Biotechnology  training

The Application of 3D Printing and ICT for Green Products and Processes

B A S I C  L E V E L

3D printing creates a tangible object by adding successive layers representing cross-sections of the object.

Contents

 

3D printing principles of operation

Definitions

3D printing creates a tangible object by adding successive layers representing cross-sections of the object. The simplest allusion there is making a layered cake (Fig. 1), only the layers are numerous and typically very thin, only about 1/5 of the millimetre.

A.

B.

Figure 1. Layers and layering in 3D printing.
A – Layered cake, representing the basic principle of 3D printing. Source: Caroline’s Cakes – Own work, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=12799030
B – 3D printed chocolate castle. Source: FM1418, CC BY-SA 4.0 <https://creativecommons.org/licenses/by-sa/4.0>, via Wikimedia Commons

3D printing is close, both in process and material, to routine ink-and-paper 2D printing.

Nevertheless, in typical 2D printing only an illusion of depth is created using perspective and colour or grayscale, whereas 3D printing creates tangible 3D objects. These may have a myriad of purposes, from rapid creation of prototypes for research and industry to printed objects for everyday or special use; machine parts; custom-made culinary items such as the chocolate castle presented in Fig. 1B; printed implantable materials for the regenerative medicine, and, potentially, ‘replacement parts’ for the human body; and novel forms of art.

A basic desktop 3D printer with PC is presented on Fig. 2.

 Figure 2. LulzBot TAZ (FAME 3D, Fargo, ND, USA), an open-source 3D printing machine based on FDM technology. Source: Ochs, J. – College, CC BY 4.0, https://commons.wikimedia.org/w/index.php?curid=59898086

Typically, the process of 3D printing of an object is additive (hence 3D printing is also known as “additive manufacturing”). It is achieved by depositing layers upon layers of a printable material (commonly termed as ‘3D ink’) until the object is complete.

3D printed objects need not to be solid within (though they might be). They may contain any type of cavities that has been set up in the data file used for printing, because every layer represents a cross-section at a specific level in the manufactured object.

A short time-lapse gif illustrating the basic process of 3D printing may be viewed here:

https://upload.wikimedia.org/wikipedia/commons/e/ed/Robot_3D_print_timelapse_on_RepRapPro_Fisher.gif

The most commonly used 3D printing nowadays is fused deposition modelling (FDM), although other types are rapidly gaining popularity.

Brief history of the field

It is commonly believed (and cited) that the very idea of 3D printing did not exist until the 1950’s when the sci-fi writer Raymond F. Jones published a short story describing use of ‘molecular spray’ directed by information from a pre-recorded data tape. Nevertheless, the possibility for controlled hands-off creation of a complex tangible object following virtual directions was foreseen about 50 years earlier by the great visionary Joseph Rudyard Kipling in his children’s story ‘How the camel got its humph’. The first attempt of 3D printing, however, did not arrive until the 1970’s, and it did entail both creation and removal of objects. Specifically, this was the patented ‘Liquid metal recorder’ by Johannes F. Gottwald (US3596285A) using electrically conductive metallic ink propelled under pressure against a surface.  The melted ink would flow at printing temperature but will solidify as it contacts the surface, then it could be removed by increasing the temperature above the melting point, enabling the reuse of the ink and the surface for further use.

As with most novel concepts, the idea of 3D printing did not meet early success. In the early 1980’s, a patent was filed by Hideo Kodama in Japan for additive manufacturing of ‘stereoscopic figure drawing device’ using UV-hardening polymer where the areas of UV irradiation were controlled by pre-set masking pattern (JP S56144478 A). Despite prompt publication of his results, Kodama could not raise much interest in his project and it was subsequently cancelled.

Four years later in France the same fate met the concept for stereolithography presented by Le Méhauté, de Witte, and André and their subsequent patent for the process, purportedly “for lack of business perspective” [http://www.primante3d.com/inventeur/].

Around that time the American William E. Masters filed the first of his series of patents (namely, the patent for ‘Computer Automated Manufacturing Process and System’ (US 4665492) that eventually laid the foundations of 3D printing as we know it.

Only two years later the American Charles Hull was granted a patent for his own ‘apparatus for production of stereolithographs’ (US4575330A), founded his own company and eventually released the first ever commercial 3D printer, the SLA-1, in 1987. The patent for the most commonly used in present day type of 3D printing – the FDM – was filed in 1989 in the US by S. Scott Crump (US5340433A) and the first FDM equipment was released in 1992. Hull also gave probably the simplest and yet complete definition of 3D printing to date, namely: “A system for generating three-dimensional objects by creating a cross-sectional pattern of the object to be formed…“, in the description of his patent for ‘Method for production of three-dimensional objects by stereolithography’ (US5174943A).

Advantages and disadvantages of 3D printing as a method of manufacture

There are numerous advantages to using 3D printing rather than traditional methods of manufacture. Some of these are listed below:

  1. Complex design

Since the object is not cut out of a block, 3D printing may handle different designs with very complex structure.

  1. Possibilities for last-minute modifications.

The design is easily modifiable and a variety of different prototypes of an object may be rapidly manufactured and tested.

  1. Easy and rapid tailoring of design to suit individual needs

Unlike traditional methods of manufacturing, the introduction of needed modifications concerns the data files rather than the machine itself and may be carried out with very little notice.

  1. Yields lightweight and durable objects

That depends on the material used, but most commercial 3D printers use plastic, although use of other materials such as plaster, metal, metallic alloys, etc. is also possible.

  1. Relatively rapid production on smaller scales

Depending on size and complexity of the design, most objects may be manufactured within hours, although larger ones may take more time.

  1. Low (compared to traditional methods of manufacture) waste of material

Again, since there is no cutting, drilling or boring, the wastage of material is negligibly low. An exception is powder-based 3D printing where excess powder is usually lost.

  1. May be more cost-effective than traditional methods of manufacture

That depends largely on the material and the process used for manufacturing.

  1. The ease of access of researchers, industry and the public to 3D printers is increasing all the time

At present, gaining access to a 3D printer is relatively easy, although there is typically a queue of customers waiting to use the equipment. The waiting time depends on the make and model of the printer, the institution it is been hosted by and the type of use the 3D printer is being put to.

  1. May be more environmentally friendly than traditional methods of manufacture

Again, this depends of the type of material used, the intensity of use and the maintenance of the equipment. Discarded objects, wastewater and small particles emission, however, may pose a problem (see below).

