Doctor of Philosophy / Department of Grain Science and Industry / Praveen V. Vadlani / Distillers Dried grain with Solubles (DDGS) is a co-product of grain-based ethanol and is primarily used as livestock feed. With increasing production of DDGS, it is imperative to produce value-added products and/or find new applications of DDGS to help sustain the biofuel industry. Carotenoids are expensive yet essential feed additives. Since animals cannot synthesize carotenoids and animal feeds including DDGS are generally poor in carotenoids, about 30-120 ppm of total carotenoids is added to animal feed to improve animal health. The objectives of this study were to 1) produce carotenoid (astaxanthin and β-carotene)-enriched DDGS by Phaffia rhodozyma and Sporobolomyces roseus monoculture and mixed culture submerged fermentation of whole stillage, 2) optimize fermentation media by response surface methodology (RSM) and mixture design followed by validation, 3) evaluate the nutritional profile of carotenoid-enriched DDGS, 4) improve carotenoid production by the use of precursors, and 5) develop carotenoid-enriched feeds namely, wheat bran, rice bran and soybean products. Carotenoid-enriched DDGS was produced from both monoculture and mixed culture fermentation with yields ranging from 17-233 µg/g. Upon media optimization, astaxanthin and β-carotene yields, especially in P. rhodozyma were enhanced by 177% and 164% to yield 98 and 275 µg/g respectively. Nutrition profiling of the carotenoid-enriched DDGS showed that the secondary fermentation resulted in low fiber, protein and %N and enhanced fat. Fiber was reduced by 77% and 66% by P. rhodozyma and S. roseus respectively, whereas the crude fat increased by 80% in mixed culture fermentation. Additionally, abundant vaccenic acid, a monounsaturated fatty acid was seen in S. roseus and mixed culture fermented DDGS. Vaccenic acid is a precursor of conjugated linolenic acid which is known to confer numerous health benefits. Fermentation of milo DDGS, wheat bran, rice bran and soybean products also resulted in carotenoid enrichment, with the best astaxanthin yield of 80 µg/g in rice bran, and best β-carotene yield of 837 µg/ g in soy flour. Precursors like mevalonic acid, apple pomace and tomato pomace increased carotenoid yield in DDGS and other substrates, with the yield increment depending on the substrate. Mevalonic acid resulted in the best astaxanthin and β-carotene yield increment by 140% and 236% resulting in 220 µg/g and 904 µg/g respectively in corn DDGS. Apple pomace and tomato pomace resulted in 29% carotenoid yield increment. Numerous studies thus far have used cheap agricultural substrates to produce carotenoids especially astaxanthin using P. rhodozyma with the intent of extracting the carotenoids for use in animal feed. However, by fermenting the animal feed directly, carotenoid-enriched feed can be produced without the need for extraction. By this simple yet novel carotenoid value addition, premium feeds or feed blends can be developed. Apart from carotenoid enrichment, low-fiber DDGS can help expand the market base of DDGS for use in non-ruminant feeds. Carotenoid value addition of DDGS can not only help sustain the biofuel industry but can also capture the aquaculture feed base which heavily relies on astaxanthin supplementation.

Orientador: Ricardo Alan Verdú Ramos / Resumo: A biomassa derivada de microalgas apresenta um grande potencial devido a sua sustentabilidade e alta produtividade, sendo possível extrair lipídios para produção de biodiesel. Entretanto, desafios na cadeia de produção como um todo devem ser resolvidos para que o biodiesel de microalgas seja viável. Uma das etapas críticas é o cultivo, sendo o meio de cultura um elemento de alto custo. O objetivo principal deste trabalho é avaliar o crescimento de microalgas visando produção de lipídios para biodiesel, utilizando como fontes de nutrientes a vinhaça originada do processo produtivo de etanol no setor sucroalcooleiro. Foram isolados e indentificados três gêneros nativos de microalgas: uma cianobactéria Aphanocapsa sp., uma clorofícea Oocystis sp. e outra clorofícea Scenedesmus sp. O cultivo da microalga Scenedesmus sp. em fotobiorreator de placas planas com meio de cultivo MBM (Modified Bristol Medium) se mostrou modesta em termos de produtividade de biomassa (8 mg/l.dia) e em teor de lipídios na biomassa seca (1,5%). O cultivo dessa mesma microalga em tubos de ensaios com meio alternativo utilizando vinhaça (três diluições de 2%, 5% e 10% em volume) no meio de cultura mostrou desempenho comparável em relação ao meio sintético MBM, sendo que a partir do dia 6, os quatros cultivos se estabilizam em torno de uma concentração celular de 6×106 de células/ml, indicando que a vinhaça pode ser uma fonte de nutrientes de baixo custo para o cultivo de microalgas. Deste modo, é possível r... (Resumo completo, clicar acesso eletrônico abaixo) / Mestre

