Browsing by Author "Ranade, Vivek V."

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    Economic and environmental assessment of succinic acid production from sugarcane bagasse
    (American Chemical Society, 2021-09-15) Shaji, Arun; Shastri, Yogendra; Kumar, Vinod; Ranade, Vivek V.; Hindle, Neil
    This work presents technoeconomic analysis (TEA) and life cycle assessment (LCA) of a novel biorefinery producing succinic acid (SA) from sugarcane bagasse. The process consists of acid pretreatment, fermentation, followed by downstream separation and purification. Experimental data for pretreatment and fermentation are adapted for a plant processing 4 t/h of dry bagasse, producing 405 kg/h of succinic acid with the same quantity of acetic acid as a side product. Downstream separation is simulated in ASPEN PLUS. The facility is assumed to be annexed to and heat-integrated with an existing sugar mill in India. LCA is performed considering cradle-to-gate scope with 1 kg of SA as the functional unit. The TEA results show that although the process is currently not economically feasible, expected improvements in fermentation yields will make it cost-competitive. For the expected yield, the product cost of SA is INR 121/kg ($1.61/kg), and the selling price of succinic acid should be INR 178/kg ($2.37/kg) for a payback period of 4 years. Pretreatment and fermentation are the biggest contributors to the product cost. The life cycle greenhouse gas (GHG) emissions are 1.39 kg of CO2 equiv/kg succinic acid with electricity as the major contributor. Process improvement opportunities are identified to reduce the costs, as well as life cycle impacts.
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    Process optimization for recycling of bread waste into bioethanol and biomethane: a circular economy approach
    (Elsevier, 2022-05-28) Narisetty, Vivek; Nagarajan, Sanjay; Gadkari, Siddharth; Ranade, Vivek V.; Zhang, Jingxin; Patchigolla, Kumar; Bhatnagar, Amit; Awasthi, Mukesh Kumar; Pandey, Ashok; Kumar, Vinod
    Bread is the second most wasted food in the UK with annual wastage of 292,000 tons. In the present work, bread waste (BW) was utilized for fermentative production of ethanol by Saccharomyces cerevisiae KL17. Acidic and enzymatic saccharification of BW was carried out resulting in the highest glucose release of 75 and 97.9 g/L which is 73.5 and 95.9% of theoretical yield, respectively. The obtained sugars were fermented into ethanol initially in shake flask followed by scale up in bioreactor in batch and fed-batch mode. In the fed-batch mode of cultivation, the maximum ethanol titers of 111.3, 106.9, and 114.9 g/L with conversion yield and productivity of 0.48, 0.47, and 0.49 g/g, and 3.1, 3.0, and 3.2 g/L.h was achieved from pure glucose, glucose-rich acidic and enzymatic hydrolysates, respectively. Further to improve the process economics, the solid residues after acidic (ABW) and enzymatic (EBW) hydrolysis of BW along with respective fermentation residues (FR) obtained after the ethanol production were pooled and subjected to anaerobic digestion. The solid residue from ABW + FR, and EBW + FR yielded a biochemical methanation potential (BMP) of 345 and 379 mL CH4/g VS, respectively. Life cycle assessment of the process showed that the total emissions for ethanol production from BW were comparable to the emissions from more established feedstocks such as sugarcane and maize grain and much lower when compared to wheat and sweet potato. The current work demonstrates BW as promising feedstock for sustainable biofuel production with the aid of circular biorefining strategy. To the authors knowledge, this is the first time, such a sequential system has been investigated with BW for ethanol and biomethane production. Further work will be aimed at ethanol production at pilot scale and BMP will be accessed in a commercial anaerobic digester.
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    Sugarcane bagasse based biorefineries in India: potential and challenges
    (Royal Society of Chemistry, 2020-11-10) Konde, Kakasaheb S.; Nagarajan, Sanjay; Kumar, Vinod; Patil, Sanjay V.; Ranade, Vivek V.
