Developing a separation system to enable real-time recovery of acetone-butanol during fermentation

Abstract

Methods such as gas stripping and vacuum-assisted gas stripping (VAGS) result in significant removal of water from the bioreactor, thus requiring continuous water replenishment in the bioreactor. In this study, we developed a hydrophobic stainless steel meshes capable of selectively recovering concentrated ABE stream from the bioreactor during VAGS. Three stainless steel meshes with pore sizes of 180 µm, 300 µm, and 425 µm were made hydrophobic and oleophilic with zinc oxide (ZnO) and polydimethylsiloxane (PDMS). Butanol concentrations in the model solutions range from 3 to 10 g/L which mimic concentrations typically produced during batch ABE fermentation. The meshes were integrated in a 5-L bioreactor containing 2.5 L of operational ABE model solution followed by the evaluation of selective extraction of ABE from both cell-free and Clostridium beijerinckii -rich ABE model solutions. The results show that the 180-µm ZnO/PDMS-coated mesh retained 54–64% more water in the bioreactor without C. beijerinckii cells and 61–65% more water with cells compared to the uncoated mesh. Furthermore, the butanol concentration of condensates recovered with 180-µm ZnO-PDMS-coated mesh was up to 10.8-fold greater than that of uncoated counterpart. Our data demonstrate that the developed ZnO-PDMS mesh can recover high concentrations of ABE while selectively retaining water in the bioreactor. Additionally, this technology demonstrates the potential for real-time ABE recovery during the fermentation of lignocellulosic and colloidal materials, without the concern of clogging the separation system. Key points • Hydrophobic mesh enhanced water retention in the bioreactor by up to 1.65-fold. • Butanol concentration in the collected condensate was increased by up to 10.8-fold. • Hydrophobic mesh is compatible with fermentation of lignocellulose. Supplementary Information The online version contains supplementary material available at 10.1007/s00253-024-13340-x.