Intensification of biobased processes

543 Pages·2018·33.82 MB·English

by  Górak

Intensification of Biobased Processes
Green Chemistry Series
Editor-in-chief:
James H. Clark, Department of Chemistry, University of York, UK
Series editors:
George A. Kraus, Iowa State University, USA
Andrzej Stankiewicz, Delft University of Technology, The Netherlands
Peter Siedl, Federal University of Rio de Janeiro, Brazil
Titles in the series:
1: The Future of Glycerol: New Uses of a Versatile Raw Material
2: Alternative Solvents for Green Chemistry
3: Eco-Friendly Synthesis of Fine Chemicals
4: Sustainable Solutions for Modern Economies
5: Chemical Reactions and Processes under Flow Conditions
6: Radical Reactions in Aqueous Media
7: Aqueous Microwave Chemistry
8: The Future of Glycerol: 2nd Edition
9: Transportation Biofuels: Novel Pathways for the Production of Ethanol,
Biogas and Biodiesel
10: Alternatives to Conventional Food Processing
11: Green Trends in Insect Control
12: A Handbook of Applied Biopolymer Technology: Synthesis, Degradation
and Applications
13: Challenges in Green Analytical Chemistry
14: Advanced Oil Crop Biorefineries
15: Enantioselective Homogeneous Supported Catalysis
16: Natural Polymers Volume 1: Composites
17: Natural Polymers Volume 2: Nanocomposites
18: Integrated Forest Biorefineries
19: Sustainable Preparation of Metal Nanoparticles: Methods and
Applications
20: Alternative Solvents for Green Chemistry: 2nd Edition
21: Natural Product Extraction: Principles and Applications
22: Element Recovery and Sustainability
23: Green Materials for Sustainable Water Remediation and Treatment
24: The Economic Utilisation of Food Co-Products
25: Biomass for Sustainable Applications: Pollution Remediation
and Energy
26: From C–H to C–C Bonds: Cross-Dehydrogenative-Coupling
27: Renewable Resources for Biorefineries
28: Transition Metal Catalysis in Aerobic Alcohol Oxidation
29: Green Materials from Plant Oils
30: Polyhydroxyalkanoates (PHAs) Based Blends, Composites
and Nanocomposites
31: Ball Milling Towards Green Synthesis: Applications,
Projects, Challenges
32: Porous Carbon Materials from Sustainable Precursors
33: Heterogeneous Catalysis for Today's Challenges: Synthesis,
Characterization and Applications
34: Chemical Biotechnology and Bioengineering
35: Microwave-Assisted Polymerization
36: Ionic Liquids in the Biorefinery Concept: Challenges and Perspectives
37: Starch-based Blends, Composites and Nanocomposites
38: Sustainable Catalysis: With Non-endangered Metals, Part 1
39: Sustainable Catalysis: With Non-endangered Metals, Part 2
40: Sustainable Catalysis: Without Metals or Other Endangered Elements,
Part 1
41: Sustainable Catalysis: Without Metals or Other Endangered Elements,
Part 2
42: Green Photo-active Nanomaterials
43: Commercializing Biobased Products: Opportunities, Challenges,
Benefits, and Risks
44: Biomass Sugars for Non-Fuel Applications
45: White Biotechnology for Sustainable Chemistry
46: Green and Sustainable Medicinal Chemistry: Methods, Tools
and Strategies for the 21st Century Pharmaceutical Industry
47: Alternative Energy Sources for Green Chemistry
48: High Pressure Technologies in Biomass Conversion
49: Sustainable Solvents: Perspectives from Research, Business
and International Policy
50: Fast Pyrolysis of Biomass: Advances in Science and Technology
51: Catalyst-free Organic Synthesis
52: Hazardous Reagent Substitution: A Pharmaceutical Perspective
53: Alternatives to Conventional Food Processing: 2nd Edition
54: Sustainable Synthesis of Pharmaceuticals: Using Transition
Metal Complexes as Catalysts
55: Intensification of Biobased Processes
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Intensification of Biobased
Processes
Edited by
Andrzej Górak
TU Dortmund University, Germany and Lodz University of Technology, Poland
Email: [email protected]
and
Andrzej Stankiewicz
Delft University of Technology, The Netherlands
Email: [email protected]
Green Chemistry Series No. 55
Print ISBN: 978-1-78262-855-2
PDF ISBN: 978-1-78801-032-0
EPUB ISBN: 978-1-78801-457-1
ISSN: 1757-7039
A catalogue record for this book is available from the British Library
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Preface
Process intensification is commonly mentioned as one of the most promi­
sing development paths for the chemical processing industry and one of
the most important progress areas for chemical engineering research. While
remaining a hot topic, bioprocessing still poses various important tech­
no­economic and environmental challenges, such as product yields, exces­
sive energy consumption for separations in highly watery systems, batch
operation or the downstream processing bottlenecks in the production of
biopharmaceutical products. Many of those challenges can be addressed by
application of the different process intensification technologies discussed in
the present book. The book addresses process intensification in white, green
and red biotechnology, both in upstream and downstream processing. Appli­
cation of an intensified process is demonstrated for the whole spectrum of
manufacturing processes. Consequently, the book addresses four clusters
of bioproducts: biofuels and commodity, fine chemicals, cosmetics and
pharmaceuticals, food products and advanced materials.
