Production Methods Research Articles

Genome-guided bioprospecting for industrially important enzymes from a thermophilic Bacillus subtilis strain SR-7, an isolate from hot spring of Madhya Pradesh, India

The study focused on isolating thermophilic bacteria from the hot springs of Madhya Pradesh, India, with the aim of identifying strains capable of producing industrially valuable enzymes. Among the 15 isolated strains, SR-7 identified as Bacillus subtilis exhibited significant enzyme activity, leading to its selection for further investigation. Genomic analysis revealed key characteristics of SR-7, including a 3,593,163 base pair chromosome with a GC content of 44.14 %. The genome was found to contain 55 tRNA genes, four rRNA clusters, and 3744 protein-coding genes. These genes encompass essential metabolic pathways and genes responsible for thermophilic adaptation, highlighting the potential for industrial applications. Further experimentation demonstrated SR-7 have the ability to produce various enzymes of industrial significance, such as amylase, lipase, cellulase, protease, lecithinase, gelatinase, and pectinase. Importantly, enzyme production was observed across a broad pH range (6.5 to 10) and temperature spectrum, indicating the versatility and adaptability of SR-7 to different environmental conditions. The findings suggest that SR-7 holds promise as a valuable resource for the pharmaceutical and industrial sectors. Its capacity to produce thermostable enzymes suitable for a range of applications underscores its potential contribution to biotechnological processes. By harnessing the enzymatic capabilities of thermophilic bacteria like SR-7, industries can pursue more sustainable and efficient production methods, reducing reliance on traditional chemical processes and enhancing overall productivity. Further research into the enzymatic properties and genetic mechanisms of SR-7 may unveil additional avenues for its utilization in various industrial processes.

A Comprehensive Review on Studying and Developing Guidelines to Standardize the Inspection of Properties and Production Methods for Mycelium-Bound Composites in Bio-Based Building Material Applications.

Mycelium-bound composites (MBCs) represent a promising advancement in bio-based building materials, offering sustainable alternatives for engineering and construction applications. This review provides a comprehensive overview of the current research landscape, production methodologies, and standardization ideas related to MBCs. A basic search on Scopus revealed over 250 publications on MBCs between 2020 and 2024, with more than 30% focusing on engineering and materials science. Key studies have investigated the physical and mechanical properties of MBCs, optimizing parameters such as substrate type, fungal species, incubation time, and post-processing to enhance material performance. Standardizing the inspection of MBC properties is crucial for ensuring quality and reliability. Various testing standards, including those from the American Society for Testing and Materials (ASTM), the International Organization for Standardization (ISO), the Japanese Industrial Standard (JIS), European Standards (EN), Deutsches Institut für Normung (DIN), and the Thai Industrial Standards Institute (TIS), are utilized to evaluate density, water absorption, compression strength, tensile strength, insulation, and other critical properties. This review highlights the distinction between lab-scale and apply-scale testing methodologies, emphasizing the need for comprehensive evaluation protocols. Additionally, the production process of MBCs involves critical steps like substrate preparation, fungal species selection, and mycelium growth, necessitating the implementation of good manufacturing practices (GMPs) to ensure consistency and quality. The internal and external structures of MBCs significantly influence their performance, necessitating standardized inspection methods using advanced techniques such as scanning electron microscopy (SEM), X-ray computed tomography (CT) scanning, and surface profilometry. By establishing robust inspection protocols and production standards, the industry can enhance the reliability and adoption of MBCs, contributing to innovations in materials science and promoting environmental sustainability. This review underscores the importance of interdisciplinary collaboration, advanced characterization tools, and regulatory frameworks to address challenges and advance the field of MBCs.