  1. Special uses of 3D printing in reparative and regenerative medicine (3D-bioprinting)

Significant research and development effort is currently invested in developing a new generation of implantable materials. Instead of simply providing inert support, friction-friendly surfaces and bridging between intact portions of damaged tissue (which are the main functions of most implantable materials of today), the new materials may also presumably become a part of the natural habitat of the cells of the damaged tissue. Such materials may be purely of artificial origin but resemble biological tissue (biomimicking materials). One potential use of 3D bioprinting is providing optimal 3D environment of implantable materials for colonisation with living cells from the surrounding tissue. Another very promising application of 3D bioprinting is the potential for creating living tissue (and, potentially, functioning replacement organs and various ‘spare parts’ for living bodies) using living cell-based materials as printable ‘bioink’ (see below).

Potential limitations of 3D printing compared to traditional methods of manufacture may be:

  1. Limitations imposed by errors in design

While there are virtually no limits to potential design types, a single error in the design may lead to manufacture of unusable object/s. While some of the errors of design may be minimised by finishing, it may increase the time to process an order and may decrease the durability of the object.

  1. Limitation imposed by material

Most 3D printers use as ink some type of plastic polymer, although some may also print with metal and metallic alloys. Objects that are produced and then discarded may pose a problem if the material is not biodegradable and/or recyclable. Printing and post-processing may result in emission of particles that contribute to environmental pollution and may have carcinogenic potential when breathed and ingested.

Issues concerning the material for bioprinting may be aggravated further in 3D bioprinting where viability of living cells and biocompatibility is of utmost importance.

  1. Limitations imposed by size of the object

Very large objects may be difficult to manufacture in one piece. Different sections of the object may need to be printed separately and then assembled together. This may increase the time and costs for manufacturing and may decrease the durability of the object (see below).

  1. Integrity of the produced objects may be compromised

This may be an issue especially when parts are produced separately and then assembled together. Under physical stress, the layers may come apart (especially in FDM-produced objects) and complex objects may be brittle and delicate to handle.

  1. 3D -printed objects may need finishing

Essentially, this makes no difference with traditional manufacturing. Again, this may increase the time and costs for manufacturing.

  1. Cost generally not reduced with larger batches

In traditional manufacture, when the equipment is working at full capacity, the costs of manufacture per object or per batch generally tend to be lower. This is not the case with 3D printing and large volumes of manufacture may be costly.

  1. Copyright Issues

Quite self-explanatory. The issues entail not only the manufactured objects but also the software, hardware and processes used for manufacturing them.

  1. Ethical issues, concerning mainly the 3D-bioprinting of living tissue
  2. May indirectly cause reduction of jobs in the traditional manufacturing sector.

Basics of 3D printing processes and materials

Types of 3D printing processes

Many types of 3D printing technologies currently exist. What they all have in common is that tangible objects are created by deposition of successive layers rather than cutting out the object out of a solid block and/or drilling, milling of boring. Every consecutive layer represents a cross-section of the object under construction. The process is controlled by a computer equipped with designated software for creation of design files, file processing and object printing (see further for details).

Several of the most common technologies for 3D printing are briefly presented below. This list is by no means exclusive.

  • Liquid or semisolid ink-based technologies: SLA, FDM, EXT, PolyJet

All these three are based on deposition of layers of liquid (more or less viscous) ink that are then fused to one another by heat or directed light beam (emitted by an UV lamp or laser). The ink may be extruded from a nozzle or, when it is of higher consistency, fed from a spool.

  • Stereolithography (SLA)

Stereolithographic 3D printing is perhaps the most easily comprehended of all 3D printing technologies, probably because photopolymerisation is commonly used in modern dentistry. Basically, stereolithography is light-curing of photosensitive material extruded in a layer-by-layer fashion onto a movable platform. The wavelength of the light source is most often in the UV range but other wavelengths may also be used. SLA materials polymerise via free-radical polymerisation.

Different parts of the object may need to be supported in the making of the object so as to avoid the collapse of the whole structure.  Successive layers are made to adhere to each other by cross-polymerisation of the just polymerised layer to the newly deposited layer where polymerisation is still incomplete. Since polymerisation may take some time to complete, the printed object usually needs some time in order to harden, then supports are removed (if any of these remain after the last layer has been deposited), then a final post-processing may take place.

A SLA printed 3D model is presented in Fig. 3.

Figure 3. Stereolithograph of bony labyrinth of the inner ear in man. Source: Didier Descouens, CC BY-SA 4.0 <https://creativecommons.org/licenses/by-sa/4.0>, via Wikimedia Commons

The ink used in SLA-based printing is usually liquid in its unpolymerised form. It is mostly epoxy or acrylic-based, although trimethylene carbonate, polycaprolactone, and polylactide-based inks may also be used. Use of such materials yields printed objects with significant rigidity that are, nevertheless, quite fragile. Thus, SLA is quite suitable for rapid prototyping and research purposes (e.g., tissue engineering scaffolds) but not for objects that need to be durable. SLA has quite high resolution (minimal layer thickness is 50 μm) and therefore is very reliable when fine detail is crucially important.

Objects created by SLA may be light-sensitive and may tend to disintegrate over time, especially when kept in light environments.

Solvents are rarely used in SLA printing, therefore, the risk of escape of fumes to the atmosphere is low. Due to the fragility of SLA-printed objects, nevertheless, discarded objects may present an environmental hazard. The use of UV calls for special precautions in order to avoid accidental exposure of surfaces, objects and operators to the curing beam. Some of the inks used for stereolithography may have significant neurotoxic and carcinogenic potential. Also, UV-mediated formation of ozone may need to be considered.

  • Fused deposition modelling (FDM), also known as fused filament fabrication (FFF)

At present, this is the most commonly used technology for 3D printing. FDM technology is based on extrusion of a filament of thermoplastic ink fed from a spool through a moving heated printer nozzle. The ink within the nozzle is heated just above its melting point and is extruded in semi-solid form that solidifies almost instantly after a layer is deposited.  The object is built upon a moving platform that is gradually lowered as the structure grows (Fig. 4).

Figure 4. Working principle of FDM printers. Source: By Gringer – Own work, CC0, https://commons.wikimedia.org/w/index.php?curid=73614647.

The minimal layer thickness for FDM is 100 μm. The most commonly used ink materials for FDM are acrylonitrile butadiene styrene (ABS), polylactide (PLA) and polyethylene terephthalate glycol (PETG). Others, such as polyphenyl ether (PPE), polyurethane (PU), polyethylene terephthalate glycol (PETG), polyphenylsulphone (PPSP), polycarbonate (PC), polyetherimide (PEI), polyether ketone (PEEK), polyamide (PA, commonly known as nylon) are also in use.  Polyvinyl alcohol (PVA) may also be used, but since it is hydrophilic, PVA is most commonly used for manufacturing easily removable supports for a structure printed using other type of thermoplastic ink.