Chapter 1 by Noorman, van Winden, Heijnen and van der Lans shows how
the four principles of intensification of chemical processes, published by
van Gerven and Stankiewicz,1 can improve fermentation processes. The
four intensification examples provided demonstrate that debottlenecking
of the oxygen transfer capacity is the most important principle, followed by
liquid mixing. The next chapter by Boodhoo reviews the progress made in
developing and applying rotating reactors for bioprocessing. It focuses on
the whole cell fermentation and biotransformations in the rotating fluidi­
zed bed, the rotating bed bioreactor, the rotating biofilm contactor and the
rotating membrane reactor. Chapter 3 by Kiss and Bîldea presents intensi­
fied downstream processing options in the production of the major biofuels,

Green Chemistry Series No. 55
Intensification of Biobased Processes
Edited by Andrzej Górak and Andrzej Stankiewicz
© The Royal Society of Chemistry 2018
Published by the Royal Society of Chemistry, www.rsc.org
vii
viii Preface
such as biodiesel, bioethanol, biobutanol and dimethyl ether. It reviews sev­
eral intensified separation technologies: reactive distillation, dividing­wall
column, reactive dividing­wall column, catalytic cyclic distillation and heat
pump­assisted extractive distillation. In situ product removal is discussed in
Chapter 4. Cuellar and Straathof show here how to enhance yield and pro­
ductivity through the removal of biotransformation products from the reac­
tion mixture. In Chapter 5, de Haan and Birajdar analyze the application of
new materials (ionic liquids, deep eutectic solvents, polymers, modifiers
and supramolecular structures) and new techniques (ultrasound, micro­
wave, centrifugal and electric field) as a means to increase the extraction
efficiency and selectivity in solvent extraction processes. Organic solvent
nanofiltration presents another separation method applicable to renew­
able feedstocks or products. Chapter 6 by Werth and Skiborowski discusses
the potential of this membrane technique for important application areas
in the oleochemical industry. Integrating separation and reaction in a single
device, the Simulated Moving Bed Reactor is a paradigmatic representative
of multifunctional reactors, one of the most relevant process intensification
strategies. In Chapter 7, Rodrigues, Faria and Graça discuss the application
of this multifunctional reactor for production of biodiesel, additives and
blending agents. Chapter 8 by Adewuyi addresses intensification of the enzy­
matic hydrolysis of cellulose using a high multi­frequency ultrasonic reactor
and the effects of ultrasound on enzyme stability. The technique has appli­
cation potential in biofuel production and biorefinery processes. Chapter 9
by Sinha and Rai deals with the hydroprocessing of vegetable oils in micro­
channel reactors with catalyst coatings. Innovative concepts for reactive sep­
aration processes, such as reactive absorption and reactive distillation, that
make use of enzymes are discussed in Chapter 10 by Wierschem, Leimbrink,
Skiborowski, Heils, Smirnova and Górak. These techniques offer energy and
investment savings or improved selectivity by high enantioselectivity and
high reaction rates at mild process conditions. Enantioselective reactions
are also discussed in Chapter 11 by Shivaprasad and Emanuelsson, which
focuses on the integration of upstream and downstream through new equip­
ment concepts like membrane reactors, microreactors, monolithic reactors
and rotating disc reactors for enzyme catalyzed reactions. In Chapter 12,
Weatherley, Gangu, Scurto and Petera present a short review of the field of
enzymatic biotransformations and their application to chemical reactions
and products of industrial relevance. Extractive whole­cell biotransforma­
tion involving the benzylic chiral hydroxylation of naphthalene and lipolytic
hydrolysis of a triglyceride ester using a microbial lipase are discussed in