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / During the distillation of alcohol is a residue called vinasse generated with high content of organic matter and high pollution potential. As the largest industry effluent of alcohol, stillage is an ecological problem. Faced with this problem, treatment is necessary. Within the context arises the UASB (upflow anaerobic sludge blanket) Seeking sustainability in the agricultural industry, in addition to treating vinasse, biogas is captured for energy use, and may get an economic return. This study aimed to analyze by means of physical-chemical parameters such as temperature, pH, detention time and hydraulic retention rate of climb, macro-nutrients, COD and qualitative methane generation, the behavior of two reactors, pilot scale, performing a comparative characteristics of effluents from a distillery. Thus was determined the efficiency of reduction of the organic load by analyzing the vinasse obtained from two different sources, amylaceous and saccharide. The reduction of the organic load in the effluent was greater potato reached 95.75%, while the sugar cane reached 81.56% removal of COD, satisfactory results for UASB-type reactors. / Durante o processo de destilação do álcool, é gerado um resíduo chamado vinhaça com alto teor de matéria orgânica e alto potencial poluidor. Sendo o maior efluente da indústria do álcool, a vinhaça representa um problema ecológico. Frente a este problema, o tratamento se faz necessário. Dentro do contexto surge o reator UASB (upflow anaerobic sludge blanket) Visando a sustentabilidade na agroindústria, além de tratar a vinhaça, o biogás é captado para uso energético, podendo obter um retorno econômico. Este trabalho objetivou analisar por meio de parâmetros fisico-químicos como temperatura, pH, tempo de detenção e retenção hidráulica, velocidade ascensional, macro-nutrientes, DQO e geração qualitativa de metano, o comportamento de dois reatores, em escala piloto, realizando um comparativo das características dos efluentes de uma microdestilaria. Dessa forma foi determinada a eficiência da redução da carga orgânica, analisando o vinhoto proveniente de duas diferentes fontes, amilácea e sacarídea. A redução da carga orgânica foi maior no efluente da batata atingindo 95,75%, enquanto a cana-de-açúcar atingiu 81,56% da remoção da DQO, resultados satisfatórios para reatores do tipo UASB.

Made available in DSpace on 2015-05-14T12:09:23Z (GMT). No. of bitstreams: 1 arquivototal.pdf: 1888869 bytes, checksum: dbaae38c1299dd8ef37444fdd79d603a (MD5) Previous issue date: 2013-03-27 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior - CAPES / Sugar-alcohol industries are characterized by high water demand, and generate proportional volumes of waste to be disposed. Within the ethanol production process, stillage emerges as an effluent, that is, 15 liters of stillage for every liter of ethanol produced, which is characterized as a high effluent polluting stream: about one hundred times higher than domestic sewage. Its potential pollution is due to the richness in organic content, low pH, high corrosivity and high values of chemical oxygen demand (COD). This work aims to characterizing stillage "in natura" and the use of various coagulants for its treatment, such as FeCl3, Al2SO4 and CaO, in order to treat stillage preliminarily. After the coagulation / flocculation processes, evaluated as a function of the coagulants concentration, the treatment with activated carbon produced from sugar cane bagasse were carried out. The porous structure of carbons and the adsorption of N2 (g). The efficiency of the treatments were quantified in terms of the removal of COD, BOD5, TOC, total solids, color and turbidity. The experimental results showed that the coagulation / flocculation processes, with the coagulant s concentration of 10 g/l, removes a significant amount of organic load, color and turbidity. The subsequent procedure with the activated carbon treatment completes the purification of stillage satisfactorily, that reached average removal rates above 90% for COD, and up to 99% for color and turbidity. / As indústrias sucroalcooleiras se caracterizam por grande demanda de água e geram volumes proporcionais de resíduos a serem descartados. No processo produtivo do etanol, a vinhaça surge como um efluente, ou seja, para cada litro de etanol produzido são gerados 15 litros de vinhaça, sendo caracterizada como um efluente de elevado poder poluente, cerca de cem vezes maior que o do esgoto doméstico. Seu potencial poluidor decorre da sua riqueza em matéria orgânica, baixo pH, elevada corrosividade e altos valores de Demanda Química de Oxigênio (DQO). Este trabalho teve como objetivo caracterizar a vinhaça in natura e avaliar a utilização de diversos coagulantes como FeCl3, Al2SO4 e CaO, com o intuito de tratar preliminarmente a vinhaça. Após o processo de coagulação/ floculação, analisado em função da concentração dos coagulantes, foi realizado o tratamento com carvão ativado produzido a partir do bagaço de cana, sendo determinada a estrutura porosa do carvão e adsorção de N2(g). A eficiência do tratamento foi quantificado em termos de remoção de DQO, DBO5, sólidos totais, cor e turbidez. Os resultados experimentais mostraram que o processo de coagulação/ floculação com concentração de coagulante de 10 g.L-1 removeu uma quantidade significativa de carga orgânica, cor e turbidez. A etapa subsequente com o tratamento do carvão ativado completou satisfatoriamente a purificação da vinhaça, gerando eficiência de remoção superior a 90% para a DQO e 99% para cor e turbidez.

