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In this project, a novel bio-reactor technology in which reaction is coupled with product separation was developed to pilot/demonstration scale. Combining reaction with separation during a fermentation allows the fermentation of highly concentrated feeds and allows the fermentation of streams with high levels of salts/non-fermentable inhibitors. Simultaneous saccharification and fermentation of polysaccharides such as starch and cellulose can also be combined with ethanol separation in the Continuous Stirred Reactor Separator (CSRS). Application of the bio-reactor to various substrates was investigated on a lab scale with fermentation of raw starch, cane molasses, xylose, whey permeate and permeate mother liquor. Flocculating yeast strains for high density sucrose/glucose fermentation were selected and adapted to form fast settling pellets. A strain of K marxianus capable of fermenting high salt permeate mother liquor was also selected and adapted. A low energy solvent ethanol recovery system was developed for ethanol recovery from the vapors leaving the reactor/separator. This Solvent Absorption/Extractive Distillation (SAED) process gives a low energy method for purifying the ethanol to an anhydrous product. The amount of energy needed to recover an anhydrous ethanol product from a CSRS stage running at 8% ethanol was calculated to be under 8,000 BTU/gallon. This process may also have further application in VOC (volatile organic carbon compounds) removal from air streams. During this project, a 24,000 Liter CSRS was designed, fabricated, installed, and operated at a small batch ethanol plant (Permeate Refining Inc) in NE Iowa. The reactor was operated on a semi-continuous basis over a period of 18 months. A Solvent Absorption Extractive Distillation (SAED) system was also recently completed and installed at the Permeate Refining Inc. site for ethanol recovery/dehydration

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A low-energy continuous reactor-separator for ethanol from starch, whey permeate, permeate mother liquor, molasses or cellulosics. Project final report, April 1, 1994--February 28, 1997