The heatable ink for FDM may be also in the form of rods or granules. A variation of FDM uses cold extrusion of unheated ink, usually supplied as slurry or paste.

A FDM printer with spool of filament is presented in Fig. 5.

Figure 5. PRUSA i3 MK2 FDM printer (Prusa Research, Prague, Czech Republic) with spool and a completed object. Image source: Wikimedia Commons, http://reprap.org/wiki/File:Prusai3-MK2.jpg.

Being relatively low-cost, FDM is especially popular among hobbyists and desktop model makers. In addition, FDM is commonly used for rapid prototyping in engineering, in manufacture of high-performance parts and machinery, in education and in art.

The objects manufactured by FDM are significantly more durable than these produced by SLA and with very good quality of detail reproduction. Different quality FDM inks yield objects with different properties with regard to durability, rigidity and flexibility (see below).

Disadvantages of 3D printing by FDM are mainly related to potential environmental hazards (use of solvents, emission of small particles during post-processing, and the fact that the discarded objects are quite durable).

  • Semi-solid Extrusion (EXT) 3D Printing

EXT 3D printing is another technology based on extrusion. The ink is usually polymer-solvent mixture with the consistency of paste. EXT materials are not thermoplastic, allowing for printing at low temperatures. Again, the object is built upon a moveable platform.

EXT is commonly used in research (e.g., tissue scaffolds) and for pharmaceutical purposes (targeted and/or timed delivery of drugs). Biosafety is ensured by using inks based on polyvinylpirrolidone, polyethylene glycol, methycelullose, hydroxypropyl methylcellulose, polycaprolactone and other materials. EXT is one of the potental approaches for priting living tissue from a hydrogel containing living cells.  Also, extrusion using viscous foodstuff paste (icing, chocolate, jelly, etc.) is a preferred method for 3D printing for the food industry (Fig. 6).

Figure 6. Extrusion printing for the food industry. Source: Grup de recerca de la Universitat de Columbia – https://www.creativemachineslab.com/digital-food.html, CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=84202502

Since the material for EXT 3D printing is neither photosensitive nor thermoplastic, layers do not typically solidify instantly. Thus, newly printed 3D object may need time to set and/or dry after completion as the solvent/s evaporate. It may also be prone to warping, shrinkage and deformation. Minimal layer thickness for EXT is 800 μm. This low resolution is inherent to semi-solid extrusion techniques.

  • PolyJet

PolyJet is another liquid-based 3D printing technology. Like SLA, it is based on layer-by layer UV-curing of a photosensitive polymer. The ink, however, is released from the printer head in droplets that accumulate on a building platform as directed by a designated software. PolyJet technology allows for mixing of inks, resulting in greater variety of properties for the manufactured objects.

PolyJet inks encompass great diversity of materials. Among the commonly used are ABS (different modifications), the related compound acrylic styrene acrylonitrile (ASA, more heat-resistant and UV-resistant than ABS), polycarbonate and polyetherketone ketone (PEKK). Various photosensitive materials that are used in other liquid-based 3D printing technologies may be used in Polyjet as well. There are also the specifically designed series of Vero PolyjetTM inks patented by one of the market leaders in 3D printers and materials, Stratasys. Prominent members of biocompatible PolyJet materials are MED610 and MED620, a methacrylate-based resin used in the medicine and dentistry for rapid prototyping.

Advantages of using PolyJet are the relatively high resolution (minimal layer thickness is 160 μm, allowing for creation of stable structures with complex geometry and exquisite detail) and the great variety of properties (strength, flexibility, colours, etc.). The disadvantages are (beside the common drawbacks of 3D printing described above) the inherently high levels of emission of small particles, the use of UV light and the emission of toxic fumes when curing objects manufactured with some types of inks (e.g., ASA). Printed objects may need post-processing and may be photosensitive.

  • Powder based (PB) 3D printing

PB 3D printing technology is based on deposition of successive layers of powdered material and their binding by means of a liquid binder solution or fusing using other methods (see below). The powder is deposited in a powder bed or produced by a powder jet and is then sprayed or jetted with binder, irradiated with light or heated in order to achieve integrity of the object.

Minimum layer thickness may vary greatly in PB 3D printing and layers may be as thin as 20-30 µm with some materials. This very high resolution allows for creating very complex structures with exquisite detail.  Generally, however, the layer thickness is about as 200 µm.

Powdered materials are usually produced by cryogenic grinding in a ball mill at a temperature that is below the glass transition temperature of the material. The grinding may be using low-temperature gases (liquid CO2 or liquid nitrogen – dry powdering) or a mixture of low-temperature gas and organic solvents (wet grinding). In its simplest form, PB 3D printing is achievable using materials such as powdered starch or gypsum bound together with glue (Fig.7). Dyes and plasticiser compounds may be added to the binding solution in order to achieve the desired properties.

Figure 7. Rapid prototypes manufactured by powder-based 3D printing. Source: S Zillayali, CC BY-SA 3.0 <https://creativecommons.org/licenses/by-sa/3.0>, via Wikimedia Commons.

Disadvantages of PB-based 3D printing are related, on the one hand, on the physical properties of the objects created with this type of technology, and, on the other hand, to the need for post-processing in order to achieve maximum quality. Objects built by PB 3D are inherently highly porous and, therefore, exhibit poor mechanical resistance and may be fragile.

PB-printed objects invariably need time for evaporation of solvents. Post-processing is usually necessary in order to remove excess powder (hence a certain amount of material is always wasted) and to improve the properties of the manufactured objects (strength, colour, polish, etc.). Emission of potentially harmful small particles is a serious concern in all PB-based technologies for 3D printing.

PB has been successfully used in research, dentistry and medicine for manufacture of implants and fabrication of drugs with specific pharmacokinetic properties such as rapidly disintegrating tablets, drugs with delayed, pulsatile or extended release. Biosafety of these dosage forms is ensured by using methacrylate or ethyl cellulose as carriers of the bioactive substance.

  • ColorJet

ColorJet is not exactly a technology, but a brand of powder-based 3D printers and supplies manufactured in India. It offers one of the simplest solutions in PB 3D printing. The material used is most commonly white plaster powder although plastic may also be used (e.g., the company’s own patented Visijet C4 Spectrum powder). The material is layered onto a movable platform and bound by adhesive. The binder may contain different dyes, conferring different colours to the model being built.

