Anastasios J. Karabelas

An integrated process scheme is developed for valorizing filtered liquid digestates (FLD) from an industrial anaerobic digestion (AD) plant treating dairy-processing effluents with relatively low nutrient concentrations. The process scheme involves FLD treatment by nanofiltration (NF) membranes, followed by struvite recovery from the NF-retentate. An NF pilot unit (designed for this purpose) is combined with a state-of-the-art NF/RO process simulator. Validation of simulator results with pilot data enables reliable predictions required for scaling up NF systems. The NF permeate meets the standards for restricted irrigation and/or reuse. Considering the significant nutrient concentrations in the NF retentate (i.e., ~500 mg/L NH4-N, ~230 mg/L PO4-P), struvite recovery/precipitation is investigated, including determination of near-optimal processing conditions. Maximum removal of nutrients, through production of struvite-rich precipitate, is obtained at a molar ratio of NH₄:Mg:PO₄ = 1:1.5:1.5 and pH = 10 in the treated stream, attained through the addition of Κ₂HPO₄, ΜgCl₂·6H₂O, and NaOH. Furthermore, almost complete struvite precipitation is achieved within ~30 min, whereas precipitate/solid drying at modest/ambient temperature is appropriate to avoid struvite degradation. Under the aforementioned conditions, a significant amount of dry precipitate is obtained, i.e., ~12 g dry mass per L of treated retentate, including crystalline struvite. The approach taken and the obtained positive results provide a firm basis for further development of this integrated process scheme towards sustainable large-scale applications.

There is a need to develop facile methods for the determination of UV light extinction characteristics of photocatalysts. For this task, a novel technique is proposed, applicable to dispersed photocatalyst processes of practical interest. The technique is demonstrated by obtaining fairly extensive data sets of transmittance and extinction coefficients, using TiO₂ particle suspensions at various concentrations and pH values ~3, ~5, and ~8, with light lamps of different irradiation types (i.e., UVC and UVA), immersed in the medium. To estimate the light absorption coefficient, under various tested conditions, the simplified Kubelka–Munk model is employed. The results obtained, regarding both the total light extinction and absorption coefficient, are in accord with similar literature data. The demonstrated technique is considered useful for process development studies and the design of photocatalytic reactors.

Effective permeability K_P, the ultrafiltration coefficient (K_UF), the sieving coefficient (SC), and the loss/permeation of proteins (primarily albumin) are key parameters/specifications characterizing hemofilter (HF) performance. However, there are uncertainties regarding their determination. This work aims (a) to demonstrate that the co-current flow (of blood and dialysate) can lead to beneficial unidirectional filtration (from blood/plasma to dialysate) under a fairly uniform local trans-membrane pressure (TMP), unlike the presently employed counter-current flow; (b) to study the temporal evolution of key HF performance parameters under co-current flow, particularly during the important early stage of hemocatharsis (HC). Experiments with human plasma and BSA solutions in co-current flow mode (for which a fluid mechanical model is developed) show a fairly uniform local/axial TMP, which also improves the local/axial uniformity of protein membrane fouling, particularly under (currently favored) high convective flux operation. Due to incipient membrane fouling, a significant temporal variability/decline in the effective K_P is observed, and, in turn, of other parameters (i.e., the Kuf, SC, and permeation/mass flux M_m for albumin and total proteins). A satisfactory correlation of the albumin/protein mass flux M_m with permeability K_P is obtained, indicating strong inter-dependence. In conclusion, co-current flow, allowing for a fair local TMP axial uniformity, enables the acquisition of accurate/representative data on the evolution of HF parameters, facilitating their interpretation and correlation. The new results provide a basis for exploring the clinical application of the co-current flow.

This study describes the enzymatic production of second-generation biodiesel using low-quality acid oil as a substrate. Biolipasa-R, a commercially available and low-cost lipase, was employed for enzymatic transesterification. Response surface methodology was applied to optimize the enzymatic transesterification process. The optimal conditions for biodiesel production, which comprised 42% lipase concentration (per weight of oil), 32% water content (per weight of oil), a methanol to oil molar ratio of 3:1, pH 7.0 and reaction temperature 30°C, resulted in the highest fatty acid methyl ester (FAME) content (71.3%). Subsequently, the synergistic effect of two lipases with different regioselectivities under the optimum transesterification conditions was studied, aiming at the enhancement of process efficiency. The transesterification efficiency of immobilized Biolipasa-R was determined and compared to that of Biolipasa-R in its free form. The results revealed a good performance on FAME content (66.5%), while the recycling of immobilized lipase resulted in a decrease in transesterification efficiency after three consecutive uses.