Unveiling the potential of novel Metschnikowia yeast biosurfactants: triggering oxidative stress for promising antifungal and anticancer activity

BackgroundSophorolipids are glycolipid biosurfactants with potential antibacterial, antifungal, and anticancer applications, rendering them promising for research. Therefore, this study hypothesizes that sophorolipids may have a notable impact on disrupting membrane integrity and triggering the production of reactive oxygen species, ultimately resulting in the eradication of pathogenic microbes.ResultsThe current study resulted in the isolation of two Metschnikowia novel yeast strains. Sophorolipids production from these strains reached maximum yields of 23.24 g/l and 21.75 g/l, respectively, at the bioreactors level. Biosurfactants sophorolipids were characterized using FTIR and LC–MS techniques and found to be a mixture of acidic and lactonic forms with molecular weights of m/z 678 and 700. Our research elucidated sophorolipids’ mechanism in disrupting bacterial and fungal membranes through ROS generation, confirmed by transmission electron microscopy and FACS analysis. The results showed that these compounds disrupted the membrane integrity and induced ROS production, leading to cell death in Klebsiella pneumoniae and Fusarium solani. In addition, the anticancer properties of sophorolipids were investigated on the A549 lung cancer cell line and found that sophorolipid-11D (SL-11D) and sophorolipid-11X (SL-11X) disrupted the actin cytoskeleton, as evidenced by immunofluorescence microscopy. The A549 cells were stained with Acridine orange/Ethidium bromide, which showed that they underwent necrosis. This was confirmed by flow cytometric analysis using Annexin/PI staining. The SL-11D and SL-11X molecules exhibited low levels of haemolytic activity and in-vitro cytotoxicity in HEK293, Caco-2, and L929 cell lines.ConclusionIn this work, novel yeast species CIG-11DT and CIG-11XT, isolated from the bee’s gut, produce significant yields of sophorolipids without needing secondary oil sources, indicating a more economical production method. Our research shows that sophorolipids disrupt bacterial and fungal membranes via ROS production. They suggest they may act as chemo-preventive agents by inducing apoptosis in lung cancer cells, offering the potential for enhancing anticancer therapies.

Bronze Age to Roman period salt production in the coastal areas of peninsular Italy: Palaeoenvironments, production methods and archaeological evidence

The landscape characteristics and salt production methods along the coasts of peninsular Italy from the Bronze Age to the Roman period are examined, with a focus on the significance of marine salt for Italy's ancient food economy, given the limited availability of rock salt. Two main methods of marine salt production are highlighted. Briquetage involves using clay or pottery containers to evaporate seawater, which requires specific environmental conditions such as clay availability and significant human labour and technological skill. Conversely, salterns consist of creating shallow ponds or pools for seawater evaporation, demanding flat coastal areas, a stable climate, and controlled seawater flow. While this method is less labour-intensive, it requires substantial initial infrastructure.The potential for salt production in Italy's coastal palaeoenvironments using either method has been evaluated. Key factors include coastal geomorphology, climate stability, and access to raw materials. This environmental data supports an analysis of archaeological remains from salt production sites active from the Bronze Age to the Roman period. The assessment focuses on the material evidence such as clay containers from briquetage and structural remains of salterns, aiming to understand the spatial and temporal distribution of these sites.The discussion also explores the geopolitical implications of salt production, examining how the distribution and development of these sites were affected by broader geopolitical shifts in Italy, including the impact of (proto)urbanization on the expansion and adaptation of salt production practices.

Boosting pH-universal electrosynthesis of hydrogen peroxide by regulating three-phase interface of carbon gas penetration electrode

Electrochemical oxygen reduction is a sustainable method for onsite H2O2 production. However, pH-universal H2O2 electrosynthesis still suffered from low kinetics and efficiency. Here carbon nanotube hollow fiber (CNT-HF) with porous fiber wall is designed to enhance H2O2 electrosynthesis via tailoring the three-phase interface. The CNT-HF gas penetration electrode with enhanced local electric field is favorable for boosting oxygen mass transfer and regulating catalyst-electrolyte interfacial protons, resulting in significantly enhanced H2O2 production performance in comparison with CNT planar gas diffusion electrode under pH-universal media. Its H2O2 production efficiency is 98.1% at pH 13. Meanwhile, H2O2 production efficiency of 96.1% and high H2O2 concentration of 46.4 g L-1 are achieved at pH 1 with 20 mM K+. Experimental and simulation results reveal the boosted H2O2 electrosynthesis on CNT-HF is mainly contributed from its significantly reduced diffusion layer thickness, enhanced local electric field and interfacial proton regulation by K+ enriched at electrode surface.

Anti-Frosting and Defrosting Fins with Hierarchical Interlocking Structure for Enhancing Energy Utilization Efficiency of Heat Exchanger.