ColorJet is most commonly used for rapid prototyping.  Minimum layer thickness is about 100 μm but may vary with different materials.

Colorjet provides a budget solution where durability, brittleness and porosity are not of great concern. Therefore, it is an acceptable solution for manufacturing of models for education, research and commercial purposes (e.g., sales models) and in art. A similar process using edible powder and binder solution is commonly used in the food industry to create customised sweets and dishes.

Objects printed by ColorJet may need extensive post-processing. Plaster structures need to harden after their completion and the solvents must evaporate. Then the object is polished and impregnated with another type of binder (usually acrylic) to achieve maximum strength and to decrease surface porosity. Fumes of solvent may be an environmental concern, as well as small particles emission.

  • Selective Laser Sintering (SLS)

SLS shares the common characteristics listed above for PB 3D printing. In SLS the powdered material is layered and a directed light beam generated by the printer head partially liquefies and fuses the layers to one another as the structure is being built in a process commonly termed as necking (Fig. 8).

Figure 8. Formation of a ‘neck’ between two fusing layers (arrows). Source:  Mendoza.755 – Own work, CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=76830144

Minimum layer thickness in SLS is about 100 μm.

SLS works very well with materials with high melting point and is therefore most commonly used with metal-based inks. Plastic (polyamide, polycarbonate, polystyrene and others), thermoplastic resin, glass and ceramic powders may also be used. SLS is often used for rapid prototyping in research (especially tissue scaffolding) and in dentistry. As of now, the opportunities for development of SLS-based technology in the pharmaceutical industry are quite limited as the radiant energy and the heat generated in the course of layer fusion may seriously compromise the properties of the bioactive substance.

Powdered foodstuffs (cocoa, sugar, etc.) may be used for 3D printing in the food industry.

  • Selective laser melting (SLM)

SLM is often viewed as a derivation of SLS, as it is used mainly for printing with metal and metallic alloy powders. Nevertheless, while SLS printer head laser generates just enough energy to fuse the layers to one another, SLM uses a high-power laser that may melt completely a block of metal and then let is set in the desired shape similarly to casting. SLM produces objects that are significantly less porous than SLS and have better mechanical resilience due to homogenous internal structure. A disadvantage of SLM is that objects require polishing after their completion as it generates structures with increased surface graininess.

Electronic beam melting (EBM) is a subtype of SLM that uses similarly and electronic beam to melt metallic powders.

  • Selective heat sintering (SHS)

SHS is based essentially on the same principle as SLS but the ink is thermoplastic and, respectively, the layer-by-layer fusion is obtained using heat generated by a thermal printer head. The most common material used in SHS is plastic (specifically, polyamide, but other polymers may also be used).

All objects produced by SLS or SHS are prone to warping and shrinkage.  Mechanical properties of the printed objects may be inconsistent from object to object as well as from batch to batch. SLS and SHS-made objects often require post-processing, such as removal of supports and coating with sealer agents in order to decrease surface porosity.

  • Multi jet fusion (MJF)

MJF 3D printing is a hybrid of the ColorJet approach (use of chemical binders) and SHS (use of heat) that works mainly with polyamide (Nylon). Basically, finely grained polyamide powder is layered onto a powder bed, sprayed or jetted with binder and is then heated selectively as instructed by a pre-programmed software. Minimum layer thickness is about 80 µm. When the object is complete, post-processing takes place (removal of excess powder, polishing, etc.). MJF produces objects that are less porous and therefore more consistent in their mechanical properties than SLS or SHS and has better capacity for reproduction of fine detail. Surface finish is also better with MJF. Chemical fumes and generation of small particles is a concern, as with all PB 3D technologies.

Post-processing requirements for different 3D printing technologies

Not all objects made by 3D printing require post-processing. Nevertheless, many do need more work after the structure is complete. Whether an object needs post-processing depends on the material, the technology, the desired aesthetical or mechanical properties, and other factors.

Generally, there are several types of post-processing of 3D-printed objects:

  • Setting and/or hardening

Almost all 3D printed structures need some time after their completion in order to mature and achieve optimal mechanical properties. Objects made by extrusion-based processes (especially those that use semisolid mixtures of polymer and solvent) and powder-based processes using materials that have been impregnated with binder solutions are especially sensitive to mechanical stress immediately upon completion. In this case post-processing includes the time for solvent evaporation and hardening. In some cases (but not always), this may be facilitated by increase of the ventilation in the premises where completed objects are kept.

  • Supporting of unfinished structures

Complex structures containing overhangs may not be stable during manufacture without supports, albeit temporary. These supports need to be removed after the structure is complete, increasing the time to completion and the production costs (especially if this involves manual labour). In SLA-based 3D printing, supports for a structure printed with thermoplastic ink are most commonly made of polyvinyl alcohol. Since it is soluble, such supports may be easily removed during post-processing with a jet of water. The latter, however, requires plumbing, access to water and decontamination system for wastewater (which may increase the costs as well). Temporary support structures in SLS and SHS are usually made of unsintered material that may be vacuumed out or air-blasted away.

  • Removal of excess material

This is crucial for object made by most powder-based methods. Excess powder needs to be removed using vacuum, air blast or a jet of water (again, this raises concerns about water supply and decontamination of wastewater).

  • Polishing

Polishing is a must for improving of the mechanical characteristics of mechanical parts (especially those subjected to movement and friction) and objects with increased graininess of the surface (such as those produced by selective laser melting). Objects with aesthetical properties may also need polishing.

  • Sealing of surface pores

This is an important post-processing step for technologies that yield objects with increased porosity, such as SLS or SHS. Surface pores may be sealed with impervious coatings such as cyanoacrylate coatings or by hot isostatic pressing.

  • Painting

This is not commonly needed, as most 3D printing processes use differently coloured materials or differently coloured binders.