Submitted by Róbinson Gerardo Trindade Portilla Erazo null (robinson.gtpe@gmail.com) on 2017-09-27T14:49:27Z No. of bitstreams: 1 Dissertacao_Robinson_VF_Repositorio_26-09-2017.pdf: 2688773 bytes, checksum: 22f612426a45deee274ee0dbd4e1fcba (MD5) / Approved for entry into archive by Monique Sasaki (sayumi_sasaki@hotmail.com) on 2017-09-28T14:26:52Z (GMT) No. of bitstreams: 1 portillaerazo_rgt_me_ilha.pdf: 2688773 bytes, checksum: 22f612426a45deee274ee0dbd4e1fcba (MD5) / Made available in DSpace on 2017-09-28T14:26:52Z (GMT). No. of bitstreams: 1 portillaerazo_rgt_me_ilha.pdf: 2688773 bytes, checksum: 22f612426a45deee274ee0dbd4e1fcba (MD5) Previous issue date: 2017-08-03 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / A biomassa derivada de microalgas apresenta um grande potencial devido a sua sustentabilidade e alta produtividade, sendo possível extrair lipídios para produção de biodiesel. Entretanto, desafios na cadeia de produção como um todo devem ser resolvidos para que o biodiesel de microalgas seja viável. Uma das etapas críticas é o cultivo, sendo o meio de cultura um elemento de alto custo. O objetivo principal deste trabalho é avaliar o crescimento de microalgas visando produção de lipídios para biodiesel, utilizando como fontes de nutrientes a vinhaça originada do processo produtivo de etanol no setor sucroalcooleiro. Foram isolados e indentificados três gêneros nativos de microalgas: uma cianobactéria Aphanocapsa sp., uma clorofícea Oocystis sp. e outra clorofícea Scenedesmus sp. O cultivo da microalga Scenedesmus sp. em fotobiorreator de placas planas com meio de cultivo MBM (Modified Bristol Medium) se mostrou modesta em termos de produtividade de biomassa (8 mg/l.dia) e em teor de lipídios na biomassa seca (1,5%). O cultivo dessa mesma microalga em tubos de ensaios com meio alternativo utilizando vinhaça (três diluições de 2%, 5% e 10% em volume) no meio de cultura mostrou desempenho comparável em relação ao meio sintético MBM, sendo que a partir do dia 6, os quatros cultivos se estabilizam em torno de uma concentração celular de 6×106 de células/ml, indicando que a vinhaça pode ser uma fonte de nutrientes de baixo custo para o cultivo de microalgas. Deste modo, é possível reduzir custos em uma importante etapa do processo global de produção de biodiesel de microalgas, viabilizando economicamente esta alternativa energética. / The biomass derived from microalgae presents great potential due to its sustainability and high productivity, it being possible to extract lipids to produce biodiesel. However, challenges in the production chain as a whole must be solved to make microalgae biodiesel viable. One of the critical steps is cultivation, with the culture medium being a costly element. The main purpose of this work is to evaluate the microalgae growth focusing in lipid production for biodiesel using as sources of nutrients the vinasse originated from the sugar-alcohol production process. Three natives microalgae genres have been isolated and identified: cyanobacteria Aphanocapsa sp., chlorophycea Oocystis sp. and other chlorophycea Scenedesmus sp. The cultivation of the microalgae Scenedesmus sp. in flat plate photobioreactor with Modified Bristol Medium (MBM) was modest in terms of biomass yield (8 mg/l.day) and lipid content in dry biomass (1.5%). The cultivation of this same microalga in test tubes in an alternative medium using vinasse (three dilutions of 2%, 5% and 10% in volume) in the culture medium showed a comparable performance in relation to the MBM, starting in the 6th day the stabilization of the cell concentration in 6×106 cells/ml for the four cultives, indicating that the vinasse can be a source of low cost nutrients for the cultivation of microalgae. In this way, it is possible to reduce costs at an important stage in the overall process of microalgae biodiesel production, making this energy alternative economically viable. / CAPES: 1420416