    Sugarcane bagasse (SCB) is one of the world's most abundant agricultural residues and in an Indian context, ∼100 million tonnes per annum is produced. The current use of SCB is restricted to the cogeneration of steam and power; however considering its potential, cogeneration is not the best valorisation route. Furthermore, with falling electricity prices and reducing global sugar prices due to excess sugar stock, it is inevitable that the waste generated (SCB) by sugar mills are utilised for generating revenue sustainably. With this background, this review aims to put forth a biorefinery perspective based on SCB feedstock. Biogas and bioethanol are the Government of India's current focus with policies and subsidies clearly pointing towards a sizeable future market. Therefore, alongside these biofuels, high-value chemicals such as xylitol, succinic acid and lactic acid were identified as other desired products for biorefineries. This review firstly discusses SCB pre-treatment options based on end applications (saccharification or anaerobic digestion, AD). Next, state-of-the-art for each of these aspects was reviewed and our perspective on a profitable biorefinery is presented. We propose an AD based biorefinery where vortex-based hydrodynamic cavitation was found to be the best choice for pre-treatment. AD is considered not only a bioprocess for energy production here but also a ‘pre-treatment’, where partial conversion of holocellulose leads to a digestate rich in a loosened fibre matrix. This digestate rich in cellulose can be enzymatically hydrolysed and further valorised biochemically. This approach would be cost effective and provide a sustainable waste management route for sugar mills.
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    Sugarcane bagasse valorization to xylitol: techno-economic and life cycle assessment
    (Wiley, 2022-04-17) Shaji, Arun; Shastri, Yogendra; Kumar, Vinod; Ranade, Vivek V.; Hindle, Neil
    A detailed techno-economic analysis and life cycle assessment (LCA) of a novel bio-refinery that produces xylitol from sugarcane bagasse are provided. The proposed process includes dilute acid pretreatment in pressurized conditions followed by fermentation (upstream section). The fermentation broth is then sent for separation and purification to the downstream section. Calculations are performed for a plant with 4 t/h of dry bagasse throughput. With a fermentation yield of 0.54 g xylitol per g of xylose, the plant produced 437.4 kg/h of xylitol. Upstream data are adapted from experimental studies, while ASPEN PLUS® flowsheet simulation is used to obtain data for the downstream section. The xylitol production facility is assumed to be annexed to an existing sugar mill in India. The total utility requirement in the process is reduced using heat integration strategies. Cradle-to-gate scope is considered for the LCA and 1 kg of xylitol is taken as the functional unit. The product cost of xylitol is calculated to be 230 INR/kg (US$3.17/kg). For a 4 year payback period, the selling price of xylitol must be 450 INR/kg (US$6.2/kg). The fermentation and pretreatment sections are the major components of the product cost. The LCA results show that the life cycle greenhouse gas emissions are 2.759 kg CO2 eq. per kg xylitol. The electricity requirement within the plant is identified as the major source of greenhouse gas emissions, and reduction of fermentation duration is identified as a key factor. The results identify opportunities to improve the process from an economic as well as an environmental standpoint. © 2022 Society of Chemical Industry and John Wiley & Sons, Ltd.
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    Techno-economic analysis for the production of 2,3-butanediol from brewers’ spent grain using pinch technology
    (American Chemical Society, 2022-12-31) Mailaram, Swarnalatha; Narisetty, Vivek; Ranade, Vivek V.; Kumar, Vinod; Maity, Sunil K.
    2,3-Butanediol (BDO) is a versatile platform chemical with great potential as the precursor for various value-added derivatives across different industrial sectors. This work thus presents a techno-economic feasibility study for microbial BDO production from C5 and C6 sugars derived from brewers’ spent grain (BSG). Water-soluble carbohydrates obtained from pretreatment were further utilized for the biogas generation. Besides, the solid residue generated after fermentation and biogas were used to generate high-pressure steam and electricity. The process integration was carried out using pinch technology for various BDO titers and plant capacities. The pinch analysis helped in the reduction of hot and cold utility consumption by about 34 and 18%, respectively. The minimum hot and cold utility consumption was 4.59 and 10.97 MW for 100 MT BSG per day with 100 g/L BDO titer, respectively. The cooling water consumption was decreased, and electricity generation was increased with the increase in BDO titer, while the BDO production cost reduced marginally. For 100 MT BSG per day, the BDO production cost was US$1.84, US$1.76, and US$1.74/kg for BDO titers of 80, 100, and 120 g/L, respectively. However, the unitary BDO production cost was only US$1.07 for 2000 MT BSG per day. For 100 g/L BDO titer, the minimum BDO selling price was US$3.63 and US$2.00/kg for 100 and 2000 MT BSG per day, respectively, with 8.5% return on investment and 5 years as the payback period.