Which process for which? Basic considerations when selecting 3D printing technology suited for a particular application

While all 3D printing technologies may have overlapping applications (e.g., rapid prototyping), there are factors that may weigh in when a 3D printing technology is selected for a particular project or a specific industrial solution. Main considerations are:

  • Type of material that may be used to print an object. Many 3D printers on the market may use a variety of different materials. Architectural, sale and exhibition models as well as models made for educational purposes may conveniently be created by ColorJet, SLA and FDM technologies that use plaster or different types of plastic. Small desktop machines that serve hobbyists and artists are usually based on FDM technology. SLS/SLM and SHS are usually employed when the objects must be made from metal and metallic alloys.
  • Availability of 3D printing machine. Usually, orders for a particular machine are queued and work in a ‘first come, first served’ fashion. In regions where 3D printers are hardly available, this factor may be of prime importance, prevailing over the type of material.
  • Availability of material. Plastic is versatile, available and, except for high-performance polymers, relatively cheap, while metal may be more costly.
  • Costs for production per object. These are related to the technology used for creation of objects, the material used and the needs for post-processing. It was already mentioned that, unlike casting, scaling up in 3D printing does not always bring the unit price down. The price per object includes not only the costs for manufacturing but also the post-processing costs (if it is needed) as well as the costs incurred by measures for decreasing environmental pollution. Among commonly used PB technologies, SHS is a more budget-oriented solution than SLS as purchase and maintenance of a thermal printer head is generally less expensive than a laser printer head. Objects manufactured by SHS are therefore generally cheaper that those made by SLS and the process may easily be scaled down for small-sized orders.
  • Rapidity of manufacture, including post-processing and the time for queueing of orders. Small objects may be printed in a matter of minutes to hours. The time for printing increases with the size of the objects to a whole day and, ultimately, with very large objects, up to a several days, although the latter is rare. Post-processing times may also be a concern. Extrusion technologies does not typically need finishing, but the object may need time to set and harden. ColorJet-made objects need time for drying and setting. Powder-based technologies almost invariably need time for post-processing and it increases the costs as well as the time for manufacturing,
  • Properties of the end product (mechanical properties, aesthetical value)

Plastic 3D printing ink may come in many different varieties with different mechanical properties. Depending on the purpose of the use of the object, the preferences may be for plastic (lightweight and, at the same time, durable, easily dyed, easily polished, thermo-and photocurable) or for metal (resilient, resistant to UV and heat, colouring and polishing may need special equipment and processes).

Among the plethora of varieties of plastic, different polymers with different mechanical resilience are available. Generally, SLA printing allows for finely polished structures with exquisite detail that are, nevertheless, quite brittle. It is therefore unsuited for applications where durability is crucially important. FDM yields significantly more durable objects than SLA, yet there are different grades of mechanical resilience depending on the material used. Generally, PVA, ABS and PLA are ”commodity” inks for FDM. These are relatively cheap but the resulting objects are prone to warping. Objects printed with PLA are also quite brittle. ABS-printed objects are photosensitive. Use of polyurethane yields parts with significant degree of flexibility. Next step in FDM quality is PC, PETG and PPE. These materials are used mainly as engineering materials for manufacture of mechanical parts and tools. PETG is also food-safe. High-resistance FDM inks are PEI and PEEK which are used for parts and devices that need to exhibit very high resistance, such as moving and/or strain-bearing parts and when thermal stability is crucial. All 3D printed objects might be prone to delamination under stress, but PEEK printed objects exhibit excellent layer-to layer adhesion and are therefore very durable. It is, however, quite expensive, and as the melting point is higher than of the other FDM inks, the printer needs to have the capability for heating the nozzle to high temperatures.

3D printed drug dosage forms and tissue scaffolding have specific requirements that are generally met by extrusion methods (especially semisolid extrusion such as EXT) and some of the powder-based technologies (but not these that require large amounts of radiant or infrared energy such as SLS and SHS). As minimal layer thickness for EXT is almost 1 mm, the printed structures are coarser and less detailed.

Powder-based methods have very high degree of resolution and therefore confer better reproduction of fine detail. This is especially true for SLS (it, however, works mainly with metallic powders) but MJF (works readily with plastic) also compares favourably in terms of resolution.

The structures produced by most PB technologies are also durable (except for ColorJet-printed plaster objects) but porosity may compromise their mechanical properties. When the latter is a serious issue, SLM may be a solution, provided that proper post-processing is carried out.

  • Environmental concerns (related to manufacture or post-processing or the biodegradability of discarded objects).

Extrusion-based and some of the PB technologies generate solvent fumes. Powder-based technologies generate large amounts of small particles. All these have significant potential harmful effects and need to be filtered out and/or decontaminated.

Commonly used software for 3D printing

3D printing uses previously collected data that has been stored on a digital information carrier. In the course of 3D printing of a complex object, the momentary changes in the pattern of deposition of the ongoing layer are dictated by the information of specific cross-sections in the digital file representing how exactly the structure must look like at this particular point. Thus, structures with simple patterns may be represented by fewer cross-sections while digital files for structures with intricate patterns ought to contain more cross-sections, indicating where and how the structure is altered. Every cross-section represents a closed polygon and corresponds to a different position along the z axis. Cross-sections must not overlap or intersect and, at best, must be without voids in between. Small discrepancies may be cleared out by the software without significant shape and structure alterations.

Computer-assisted design (CAD) images are most commonly used for 3D printing. Those may be the conventional 2D DWG images generated by AutoCAD although these need to be converted to 3D by designated software, e.g., Sketchup Pro. Stereolithography file format (Standard Tessellation Language, STL) was the first to be specifically designated for additive manufacturing. It was developed and adapted for use in the 1980-ties by 3D Systems, a company founded by Charles Hull, the inventor of SLA. Apart from AutoCAD, commonly used CAD software capable of exporting or converting data to STL format are Alibre, Mechanical Desktop, I-DEAS, SolidDesigner, ProE and others. Online converters are also readily available, such as AnyConv (https://anyconv.com/stl-converter/).

Images generated by a 3D scanner or by photogrammetry of a typical 2D digital image (taken by a digital camera) may also do for additive manufacturing. Depending on the source of the data for the object, the final result may be more or less true to the initial image.  CAD images usually result in objects with significantly less errors than other types of digital data. These errors may be corrected later.  There are many different brands of software for photogrammetry, mainly Microsoft Windows-based (Zephyr3D, PhotoModeler, PhotoSynth and others) but there are some may use other operating systems such as Linux and MacOS (e.g., Pix4D Mapper, Metashape, OpenDroneMap and others). A detailed list of commonly used photogrammetry software with their basic characteristics may be viewed here:

https://en.wikipedia.org/wiki/Comparison_of_photogrammetry_software

Online tools for photogrammetry are also available, such as the mentioned above AnyConv (https://anyconv.com/stl-converter/).