Programa de Apoio aos Planos de Reestruturação e Expansão das Universidades Federais / Brazil is a tropical country with a huge amount of natural energy resources. In view of the growth that the country is experiencing, such resources exploitation becomes increasingly attractive. Among many resources alternatives, the biomass is one of the most notable mainly due to its applicability in farms and agro-industries around the country. The use of biomass to ethanol production, even on a small scale, results in a considerable production of stillage waste production that presents high organic matter content and that is seen as a highly polluting effluent. The anaerobic digestion of stillage in Upflow Anaerobic Sludge Blanket (UASB) reactors is an efficient alternative to stillage treatment as well as to biogas production. This work presents the study of empirical modeling, using tools such as artificial neural networks (ANN) and parametric identification, of an UASB reactor operation which treats the distillation stillage of ethanol produced from two different biomasses: raw starch (potato) and saccharide (sugar cane). The inputs used in the models were chosen by statistical methods according to a series of parameters that are monitored during the experimental reactor operation, where it is evident the importance of the initial Chemical Oxygen Demand, temperatures and the period of operation of the reactor with the same charge. The results were promising for the use of such tools in performance estimation of highly complex biological systems such as the anaerobic digestion, chosen as case study in this work, being achieved in the best cases a correlation of 0,98841 for potato stillage, and a correlation of 0,99738 for the stillage of sugar cane using neural networks. / O Brasil é um país tropical com uma quantidade enorme de recursos naturais energéticos. Tendo em vista o crescimento que o país está vivenciando, a exploração destes recursos energéticos se torna a cada dia mais atrativa. Entre as diversas alternativas, a biomassa está entre as mais notáveis principalmente pela sua aplicabilidade em propriedades rurais e agroindústrias de todo território nacional. A utilização de biomassa, para produção de etanol, mesmo em pequena escala, resulta em uma considerável produção de vinhaça resíduo de produção que apresenta elevado teor de matéria orgânica e é visto como um efluente altamente poluente. A biodigestão anaeróbia da vinhaça em reatores anaeróbios de fluxo ascendente e manta de lodo (UASB) é uma alternativa eficiente tanto para o tratamento da vinhaça quanto para a produção de biogás. Este trabalho apresenta o estudo da modelagem empírica, usando ferramentas tais como redes neuronais artificiais (RNAs) e identificação paramétrica, do funcionamento de um reator UASB tratando a vinhaça obtida com a destilação do etanol produzido a partir de duas biomassas diferentes: matéria-prima amilácea (batata) e sacarídea (cana-de-açúcar). As entradas usadas nos modelos foram selecionadas através de métodos estatísticos a partir de uma série de parâmetros monitorados durante a operação experimental do reator, onde fica evidente a importância da Demanda Química de Oxigênio inicial, das temperaturas e do período de operação do reator com a mesma carga. Os resultados mostraram-se promissores para o uso destas ferramentas para a predição da performance de sistemas biológicos de alta complexidade tais como a digestão anaeróbia, nos melhores casos sendo alcançado uma correlação de 0,98841 para a vinhaça de batata, e uma correlação de 0,99738 para a vinhaça de cana-de-açúcar usando redes neuronais.

A significant by-product of bioethanol plants is whole stillage, commonly used to produce animal feed due to its nutritious value, has a potential to be used to produce various value-added products while eliminating a costly process step is an alternative approach. In this study, production and separation of additional ethanol, fungal biomass and enzyme were successfully achieved with the cultivation in membrane bioreactors in batch process condition. Process optimization studies regarding fermentation and filtration conditions were carried out. Up to 10.4 g/l ethanol per litre of used whole stillage can be produced in simultaneous saccharification and fermentation (SSF) condition without any pH adjustment and additional pretreatment step. Also, 50% diluted whole stillage provided 87% higher ethanol production comparing to non-diluted medium. Moreover, 71 % higher biomass production was obtained with the filtrate of 50% diluted whole stillage comparing to 25% diluted one. Considering the achieved results, a two-stage cultivation using SHF (Separate Hydrolysis and Fermentation) strategy in membrane bioreactors for separation of ethanol, lignin-rich stream, protein-rich fungal biomass and enzymes was proposed. The present thesis showed that the integration of filamentous fungi with membrane bioreactors can increase the range of products that can be produced from whole stillage.