detail. Recent developments in microalgae cultivation and downstream pro­
cessing with a focus on microalgae biorefinery are presented by Lam, Ver-
muë, Janssen, Barbosa, Wiffels, Eppink and van den Berg in Chapter 13. Here,
the current state­of­development and future directions towards large scale
bulk­chemical production from microalgae are discussed. Chapter 14 by Pal
discusses process intensification and business sustainability in production
of a very important bioproduct i.e. glutamic acid. Integration of appropriate
Preface ix
membrane modules with a traditional fermenter leads to an economically
viable green process. The next two chapters deal with intensified production
methods of recombinant proteins. Baur and Morbidelli describe, in Chapter
15, novel techniques involving continuous or semi­continuous steady­state
upstream and downstream processing. They show that continuous perfu­
sion bioreactors enable large reductions in reactor volumes. In Chapter 16,
aqueous two­phase extraction is discussed by Brandenbusch, Zeiner and Merz
as an alternative to chromatography in purification of biopharmaceuticals.
The contribution emphasizes the role of phase thermodynamics in process
design. Chapter 17 by Vaghari, Jafarizadeh-Malmiri, Harcourt, Sarabadani,
Anarjan and Berenjian deals with functional foods, like essential oils and
carotenoids, that are hydrophobic components having low water solubility
and consequently low bioavailability. They present an overview on process
intensification technologies used in functional foods for increasing the
eco­efficiency of the process with the benefit of lower capital costs, substan­
tial energy saving and decreased utilization of solvents. Chapter 18, written
by Turk, Perino, Petitcolas and Chemat, presents a panorama of current knowl­
edge on microwave­assisted extractions of antioxidants, flavors, fragrances,
natural colors, fats and oils. Industrial scale applications in some pioneer­
ing companies are shown. An overview of membrane processes in the food
processing industry is presented by Cassano, Conidi and Drioli in Chapter 19.
The combination of membrane unit operations leads to high quality
products, recovery of high added­value compounds and savings on pro­
duction and energy costs. The two most important bottlenecks in brewing
processes are time consuming enzymatic reactions and the fact that many
processes are running simultaneously. In addition, large volumes need to be
transported along the production chain. Chapter 20 by Muster-Slawitsch and
Brunner highlights several approaches to process intensification and shows
that a holistic optimization is important in brewing, as changes in one pro­
cess may have implications in another. In Chapter 21, Dekkers and van der
Goot present novel routes and processing concepts to make meat analogs
in order to reduce meat consumption. The chapter ends by reviewing pos­
sible raw materials to be used in those applications and the importance of
understanding the effect on functional properties when preparing the ingre­
dients. The last two chapters of the book deal with the intensified manu­
facturing of advanced biomaterials. Direct Digital Manufacturing emerged
as a technological innovation that reduces the capital required to achieve
the required economy of scale. Chapter 22 by Morouço highlights its use
in the pharmaceutical domain, for surgical planning and training and for
tissue engineering. These areas of research can overlap the drawbacks of con­
ventional methods, exploring advances in the design and printing processes
as a process intensification method. Finally, the last chapter by Stankiewicz
shows how alternative energy forms like electric, magnetic, electromagnetic
and acoustic fields can be used in manufacturing of advanced biomaterials
with a broad range of medical applications, from body parts replacements
and tissue repairs to targeted drug delivery and advanced diagnostics.