Air conditioners, being an indispensable component of contemporary living, consume a significant amount of electricity every year. The accumulation of frost, dust, and water on the fins surface hinders the efficiency of the heat exchange process, thereby reducing the effectiveness of the air conditioning system. To address these limitations, this paper proposes a large-scale and cost-effective method combining compression molding, chemical etching, and spray coating to fabricate aluminum fins (HMNA) with hierarchical interlocking structures. The HMNA exhibits outstanding durability, passive and active anti-icing, anti-frosting and defrosting, and self-cleaning capabilities associated with the robust super-hydrophobicity. The hierarchical interlocking structure effectively enhances the physical and environmental durability of the HMNA. Most significantly, the frost time of the HMNA fins assembled heat exchanger is significantly delayed by ≈700% compared to the traditional Al fins heat exchanger, while the frost layer thickness is reduced by ≈75%. This greatly reduces the frequency with which the defrosting cycle is started, thus effectively improving the efficiency of the air conditioning system. The proposed method for economical and mass production of the HMNA fins can be an excellent candidate for the development of low energy consumption air conditioning system.

An Algorithm for Nutrient Mixing Optimization in Aquaponics

Controlled environment agriculture is a promising alternative to conventional production methods, as it is less affected by climate change and is often more sustainable, especially in circular and recycling frameworks such as aquaponics. A major cost factor in such facilities, however, is the need for skilled labor. Depending on available resources, there are endless possibilities on how to choose ingredients to realize a desired nutrient solution. At the same time, the composition of the desired solution is subject to fluctuations in fish water quality, fertilizer availability, weather, and plant development. In high-evaporation scenarios, e.g., summer, nutrient solutions might be mixed multiple times per day. This results in a complex, multi-variable task that is time-consuming to solve manually, yet requires frequent resolution. This work aims to help solve this challenge by providing methods to automate the nutrient mixing procedure. A simple mass-balance-based model of a nutrient mixing tank with connections to different water sources, drains, and fertilizers is provided. Using methods of static optimization, a program was developed which, in consideration of various process constraints and optimization variables, is able to calculate the necessary steps to mix the desired solution. The program code is provided in an open-source repository. The flexibility of the method is demonstrated in simulation scenarios. The program is easy to use and to adapt, and all necessary steps are explained in this paper. This work contributes to a higher automation level in CEA.

Life cycle environmental trade-off of decarbonising UK industrial clusters — A cradle to gate approach

The industrial sector is a major source of greenhouse gas (GHG) emissions due to process emissions and a heavy reliance on fossil fuels for heat and power. Methods exist to produce low carbon versions of products made in industrial clusters, including hydrogen, carbon capture and storage and alternative production methods, but these could increase burdens to other areas of the environment, such as resource depletion and water scarcity. This study compares different decarbonisation pathways for ammonia, cement, methanol and steel produced in the UK, to determine whether decarbonising could result in unintended environmental consequences. To determine this, life cycle assessment was applied to compare 267 different pathways to the conventional (fossil fuel) baseline. We find that most pathways lead to GHG emission reductions (43 to 78 % on average) but would increase impacts to other areas of the environment, including metal resources and ecotoxicity (8 % to 5-fold and 19 % to 24-fold, on average respectively). This study is the first to assess decarbonisation pathways for unintended environmental impacts and is of interest to industry, policy makers and anyone modelling industrial lifecycle emissions.

Scalable pilot production of highly efficient 5-ply respiratory masks enhanced by bacterial cellulose nanofibers

This study presents the pilot-scale production of highly efficient real respiratory masks enhanced by bacterial cellulose nanofibers (BCNFs). The BCNFs suspension was deposited onto tissue paper substrates using fog spray technique with three BCNFs grammage levels of 0.5, 1, and 2 g/m2, followed by freeze drying. Also, two continuous and batch welding processes have been used to construct the core structure of the masks. Field emission scanning electron microscopy (FE-SEM) confirmed the uniform distribution and size of fog-sprayed BCNFs and their pore networks. With increase in BCNFs grammage, the adsorption efficiency of masks increased in both continuous and batch production methods. The mask produced through batch processing showed the highest efficiency of 99.2 % (N99) for the particulate matter of 0.3 μm, while the maximum corresponding efficiency value in continuous processing was 95.4 % (N95). The pressure drops of the masks increased with the increase in BCNFs grammage in both methods. The maximum pressure drops of N95 and N99 masks obtained were 112 ± 10 Pa and 128 ± 8 Pa, respectively. Notably, the filtration efficacy of masks was preserved when subjected to relative humidity fluctuations ranging from 30 % to 70 %. The successful findings of this study offer significant promise for future air filtration applications.