3D printing design guidelines

In order to print an object, if a STL file is not available, it must be output from a piece of software such as AutoCAD or others (see above). Most professional 3D-modeling software is proprietary, but free software is also available, mainly for education purposes for beginners in the field and for hobbyists (FreeCAD, 3D Slash, TinkerCAD, Vectary, SketchUp, Leopoly, Sculptris, Rhinoceros and others). Then the resulting STL file is used by another piece of ‘slicer’ software, such as Repetier, OctoPrint, Z-Suite, Tinkerine Suite, Cura, PrusaSlicer, Simplify3D and others to generate a file containing series of thin layers. The resulting file is used by the 3D printer host to generate a 3D object. Some pieces of slicer software function also as printer hosts, such as Cura, 3DPrinterOS, OctoPrint, MatterControl and others. While most professional 3D modelling software is usually stand-alone, free software may be available as a plugin and is much more likely to be available for operating systems other than Windows.

STL files contain raw mesh data based on triangulations of the surface of CAD models. Thus, the surface of every facet of the object is represented by a polygon mesh that must conform to a set of rules. The basic rules are four, namely:

The ‘vertex to vertex’ rule – each triangle must share 2 vertices with its neighbouring triangles;

The ‘right-hand rule’ – the vertices must be listed in counter-clockwise fashion;

The ‘pointing outwards’ rule – the direction of normal vector should point outwards;

The ‘all-positive rule’ – all the coordinates of the triangle vertices must be represented by positive numbers.

An example may be viewed in Fig. 9.

Figure 9. A polygon mesh representing a 3D image of a dolphin. Source: Chrschn, Public domain, via Wikimedia Commons.

STL files may store information in binary encoding or in ASCII encoding. Files in binary are, generally, smaller and may be easily shared, while ASCII files are used to manually read and check the STL file, e.g., when testing new CAD interfaces.

Complex objects may be a challenge to STL files as there are too many surfaces to be taken in to account in the calculations. In addition, the early STL files had very limited properties for representing colour, texture, material and internal structure (although this was resolved later). Some types of software, such as the prototypic AutoCAD may only export designs of solid objects to STL. Non-adjoining surfaces (e.g., containing gaps or overlaps) are difficult to process or adapt in STL files and would not print. Thus, in 2006 an improved version of STL formats was released that eventually was transformed in another, more versatile CAD file format, the Additive Manufacturing File format (AMF). Nevertheless, many 3D printers used today, especially those that work in the small scale, will use STL files.

AMF files can readily represent internal structure using use face-vertex polygon layout and curved triangles to define a discrete unit of volume of material. Multiple volumes may be specified for a single object. AMF files also contains information about the material, the colour and texture of the printed object or its parts and the order for printing.

Jonathan Hiller, one of the inventors of the AMF file format hosts a detailed and user-friendly site providing CAD software or 3D modelling and tutorials: https://sites.google.com/site/jonhiller/software.

Free architectural CAD drawings for AutoCAD and 3D modelling software are readily available on the Internet, e.g. https://www.arcat.com/, https://www.tinkercad.com/, https://www.sketchup.com/ and others. A free 3D CAD image is presented in Fig. 10.

Figure 10. A 3D CAD model for use in 3D printing. Source: OKFoundryCompany from Richmond, USA, CC BY 2.0 <https://creativecommons.org/licenses/by/2.0>, via Wikimedia Commons.

Free STL files, 3D printer files and 3D printer designs are available for use from www.thingiverse.com, www.youmagine.com, www.myminifactory.com, https://library.zortrax.com/, https://www.cgtrader.com/, https://cults3d.com/en, https://www.youmagine.com/ https://www.turbosquid.com/Search/3D-Models/free/stl,  and other sites.

STL editor software is available for multiple sources such as https://www.meshlab.net/, https://www.blender.org/, https://www.freecadweb.org/, https://www.3dslash.net/index.php, https://www.sketchup.com/, and others.

Test: LO2 Basic level

Welcome to your LO2-basic level questions

References

  • Kodama H. 1981. Automatic method for fabricating a three-dimensional plastic model with photo-hardening polymer. Rev Sci Instrum, 52(11): 1770–73.
  • Melchels FP, Feijen J, Grijpma DW. 2009. A poly(D,L-lactide) resin for the preparation of tissue engineering scaffolds by stereolithography. Biomaterials, 30(23-24):3801-9.
  • Shelby A. Skoog, Peter L. Goering, Roger J. Narayan. 2014. Stereolithography in tissue engineering. J Mater Sci Mater Med, 25: 845–56.
  • Alhnan A, Okwuosa M, Chijioke T, et al. 2016. Emergence of 3D Printed Dosage Forms: Opportunities and Challenges. Pharm Res, 33 (8): 1817­-32.
  • Goyanes A, Buanz AB, Basit AW, et al. 2014. Fused-filament 3D printing (3DP) for fabrication of tablets. Int J Pharm. 2014;476(1–2):88–92.
  • Wang J, Shaw LL, Cameron TB. 2006. Solid Freeform Fabrication of Permanent Dental Restorations via Slurry Micro-Extrusion. J Am Ceram Soc, 89 (1): 346–9.
  • Khaled SA, Burley JC, Alexander MR, et al. 2014. Desktop 3D printing of controlled release pharmaceutical bilayer tablets. Int J Pharm, 461(1–2):105–11.
  • Azad MA, Olawuni D, Kimbell G, et al. 2020. Polymers for Extrusion-Based 3D Printing of Pharmaceuticals: A Holistic Materials-Process Perspective. Pharmaceutics, 12(2):124.
  • Chua CK, Leong KF, An J. 2014. 1 – Introduction to rapid prototyping of biomaterials. Woodhead Publishing.
  • Sun Y, Soh S. 2015. Printing Tablets with Fully Customizable Release Profiles for Personalized Medicine. Adv Mater, 27(47):7847-53.
  • Edelmann A, Dubis M, Hellmann R. 2020. Selective Laser Melting of Patient Individualized Osteosynthesis Plates-Digital to Physical Process Chain. Materials (Basel), 13(24):5786.
  • Tan W, Gao C, Feng P, et al. 2021. Dual-functional scaffolds of poly(L-lactic acid)/nanohydroxyapatite encapsulated with metformin: Simultaneous enhancement of bone repair and bone tumor inhibition. Mater Sci Eng C Mater Biol Appl, 120:111592.
  • Hiller J, Lipson H. 2009. STL 2.0: A Proposal for a Universal Multi-Material Additive Manufacturing File Format”. Solid Freeform Fabrication Symposium (SFF’09), Aug 3-5 2009, Austin, TX, USA.
  • Kodama H. 1981. Automatic method for fabricating a three-dimensional plastic model with photo-hardening polymer. Rev Sci Instrum, 52(11): 1770–73.
  • Melchels FP, Feijen J, Grijpma DW. 2009. A poly(D,L-lactide) resin for the preparation of tissue engineering scaffolds by stereolithography. Biomaterials, 30(23-24):3801-9.
  • Shelby A. Skoog, Peter L. Goering, Roger J. Narayan. 2014. Stereolithography in tissue engineering. J Mater Sci Mater Med, 25: 845–56.
  • Alhnan A, Okwuosa M, Chijioke T, et al. 2016. Emergence of 3D Printed Dosage Forms: Opportunities and Challenges. Pharm Res, 33 (8): 1817­-32.
  • Goyanes A, Buanz AB, Basit AW, et al. 2014. Fused-filament 3D printing (3DP) for fabrication of tablets. Int J Pharm. 2014;476(1–2):88–92.
  • Wang J, Shaw LL, Cameron TB. 2006. Solid Freeform Fabrication of Permanent Dental Restorations via Slurry Micro-Extrusion. J Am Ceram Soc, 89 (1): 346–9.
  • Khaled SA, Burley JC, Alexander MR, et al. 2014. Desktop 3D printing of controlled release pharmaceutical bilayer tablets. Int J Pharm, 461(1–2):105–11.
  • Azad MA, Olawuni D, Kimbell G, et al. 2020. Polymers for Extrusion-Based 3D Printing of Pharmaceuticals: A Holistic Materials-Process Perspective. Pharmaceutics, 12(2):124.
  • Chua CK, Leong KF, An J. 2014. 1 – Introduction to rapid prototyping of biomaterials. Woodhead Publishing.
  • Sun Y, Soh S. 2015. Printing Tablets with Fully Customizable Release Profiles for Personalized Medicine. Adv Mater, 27(47):7847-53.
  • Edelmann A, Dubis M, Hellmann R. 2020. Selective Laser Melting of Patient Individualized Osteosynthesis Plates-Digital to Physical Process Chain. Materials (Basel), 13(24):5786.
  • Tan W, Gao C, Feng P, et al. 2021. Dual-functional scaffolds of poly(L-lactic acid)/nanohydroxyapatite encapsulated with metformin: Simultaneous enhancement of bone repair and bone tumor inhibition. Mater Sci Eng C Mater Biol Appl, 120:111592.
  • Hiller J, Lipson H. 2009. STL 2.0: A Proposal for a Universal Multi-Material Additive Manufacturing File Format”. Solid Freeform Fabrication Symposium (SFF’09), Aug 3-5 2009, Austin, TX, USA.

