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► Successful integration of gas stripping to two-stage process for butanol production. ► 160g/L butanol produced with pervaporation compared to 59g/L from gas stripping. ► Introduction of a “window of operation” for evaluating ABE processes feasibility. ► Processes with both in situ product removal and immobilization are more feasible.
Gas stripping and pervaporation are investigated for butanol recovery in a two-stage acetone–butanol–ethanol (ABE) fermentation process. The first stage is operated in a continuous mode and the second stage as a fed-batch. Gas stripping coupled to the second stage and operated intermittently enabled additional glucose feeding in the second stage and up to 59g/L butanol and 73g/L total ABE solvents in the condensate. Concentration of 167g/L butanol and 269g/L ABE in the permeate was measured in ex situ pervaporation experiments using a PDMS membrane at temperature of 37°C and pressure of 10mbars. The “operating window” tool is introduced to evaluate the feasibility of the existing ABE fermentations operated as continuous with cell recycle, as two-stages, with biomass immobilization or with integrated product removal. This tool enables the identification of the most favorable process configuration, which is the combination of cell immobilization and integrated product removal.