This study aims to integrate a novel bio-purification process employing an engineered E. coli strain in the downstream processing of lactic acid (LA) fermentation broths from low-cost renewable biological feedstocks. Fermentation broth of candy waste and digestate mixture was used as a real biological feedstock. An engineered E. coli strain that selectively catabolize impurities without catabolizing LA was initially adapted on the biological feedstock, followed by shake flask experiments to prove the bio-purification concept. Scale-up and validation in a bench-scale bioreactor followed, before developing a semi-continuous membrane bioreactor (MBR) bio-purification process. The MBR bio-purification was assessed with biological feedstocks which simulated ultrafiltration or nanofiltration permeates. Incomplete removal of impurities and increased fouling was observed in the case of the ultrafiltration permeate. Contrarily, the nanofiltration permeate was successfully treated with MBR bio-purification, since low membrane fouling, 100% maltose and acetic acid removal, and no LA catabolism was achieved. MBR bio-purification as a post-treatment step in the downstream processing of LA was demonstrated as a promising technology for increasing the purity of LA solutions.

Excessive albumin losses during HC (haemocatharsis) are considered a potential cause of hypoalbuminemia—a key risk factor for mortality. This review on total albumin losses considers albumin “leaking” into the dialysate and losses due to protein/membrane interactions (i.e. adsorption, “secondary membrane formation” and denaturation). The former are fairly easy to determine, usually varying at the level of ~ 2 g to ~ 7 g albumin loss per session. Such values, commonly accepted as representative of the total albumin losses, are often quoted as limits/standards of permissible albumin loss per session. On albumin mass lost due to adsorption/deposition, which is the result of complicated interactions and rather difficult to determine, scant in vivo data exist and there is great uncertainty and confusion regarding their magnitude; this is possibly responsible for neglecting their contribution to the total losses at present. Yet, many relevant in vitro studies suggest that losses of albumin due to protein/membrane interactions are likely comparable to (or even greater than) those due to leaking, particularly in the currently favoured high-convection HDF (haemodiafiltration) treatment. Therefore, it is emphasised that top research priority should be given to resolve these issues, primarily by developing appropriate/facile in vivo test-methods and related analytical techniques.

Complete valorization of various wastes and effluents, with significant organic content, remains a great challenge in the pursuit of a circular economy. The approach based on anaerobic fermentation, leading to valuable biogas production, has been broadly accepted and employed as an attractive processing scheme. However, despite notable research efforts, complete valorization of the digestates (involving recovery of nutrients/by-products and full recycling/reuse of treated water) requires additional work for sustainable process development. This study aims to make a contribution in this direction by demonstrating a systematic methodology for valorizing the liquid digestate. The proposed membrane-based processing scheme involves UF-membrane pretreatment of the liquid digestate (for sludge separation) and subsequent NF/RO membrane treatment for reuse/recycling of the permeate; the concentrate, enriched in “nutrients” (phosphate and ammonium compounds), can be utilized for soil fertilization, with further conditioning/processing. By performing targeted laboratory experiments and advanced simulations, the membrane-based process was developed to a relatively high technology-readiness level, including a pilot unit design/construction and preliminary testing with satisfactory results. Through pilot testing in industrial environment, further process development and optimization will be pursued, towards practical applications. The demonstrated methodology is also considered appropriate for systematic development of membrane-based processes to valorize/treat a variety of similar effluents.

Extraction of intracellular lipids of the oleaginous yeast Yarrowia lipolytica has been systematically studied aiming towards a sustainable extraction process for lipid recovery. Selection of suitable industrial (bulk) solvents and extraction parameters that lead to maximization of lipid recovery are significant issues to be addressed, with industrial applications motivating this study. Biomass from fermentation of Yarrowia lipolytica (MUCL 28849) was used in small laboratory tests to assess different solvent mixtures (i.e., methanol/hexane, isopropanol/hexane, and methanol/ethyl acetate), implementing a systematic design of experiments methodology to identify near-optimum values of key extraction variables (i.e., polar/non-polar ratio, vortex time, dry biomass/solvent ratio) in regard to lipid yield (g lipids/g dry biomass). The methanol/hexane mixture exhibited the highest extraction yield in a wide range of experimental conditions, resulting in the following optimum parameters: polar/non-polar ratio 3/5, vortex time 0.75 h, and dry biomass/solvent ratio 40. Extraction tests on a fifty-times-larger scale (in a Soxhlet apparatus employing the optimal extraction parameters) confirmed the optimization outcome by obtaining up to 27.6% lipids per dry biomass (L/DB), compared to 12.1% L/DB with the reference lipid extraction method employing chloroform/methanol. Assessment of lipid composition showed that unsaturated fatty acid recovery was favored by the methanol/hexane solvent. Fatty acid composition was not affected by the increase in Soxhlet reflux cycles, whilst the lipid yield was notably favored.