Biosensors & Biochips for Sustainable Future

B A S I C   L E V E L

Biochips appeared as an innovative microtechnology platform for analysis of bio-molecule in the 1980s.  

Contents

 

Biosensors & Biochips: An overview

Biochips appeared as an innovative microtechnology platform for analysis of bio-molecule in the 1980s. A variety of technologies, such as life sciences, information technology, microelectronics and micromechanics, are involved in the underlying technologies. Biochips are considered important potential instruments in modern life science research, medical diagnosis, drug discovery, food safety monitoring and agriculture as high-performance, miniaturized, automated and cost-effective features. Biochips are expected to allow the speed and scope of the analytical process to be dramatically increased and to provide enormous economic value. Further more, in recent years, numerous governments and industrial companies in the world have invested heavily in this sector. Biochip technology is just in its early evolution for now. This is an area which is ever-changing. The future for biochip research and development is bright. There is furious competition in this area.

In biomedical and life science research, the miniaturization of chemical and biomedical laboratory processes on microchips is a rapidly expanding field. Lab-on-chip technologies will bring a lot of benefits over their macro-sized counterparts. In particular, higher surface-to-volume ratios result in reduced chemical requirements, reduced waste, better control, rapid processing and significant ability for parallel processing and process incorporation. Lab-on-chip technologies has the potential to have a significant socio-economic impact. In laboratory medicine, completely integrated microdevices for chemical synthesis and disease diagnosis offer a scientific breakthrough and a paradigm change in chemical processing. The human genome project has made a huge contribution to this technology.

In the field of analytics, biosensors allow major innovations that are both facilitating and facilitated by developments in synthetic biology. The potential of biosensors to identify a wide range of molecules easily and precisely makes them highly important to a variety of industrial, medical, ecological, and science applications. Biosensor design strategies are as numerous as their applications, with major groups of biosensors including nucleic acids, proteins, and transcription factors. Based on the expected use, and the parameters required for optimum performance, each of these types of biosensors has advantages and limitations. Especially, considerations such as ligand specificity, sensitivity, dynamic range, functional range, output mode, activation time, ease of use, and ease of engineering must be considered when choosing the design of the biosensor.

Blueprints for Biosensors: Design & Operation

Biosensors are sensors that transform bio-recognition processes through a physico-chemical transducer into observable signals, with electronic and optical techniques as two main transducers. The creation of biosensors addresses today’s rapidly rising need for clinical diagnostics. A combination of advantages is brought on by the use of biosensors. Biosensors, first, are highly sensitive. This is because biomolecules have a high affinity for their targets, for example, antibodies catch antigens with a dissociation constant at the nanomolar scale, and DNA – DNA interactions are so much stronger than antigen-antibody. Second, biological recognition is typically very selective. The enzyme and substrate are much like a lock and a key, for example. Such high selectivity frequently leads to biosensors that are selective. Third, the production of inexpensive, integrated, and ready-to-use biosensor devices has become relatively easy to develop due to the development of the modern electronic industry. The ability to detect pathogens or perform genetic analysis in hospitals is certainly improved by these biological sensors; more importantly, they are especially useful for small clinics and even point-of-care analysis.

For biosensors with clinical applications, a range of new techniques have been developed. Biosensors are, in general, analytical devices constructed of an element of biological recognition and an optical/electronic transducer. The biological element is responsible for the capture of solution analytes and the transducer transforms the binding event to a measurable signal variation. By the nature of recognition, enzyme-based biosensors, immunological biosensors, and DNA biosensors, could categorize the type of biosensors. In addition, electronic biosensors (electrical or electrochemical), optical biosensors (fluorescent, surface plasmon resonance, or Raman), and piezoelectric biosensors (quartz crystal microbalance) are available depending on the type of transducer.

