in SSF products than in silage made from the same plant material, indicating that fermentation residue, whose quality is stabilized by the lactic acid produced, can be used as cattle feed.ConclusionsWe have successfully demonstrated an efficient on-site ethanol production system with non-sterilized whole rice crop round bale. However, issues concerning the establishment of the ethanol recovery procedure on-site and evaluation of the fermentation residue as cattle feed have to be addressed.

Highlights

In an attempt to reduce environmental loading during ethanol production from cellulosic plant biomass, we have previously proposed an on-site solid state fermentation (SSF) method for producing ethanol from whole crops, which at the same time provides cattle feed without producing wastes
The starch content in the SSF product was much lower than that in fresh plant, while the saccharides and lactic acid contents in the SSF product were comparatively higher. These results suggested that in SSF prepared with cellulase and glucoamylase, a major part of the saccharides were supplied from the degraded starch and cellulose in plants, which were converted to ethanol or lactic acid by the activities of added yeast and lactic acid bacteria
Generally, the problem areas in ethanol production from cellulosic materials are as follows: 1) the transportation of bulky materials to large factories, 2) loss of nutrients from biomass during preservation which are essential for bioethanol production, 3) pretreatment before fermentation which consumes a large amount of energy, and 4) the recycling of large amounts of effluents after ethanol distillation [15]

Summary

Introduction

In an attempt to reduce environmental loading during ethanol production from cellulosic plant biomass, we have previously proposed an on-site solid state fermentation (SSF) method for producing ethanol from whole crops, which at the same time provides cattle feed without producing wastes. During the ensiling of freshly harvested plant biomass with cellulase and glucoamylase, the added yeast and lactic acid bacteria induced simultaneous saccharification and production of ethanol and lactic acid in hermetically sealed containers on-farm. Silage is the product of natural solid-state lactic acid fermentation of lignocellulosic plant materials with low water content [5]. At the early stage of silage making, the lactic acid produced by lactic acid bacteria from WSC kills other kinds of bacteria from plant surfaces and preserves the nutrients of plant materials [5]

Methods

Results

Conclusion