A novel cleaner production for ferromagnetic materials from red mud: Process design, thermodynamic study and environment assessment

The ineffective utilization of resources and the potential harm to the ecological environment are both consequences of the accumulation of red mud (RM). This study focuses on synthesizing ferromagnetic materials (FMs) through a hydrometallurgical method, using compounds containing iron (CCI) derived from RM. The study primarily focused on process design, thermodynamic analysis, and environment assessment. Effectively, this procedure resulted in the production of two varieties of FMs: Fe2O3 and Fe3O4, exhibiting purities of 94.8 % and 98.6 %, correspondingly. The utilization of different concentrations of various flocculants (APAM, PAM, and CPAM) resulted in a substantial improvement in the flocculation process, with APAM demonstrating superior effectiveness. Based on the results of environmental assessments, it was found that the levels of toxic and hazardous substances in the residual solids were below 0.01 wt%, while in wastewater they were below 10−6 mol L−1. Furthermore, the study put forward mechanisms to explain phase transformation, flocculation, and magnetic separation. The thermodynamic calculation provided insights into the energy variation and reaction extent during the controllable synthesis of FMs. The current study provides a feasible resolution to improve the efficiency of resource recovery and reduce environmental pollution, thus encouraging the adoption of cleaner production methods.

Virus-like particles in poultry disease: an approach to effective and safe vaccination.

The poultry industry, a cornerstone of global food security, faces dynamic challenges exacerbated by viral diseases. This review traces the trajectory of poultry vaccination, evolving from traditional methods to the forefront of innovation Virus-Like Particle (VLP) vaccines. Vaccination has been pivotal in disease control, but traditional vaccines exhibit some limitations. This review examines the emergence of VLPs as a game-changer in poultry vaccination. VLPs, mimicking viruses without replication, offer a safer, targeted alternative with enhanced immunogenicity. The narrative encompasses VLP design principles, production methods, immunogenicity, and efficacy against major poultry viruses. Challenges and prospects are explored, presenting VLP vaccines as a transformative technique in poultry disease control. Understanding their potential empowers industry stakeholders to navigate poultry health management with precision, promising improved welfare, reduced economic losses, and heightened food safety.

Study on the Influence of Mandrel Speed on the Titanium Tube Continuous Retained-Mandrel Rolling Process

The continuous retained-mandrel rolling process is a promising method for titanium tube production with high efficiency and a short process. The importance of mandrel as a deformation tool supporting the inner wall is crucial. This paper thoroughly examines the influence of mandrel velocity on the deformation characteristics at the groove vertex using three approaches: numerical simulation, shear-deformation observation experiments, and microstructure analysis. The following conclusions are drawn: Decreasing the mandrel velocity enhances the penetration of shear deformation into the inner wall of the titanium tube, improves thickness uniformity, and shifts the deformation mechanism near the inner wall from twinning to dislocation slip. As a result, the volume fraction of recrystallization increases from 18.4% to 42.3%. However, the mean shear strain increases first and then decreases to a certain value as the mandrel speed decreases, which is attributed to the combined influence of the cross-shear zone and the rolling force.

Effect and mechanisms of type, content, and dispersion method of flash graphene on the rheological behaviors of fresh cement pastes

Flash Joule heating provides a facile, low-carbon, and cost-effective method for upscale graphene production, benefiting the application of graphene in modifying cement-based materials. Understanding the effect and mechanisms of flash graphene (FG) type, content, and dispersion method on the rheological behaviors of cement-based materials is essential for designing and controlling cement-based materials in different application scenarios. Therefore, this study explored the rheological behaviors of cement pastes with 2 different types of flash graphene at 4 different content levels (namely 0.1 wt%, 0.2 wt%, 0.3 wt%, and 0.4 wt% of cement mass) using 3 different dispersion methods (namely water reducer dispersion with ultrasonic treatment, dry mixing with water reducer, and mechanical dispersion with water reducer). The results indicated that the addition of FG generally increases the yield stress and plastic viscosity of fresh cement pastes. The water reducer dispersion with ultrasonic treatment and nano-boron doping shows a good effect in dispersing FG. The influence mechanisms of FG on rheological behaviors of fresh cement pastes are a competition between exert replacement, agglomeration, lubrication, and adsorption effects.

