Biosurfactants are naturally occurring surface active compounds with unique properties such as biodegradability, low toxicity and tolerance to extreme conditions. These unique properties promote their use as alternatives to traditional petrochemical and oleochemical surfactants, as they satisfy requirements for environmentally friendly manufacturing processes. However, the cost of biosurfactants is still significantly higher than chemical surfactants which hinders their large-scale commercialisation. This work presents an investigation into the production of surfactin, a lipopeptide biosurfactant, exploiting its foamability characteristics for the design and implementation of a recirculating continuous foam fractionation column operated in parallel with a bioreactor. Surfactin is a powerful amphiphilic compound produced by Bacillus subtilis. It is a plant-elicitor with antimicrobial properties offering a huge potential in the food and agricultural industries. However, surfactin has extreme foamability even at low concentrations. This foamability can lead to production problems such as large volumes of uncontrolled overflowing foam with significant product and biomass losses. Here, it is demonstrated that this overflow can be controlled, or eliminated, by integrating a foam fractionation system to the bioreactor in a recirculating loop. A dual production and separation process was engineered and enabled reaching high surfactin productivity in a controlled manner. After elucidating the surface properties of surfactin-rich broth, a foam fractionation column was designed for bench-scale production. Operation of the recirculating column in parallel with the bioreactor enabled air flow to be independently controlled for each unit. Surfactin solutions of various concentrations were tested to relate foamability to concentration over a range of bubble sizes. The sintered glass pore size was revealed to be the main factor influencing the enrichment, with a positive correlation with increasing pore size. Characterisation of the fermentation production rate enabled fractionation column air flow rate to be controlled to ensure sufficient foam surface area for product adsorption. The airflow rate was identified as the main factor impacting on the surfactin recovery rate. This characterisation enabled broth feed flow rate to be controlled to balance the removal rate with the production rate. Two processes were created coupling the newly designed fractionation column with the bioreactor operated either in aerated or non-aerated conditions. Under aerated settings, controlled surfactin production was successfully achieved at a productivity of 0.0019 g L-1 h-1 whilst simultaneously recovering 91% of the product at a maximum enrichment of 79 and 116 through the column and overflow routes, respectively. Under non-aerated settings, overflowing foam was fully avoided and 90% of the product was recovered solely through the fractionation column at an enrichment ratio of 40 under non-optimised settings. Additionally, up to 14% (g/g) increase in surfactin production was observed with the coupling of the fractionation column demonstrating a further benefit as a bioprocess intensifying device for surfactin production. This work provides a benchmark for a robust system for surfactin production, substantially improving the productivity at bench scale, potentially leading the way to more productive and less costly industrial processes for surface active compounds in a wide range of industrials fields.

abstract: Emergent environmental issues, ever-shrinking petroleum reserves, and rising fossil fuel costs continue to spur interest in the development of sustainable biofuels from renewable feed-stocks. Meanwhile, however, the development and viability of biofuel fermentations remain limited by numerous factors such as feedback inhibition and inefficient and generally energy intensive product recovery processes. To circumvent both feedback inhibition and recovery issues, researchers have turned their attention to incorporating energy efficient separation techniques such as adsorption in in situ product recovery (ISPR) approaches. This thesis focused on the characterization of two novel adsorbents for the recovery of alcohol biofuels from model aqueous solutions. First, a hydrophobic silica aerogel was evaluated as a biofuel adsorbent through characterization of equilibrium behavior for conventional second generation biofuels (e.g., ethanol and n-butanol). Longer chain and accordingly more hydrophobic alcohols (i.e., n-butanol and 2-pentanol) were more effectively adsorbed than shorter chain alcohols (i.e., ethanol and i-propanol), suggesting a mechanism of hydrophobic adsorption. Still, the adsorbed alcohol capacity at biologically relevant conditions were low relative to other `model' biofuel adsorbents as a result of poor interfacial contact between the aqueous and sorbent. However, sorbent wettability and adsorption is greatly enhanced at high concentrations of alcohol in the aqueous. Consequently, the sorbent exhibits Type IV adsorption isotherms for all biofuels studied, which results from significant multilayer adsorption at elevated alcohol concentrations in the aqueous. Additionally, sorbent wettability significantly affects the dynamic binding efficiency within a packed adsorption column. Second, mesoporous carbons were evaluated as biofuel adsorbents through characterization of equilibrium and kinetic behavior. Variations in synthetic conditions enabled tuning of specific surface area and pore morphology of adsorbents. The adsorbed alcohol capacity increased with elevated specific surface area of the adsorbents. While their adsorption capacity is comparable to polymeric adsorbents of similar surface area, pore morphology and structure of mesoporous carbons greatly influenced adsorption rates. Multiple cycles of adsorbent regeneration rendered no impact on adsorption equilibrium or kinetics. The high chemical and thermal stability of mesoporous carbons provide potential significant advantages over other commonly examined biofuel adsorbents. Correspondingly, mesoporous carbons should be further studied for biofuel ISPR applications. / Dissertation/Thesis / M.S. Chemical Engineering 2011

abstract: The aims of this project are to demonstrate the design and implementation of separations modalities for 1) in situ product recovery and 2) upstream pretreatment of toxic feedstocks. Many value-added bioproducts such as alcohols (ethanol and butanol) developed for the transportation sector are known to be integral to a sustainable future. Likewise, bioproduced aromatic building blocks for sustainable manufacturing such as phenol will be equally important. The production of these compounds is often limited by product toxicity at 2- 20 g/L, whereas it may desirable to produce 20-200 g/L for economically feasible scale up. While low-cost feedstocks are desirable for economical production, they contain highly cytotoxic value-added byproducts such as furfural. It is therefore desirable to design facile detoxification methods for lignocellulose-derived feedstocks to isolate and recover furfural preceding ethanol fermentation by Escherichia coli. Correspondingly it is desirable to design efficient facile in situ recovery modalities for bioalcohols and phenolic bioproducts. Accordingly, in-situ removal modalities were designed for simultaneous acetone, butanol, and ethanol recovery. Additionally, a furfural removal modality from lignocellulosic hydrolysates was designed for upstream pretreatment. Solid-liquid adsorption was found to serve well each of the recovery modalities characterized here. More hydrophobic compounds such as butanol and furfural are readily recovered from aqueous solutions via adsorption. The primary operational drawback to adsorption is adsorbent recovery and subsequent desorption of the product. Novel magnetically separable mesoporous carbon powders (MMCPs) were characterized and found to be rapidly separable from solutions at 91% recovery by mass. Thermal desorption of value added products was found efficient for recovery of butanol and furfural. Fufural was desorbed from the MMCPs up to 57% by mass with repeated adsorption/thermal desorption cycles. Butanol was recovered from MMCPs up to an average 93% by mass via thermal desorption. As another valuable renewable fermentation product, phenol was also collected via in-situ adsorption onto Dowex Optipore L-493 resin. Phenol recovery from the resins was efficiently accomplished with tert-butyl methyl ether up to 77% after 3 washes. / Dissertation/Thesis / Doctoral Dissertation Chemical Engineering 2017

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