Conversion of cellulosic materials to ethanol

The plant cell wall can be regarded as a giant bag-like macromolecule in which crystalline bundles of cellulose are embedded in a covalently linked matrix of hemicellulose and lignin. This heterologous polymer represents the dominant form of biomass on earth and a formidable challenge for solubilization and bioconversion. Bioconversion of lignocellulose requires the saccharification of both the hemicellulose and cellulose. Hemicellulose is composed of a mixture of sugars and can be readily hydrolysed by dilute acid at 140°C to produce a syrup containing pentoses and hexoses. However, no organisms in nature rapidly and efficiently convert both pentoses and hexoses into a single product of value. Our laboratory has developed such an organism by genetic engineering. Recombinant strains of Gram-negative bacteria (Escherichia coli or Klebsiella oxytoca or Erwinia sp.) have been constructed in which genes encoding the ethanol pathway from Zymomonas mobilis (pdc and adh) were inserted into the chromosome. These strains now efficiently convert all of the component sugars of hemicellulose and (cellulose) into ethanol. The saccharification of cellulose is more difficult and more complex. An enzymatic approach is preferred but at least three classes of enzymes are needed: endoglucanase, exoglucanase, and β-glucosidase. Klebsiella oxytoca and Erwinia sp. possess the native ability to transport and metabolize cellobiose (also cellotriose, xylobiose, and xylotriose), minimizing the need for added β-glucosidase. K. oxytoca strain P2, an ethanol-producing recombinant, has been evaluated in simultaneous saccharification and fermentation experiments to determine optimal conditions and limits of performance. Temperature was varied between 32 and 40°C over a pH range of 5.0–5.8 with 100 g 1−1 of crystalline cellulose (Sigmacell 50, Sigma Chemical Company, St. Louis, MO) as the substrate and commercial cellulase (Spezyme CE; Genencor, South San Francisco, CA). A broad optimum for fermentation was observed which allowed the production of over 44 g ethanol 1−1 (82–87% of the maximum theoretical yield). Two optimal saccharification and fermentation conditions were identified for fermentation yield, pH 5.2 at 35°C and pH 5.5 at 32°C, which produced 47 g ethanol 1−1 in 144 h (0.48 g ethanol (g cellulose) −1). Although yields were reduced at the lowest cellulase levels tested (2–5 filter paper units (g cellulose)−1), ethanol production per unit enzyme was much higher.