Experimental and Statistical Analysis of Concrete Eco-Cobble Using Organic and Synthetic Fibers

The environmental impact of traditional construction materials necessitates the development of sustainable alternatives. This study evaluates eco-cobbles as novel building materials designed to reduce environmental footprint while maintaining performance standards. The objectives were to develop an eco-friendly cobble alternative and assess its effectiveness through laboratory tests. Eco-cobbles were synthesized using recycled and bio-based materials and tested for compressive strength, flexural strength, and water absorption at 14 and 28 days. The compressive strength ranged from 11.5 MPa to 26.8 MPa, with a maximum value observed at 28 days in a mixture containing 95% concrete and 5% polyethylene terephthalate (PET). Flexural strength varied from 9.1 MPa to 28.7 MPa, with the highest value achieved in a mixture of 95% concrete and 0% fibers. Water absorption rates ranged from 2.1% to 6.6%, demonstrating an effective balance between performance and durability. Environmental assessments indicated a 30% reduction in resource consumption and a 40% decrease in carbon footprint compared to traditional cobble production methods. The findings demonstrate that eco-cobbles not only meet performance standards but also offer significant environmental benefits with a 99% compliance from the results obtained by response surface methodology plots, confirming that eco-cobbles offer a viable, sustainable alternative to conventional materials, with the potential for broader application in eco-friendly construction practices.

An Improved Production Method of Bioactive Peptides from Sturgeon Fish Cartilage

An Improved Production Method of Bioactive Peptides from Sturgeon Fish Cartilage

A CHEMCAD Software Design Approach for Non-Conventional Biodiesel Production Using Methyl Acetate as Feedstock

Biodiesel is a sustainable and renewable fuel generated from renewable resources, including vegetable oil or animal fats. It is thought to be a non-toxic fuel that degrades gradually and causes no harm to the environment. In the present study, a non-conventional supercritical method for industrial biodiesel production is investigated. The non-conventional method refers to a single-step interesterification reaction between triglycerides and methyl acetate resulting in methyl esters of fatty acids and triacetin as a secondary product. Process flowsheet modeling, using CHEMCAD chemical engineering software, was used as an investigation tool. The production capacity was set to 25,000 kg/h biodiesel. Methyl acetate requested in the biodiesel production is produced from methanol esterification with acetic acid using an intensified reactive distillation unit. Methanol, in turn, is obtained using synthetic gas derived from biomass as a raw material, the process representing a new method at the industrial level to solve problems related to the energy that is required, storage and disposal of residual materials, and pollution through the release of pollutants into the air. The methanol synthesis process is similar to the one based on natural gas, consisting of three main steps, namely: (i) synthesis gas production, followed by (ii) methanol production, and (iii) methanol purification. Acetic acid is an essential chemical product, generated in the proposed approach by a sustainable method with low energy consumption and low air emissions, more exactly methanol carbonylation. All the processes previously mentioned: (i) biodiesel production, (ii) methyl acetate production, (iii) acetic acid production, and (iv) methanol production were modeled and simulated, leading to the desired biodiesel productivity (e.g., 25,000 kg/h) with the obtained purity being higher than 99%. Relevant discussions regarding the design assumptions used, the simulation and validation results, as well as other technical issues (i.e., electricity and thermal energy consumption) for the system being simulated, are provided, leading to the conclusion that the proposed route is well suited for the desired application and can deliver significant results. The simulation outcomes have provided confidence in the feasibility and effectiveness of the chosen process design, making it a viable option for further development and implementation.

