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Biocatalytic Production of 2-α-d-Glucosyl-glycerol for Functional Ingredient Use: Integrated Process Design and Techno-Economic Assessment.

ABSTRACT: Advanced biomanufacturing builds on production processes that are both profitable and sustainable. Integrated design of process unit operations, geared to output efficiency and waste minimization and guided by a rigorous techno-economic assessment, is essential for development aligned to these central aims. Here, we demonstrate such a development for the biocatalytic production of the biological extremolyte 2-O-α-d-glucosyl-glycerol (2-GG) for functional ingredient application. The process was aligned in scale over all steps (∼180 g product; ∼2.5 L reaction mixture) and involved continuous enzymatic synthesis from sucrose and glycerol interlinked with reactive extraction and nanofiltration for product isolation (purity of ∼80 wt %) and side stream recovery. Glycerol used in ∼6-fold excess over sucrose was recycled, and hydrothermal conversion into 5-(hydroxymethyl)furfural was evaluated for the fructose by-product released from sucrose. Based on a process mass intensity (total mass input/mass product) of 146, ∼80% of the total mass input was utilized and an E-factor (mass waste/mass product) of 28 was obtained. EcoScale analysis revealed a penalty point score of 44, suggesting an acceptable process from a sustainability point of view. Process simulation for an annual production of 10 tons 2-GG was used for the techno-economic assessment with discounted cash flow analysis. The calculated operating costs involved 35 and 47% contributions from materials and labor, respectively. About 91% of the material costs were due to chemicals for the reactive extraction-acidic stripping step, emphasizing the importance of material reuse at this step. Glycerol recycling involved a trade-off between waste reduction and energy use for the removal of water. Collectively, the study identifies options and boundaries of a profitable 2-GG process. The minimum selling price for 2-GG was calculated as ∼240 € kg^-1 or smaller. The framework of the methodology presented can be generally important in applied bio-catalysis: it facilitates closing of the gap between process design and implementation for accelerated development.

SUBMITTER: Kruschitz A

PROVIDER: S-EPMC8790807 | biostudies-literature |

REPOSITORIES: biostudies-literature

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Project description:The objective of this work was to identify industrial scenarios for the most promising microalgal biorefinery value chains on the basis of product selection, yields, and techno-economic performance, using biological characteristics of algae species. The development, value creation, and validation of several new processing routes with applications in food, aquafeeds and non-food products were particularly considered in this work. The techno-economic performance of various single product value chains (SP) and multiproduct value chains (MP) was evaluated for four industrial microalgal strains. Cost-revenue optimization was done for a 10 kton microalgal dry weight y-1 simulated biorefinery plant, using flow sheeting software for equipment sizing, mass and energy flow modeling, and subsequent techno-economic evaluation. Data on yield, material and energy consumption were based on pre- and pilot size production plants (TRL 5-6). Revenue optimization was accomplished by first analyzing the performance of single product value chains of the microalgal strains. Subsequently, a strategy was developed to exploit almost all biomass based on the most promising microalgal strains. The cultivation costs are most of the time the major costs of the value chains. For the single product value chains common process bottlenecks are low product yields, especially for soluble proteins where only a small fraction of the biomass is leading to economic value. The biorefinery costs (excluding cultivation) vary significantly for various species, due to the species-specific operating conditions as well as differences in product yields. For the evaluated single product value chain scenarios the costs for utilities and other inputs were in general the highest contributing expenses. A biorefinery approach significantly increases the biomass utilization potential to marketable products from 7-28% to more than 97%. Although the cascading approach increases the total production costs of the multiproduct value chains significantly, this is more than compensated by the increased overall biomass revenue. For all selected multiproduct chains there is a significant potential to become profitable at a relevant industrial scale of 10 kton per year. Additional insights in the product functionality, quality, and their market size are needed to narrow down the wide range of foreseen product revenues and resulting profits.

Dataset Information

Biocatalytic Production of 2-α-d-Glucosyl-glycerol for Functional Ingredient Use: Integrated Process Design and Techno-Economic Assessment.

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