Establishing a commercial, lignocellulose-based, second-generation ethanol process has received several decades of attention by both researchers and industry. However, a fully economically viable process still remains a long-term goal. The main bottleneck to this achievement is the recalcitrance of lignocellulosic feedstocks, although there are several other factors, such as the huge investment required for second-generation ethanol facilities. An intelligent alternative solution discussed in this thesis is an integrated approach using firstgeneration ethanol plants for second-generation processes. Wheat is the major feedstock for first-generation ethanol in Europe; therefore, wheat-based lignocellulose waste, such as wheat straw, bran, and whole stillage fiber (a waste stream from first-generation wheat-based ethanol plants) was the primary focus of the integration model in this thesis. Since the major share of first-generation ethanol plant economics focuses on the animal feed DDGS (Distillers’ dried gains with solubles), the integration of lignocellulose should be designed in order to maintain DDGS quality. An ethanol-producing edible filamentous fungus, Neurospora intermedia, a potential protein source in DDGS, was considered for use as the fermenting microbe. The morphological and physiological aspects of this fungus were studied in the thesis, leading to the first report of fungal pellet development. An alternative approach of using dilute phosphoric acid to pretreat lignocellulose, as it does not negatively affect fungal growth or DDGS quality, was demonstrated in both the laboratory and on a 1m3 pilot scale. Furthermore, the process of hydrolysis of pretreated lignocelluloses and subsequent N. intermedia fermentation on lignocellulose hydrolysate was also optimized in the laboratory and scaled up to 1 m3 using an in-house pilot-scale airlift bioreactor. Fungal fermentation on acid-pretreated and enzyme-hydrolyzed wheat bran, straw and whole stillage fiber resulted in a final ethanol yield of 95%, 94% and 91% of the theoretical maximum based on the glucan content of the substrate, respectively. Integrating the first- and second-generation processes using thin stillage (a waste stream from first-generation wheat-based ethanol plants) enhanced the fungal growth on straw hydrolysate, avoiding the need for supplementing with extra nutrients. Based on the results obtained from this thesis work, a new model for integrated first- and second-generation ethanol using edible filamentous fungi processes that also adds value to animal feed (DDGS) was developed.

This diploma thesis deals with a design of a boiler for stillage combustion. Stoichiometric calculations and enthalpies of combustion gases have been calculated from the specified parameters. In addition, heat calculation, design of the combustion chamber dimensions and dimensioning of heat surfaces were accomplished. The boiler has an evaporator with natural circulation and a fire grate.

El objetivo principal de este estudio fue establecer la viabilidad de la producción de un fertilizante orgánico, a partir de vinaza en la Región de Lambayeque, con la finalidad de maximizar el potencial de los cultivos orgánicos y residuos de vinaza, que es un subproducto de la destilación del alcohol. Para la producción de fertilizante orgánico se utiliza la vinaza, añadiendo pajilla de arroz en proporciones de 30% y 70%, logrando así la mejora de las propiedades del fertilizante, para una mejor interpretación del secado y su soldado mezcla. El proceso de producción de fertilizante orgánico se llevó a cabo utilizando muestras concentradas de vinaza divididas en tres grupos: 55 °Bx, 65 °Bx y 75° Bx, a las cuales se le agregaron una mezcla de pajilla, en proporciones de: 45%, 50% y 55% de vinaza y el resto en los grupos establecidos. Las pruebas, que se llevaron a cabo con la ayuda un laboratorio, revelaron que es posible elaborar abono orgánico a partir de la uva respetando los estándares establecidos. Finalmente, el proyecto si es viable dado que tiene un valor actual neto (VAN) de S/ 21,798,900.89, siendo el proyecto rentable. Además, la tasa interna de rentabilidad financiera (TIR) del 121%, lo que da por entendido que aparte de devolver el capital invertido, se podrá otorgar un adicional. / The main objective of this study was to establish the feasibility of producing an organic fertilizer from vinasse in the Lambayeque Region, in order to maximize the potential of organic crops and vinasse residues, which is a by-product of alcohol distillation. For the production of organic fertilizer, the vinasse is used, adding rice straw in proportions of 30% and 70%, thus improving the properties of the fertilizer, for a better interpretation of the drying and its welded mixture. The organic fertilizer production process was carried out using concentrated vinasse samples divided into three groups: 55 °Bx, 65 °Bx and 75 °Bx, to which a straw mixture was added, in proportions of: 45%, 50% and 55% of vinasse and the rest in the established groups. The tests, which were carried out with the help of a laboratory, revealed that it is possible to produce organic fertilizer from grapes while respecting the established standards. Finally, the project is viable given that it has a net present value (NPV) of S/ 21,798,900.89, making the project profitable. In addition, the internal rate of return (IRR) is 121%, which means that in addition to returning the invested capital, an additional amount can be granted. / Tesis