The feasibility study of alternative fuels production following National Hydrogen Strategy in Slovakia

Hydrogen could be a key driving force for decarbonizing various sectors. This analysis, based on the Slovak National Hydrogen Strategy, evaluates 6 low-emission hydrogen production methods, varying in raw material, technology, and operational conditions. Technologies are assessed using three criteria: levelized cost of energy, carbon footprint, and technology readiness level. Three alternative fuels are analysed: methanol, methane, and sustainable aviation fuel (SAF). Multi-criteria decision analysis evaluates 139 combinations of criteria importance. Proton exchange membrane electrolysis and steam biogas reforming (SBR) emerge as the most advantageous technologies, ranking first in 45 and 32 cases, respectively. Economically, high-temperature electrolysis and SBR are preferred, with a levelized cost (LCOH) of 11.7 €/kg H2 under current conditions. SAF stands out as the best alternative fuel, with the lowest levelized cost of 3.3 €/kg. Reducing Slovakia's electricity price by 80% would make domestic hydrogen production increasingly competitive in Europe by 3.7 times reduction of LCOH.

Dry reforming of toluene over Ni/pyrochlore catalysts with A-site Sr doping

Dry reforming with CO2 is one potential method for tar removal and further production of syngas in biomass gasification, but the crucial catalysts with good reaction characteristics are still being developed. In the work, Ni/pyrochlore was proposed to be utilized as catalysts in the dry reforming of tar, and thermodynamic calculation, reaction progress test, and materials characterization were conducted to reveal dry reforming characteristics over Ni/pyrochlore catalysts and the reaction mechanism behind. Results show that YS0.2C catalyst exhibits the best activity (toluene and CO2 conversion of 70.1% and 79.5%) and stability among all catalysts under the optimized conditions of 700 °C with a CO2/toluene molar ratio of 7. Analysis on physicochemical properties of the catalysts indicate Sr doping can effectively promote catalytic reforming by enhanced interaction between Ni and support, CO2 adsorption and oxygen mobility. The work offers a promising catalyst type in improving tar removal by dry reforming.

Exogenous metabolite application is a potential strategy for expanding the use of direct rice seeding with the aim of reducing seeding costs

Rice is a staple food for over half of the global population, necessitates efficient and cost-effective production methods to ensure food security. However, direct seeding of rice often encounters challenges due to adverse environmental conditions, resulting in increased seeding costs. In this study, we analyzed the germination and physiological data of sixty-six rice varieties under cold and submergence conditions. Our results demonstrate that selecting rice varieties with superior germination capacity in these adverse conditions can improve germination rates by 39.43%. Transcriptomic and metabolomic analyses of two contrasting varieties revealed potential regulatory mechanisms involving hormonal pathways and the glycerophospholipid metabolism pathway. Furthermore, we found that the exogenous application of specific metabolites provides a cost-effective seed enhancement strategy for varieties with poor germination capacity. These findings suggest that combining suitable variety selection with seed enhancement treatments can significantly reduce seeding costs in rice production. This research offers valuable insights for developing resilient rice varieties and cost-effective seeding strategies, potentially contributing to improved rice cultivation practices and enhanced global food security.

Additive manufacturing — a new vector in the production and repair of rolling stock

The influence of the fourth industrial revolution, known as Industry 4.0, on modern industrial production and social life is analyzed. The main advantages of Industry 4.0 are presented, such as increasing productivity and occupational safety, developing new products and materials, as well as increasing the competitiveness of products. Special attention is paid to additive technologies and their role in modern engineering within the framework of the Industry 4.0 concept. The methods of additive technologies, their classification by materials and production methods, as well as their various applications in various industries are described in detail. An example of the successful use of additive technologies is presented on the example of JSC Uralvagonzavod Scientific and Production Corporation, where molds and rods for casting parts with high speed and quality are created using 3D printers. The project of introducing 3D printers into the service depots of the directorate of motor car rolling stock of JSC Russian Railways is considered, with an emphasis on the economic and temporary benefits from the use of additive technologies. The concept of introducing additive technologies in the maintenance and repair of rolling stock involves the creation of support depots on the railway network of JSC Russian Railways. In conclusion, the importance of training highly qualified specialists in the field of additive technologies and the need to develop educational programs to train future employees capable of solving complex tasks of creating and applying new industrial technologies is presented. Special attention is paid to synergetic approaches in education to combine learning with scientific activity and the creation of innovative technological solutions.