Electrochemical biosensors

For biological sensing, where electrodes function as either electron donors or electron acceptors, electrochemical techniques are particularly useful. Extensive electrochemical experiments have shown that the Marcus electron-transfer theory also complies with heterogeneous electron transfer between electrodes and surface-confined redox molecules, similar to donor-acceptor pairs in homogeneous solutions. This means that small distance changes in redox surface-confined molecules can cause wide variations in the heterogeneous electron-transfer rates that are supposed to translate into detectable changes of electrochemical signals. Hellinga and co-workers, for example, suggested an electrochemical sensing strategy that exploits protein ligand-mediated hinge-bending motions. A gold electrode was first coated with a self-assembled monolayer (SAM), which gives a versatile platform for site-specific protein immobilization. The maltose-binding protein (MBP) was then bound to the surface of the gold electrode with a particular orientation as the redox reporter group of ruthenium (Ru(II)) is fixed at a certain range above the electrode. As the ligand maltose binds to the active site, the Ru(II) reporter moves away from the electrode by causing a hinge-bending motion of MBP (Figure 1).

Figure 1. Construction and operation of electrochemical biosensor

This maltose-binding induced distance change causes concentration-dependent decreases in electrochemical signals, thus providing a way for maltose to be electronically sensed. The use of this highly generalized sensing approach to detect various analytes with a family of proteins or enzymes undergoing ligand-binding induced conformational changes has also been shown.

Enzyme-based biosensors

The first biosensors ever documented were glucose oxidase (GOD)-based biosensors, established by Clark and Lyons in 1962. Hyperglycemia, a chronically raised concentration of blood glucose, is common for diabetes mellitus. As a result, regular control of their blood glucose concentration is essential for diabetic patients. The benefit of electrochemistry coupled with enzyme catalysis is this biosensor, and its newer versions. An electrode immobilized with GOD was Clark’s biosensor. The oxidized form of GOD interacts with glucose in the presence of glucose and produces gluconic acid and reduced GOD, with two electrons and two protons involved. As dissolved oxygen reacts with reduced GOD, this glucose oxidation also consumes oxygen in the solution, thereby producing hydrogen peroxide and oxidized GOD, and lowering oxygen pressure. As a result, by electrochemically sensing oxygen with a Clark oxygen electrode, the electrode can detect the glucose. This kind of sensor is considered a biosensor of the “first generation.” The Yellow Springs Instrument Company (Ohio, USA) marketed this first-generation biosensor in the 1970s.

The second-generation biosensor substitutes the naturally-existing substrate, oxygen, with small artificial redox molecules that act as redox mediators and exchange electrons between electrodes and enzymes. To improve the sensor efficiency, that is, sensitivity and signal-to-noise ratio, a variety of soluble redox molecules, such as ferrocene, thionine, methylene blue, methyl viologen, were used. These mediators were initially dissolved in a solution. They obtain electrons from the electrodes and then, or vice versa, these electrons are shuttled to the redox center of the enzymes. Immobilized mediators were suggested as a step forward, in order to enhance reagentless biosensors. For example, for hydrogen peroxide, Ruan et al in 1998 documented a reagentlesssolid-state sensor. Gold electrodes were first modified with L-cysteine, and then multilayers of horseradish peroxidase (HRP) were connected by glutaraldehyde to the amine group of cysteine, and thionine was further linked to the enzyme by the same chemical link. As a result, the gold electrode was immobilized by both the enzyme and the mediator, which could detect hydrogen peroxide sensitively in the test solution without further reagent addition. An essential advantage of this configuration of the biosensor is that the mediator is fixed on the electrode surface, thereby preventing the diffusion problem.

An alternative solution that included the use of redox polymers was stated by Heller and co-workers. First, they prepared a doped polymer with Os2+complex. This type of polymer functions as a “molecular wire” and exchanges electrons between the enzyme and the electrode. The Os-polymer and glucose oxidase are then co-immobilized on the carbon electrode, which generates a sensitive response to the presence of glucose. They were able to make almost 100 % immobilized enzyme molecules electroactive by using these redox polymers, which contributed to a very high sensitivity method of glucose detection.

The commercialization of the enzyme-based second-generation biosensor was quite successful. In 1987, MediSense was established and the pensized ExactechTM glucose sensors were released. This success has led to a health care revolution for diabetic patients. Instead of traveling to hospitals, they were able to control their concentration of blood glucose at home. The MediSense and later amperometric biosensor systems consist of GOD-coated disposable, screen-printed carbon electrodes and mediators (test strips). The sensor starts to function when a droplet of blood is applied to the test strip and records the amperometric response, which is transformed to a digit displayed on the LCD, indicating glucose concentration.

More recently, by designing a reconstructed GOD enzyme, Xiao et al (2003) published a new glucose biosensor generation. They first prepared apo-GOD free of the cofactor of flavin adenine dinucleotide (FAD), then functionalized and reconstructed a 1.4-nm gold nanoparticle with FAD into the apo-GOD. By using a dithiol monolayer, such a reconstructed enzyme was aligned with gold electrodes (Figure 2). They demonstrated that this artificial enzyme’s electron transfer turnover is as high as 5000 s-1, approximately 8-fold higher than the normal enzyme (700 s-1). The gold nanoparticle in this system serves as an electron relay for the electrical wiring of the enzyme’s redox center. In this area, the glucose biosensor established by Xiao et al represents a new path, free from any mediator and highly sensitive. More recently, by using single wall carbon nanotubes (SWNTs) instead of gold nanoparticles, Willner’s group documented a modified version of this sensor and realized a similarly superior efficiency. Although there is still no commercialization of this technology, it is expected that state-of-the-art biosensors will be further improved.

Figure 2 Construction and operation of enzyme – based biosensor

Immunological biosensor

To identify environmental or clinically important targets, immunological biosensors depend on a highly specific immunological system, i.e., antibodies and antigens. In reality, immunological biosensors are a modern variant of the enzyme-linked immunosorbent assay (ELISA), with lower costs, increased speed and convenience of service, and sensitivity that is comparable or even higher.

Among the most common ones are electrochemical immunological biosensors. Two types of immunological biosensors are available. First, the electrode is immobilized with a capture antibody, which catches a particular target antigen. Via a secondary antibody tagged with redox molecules or enzymes, signal transduction is achieved. Second, an electrode antigen is immobilized, which detects specific antibodies.

Ju and co-workers established a carcinoembryonic antigen (CEA) amperometric immunological biosensor. Thionine and HRP-labeled CEA antibodies were co-immobilized on a glassy carbon electrode crosslinked with glutaraldehyde. In the solution, which was coupled to the electrode reaction of thionine, HRP catalytically reduced hydrogen peroxide, leading to a catalyzed signal. The redox center of HRP was partly blocked by catching CEA, leading to attenuation of amperometric signals.

Rusling and colleagues have recently taken advantage of SWNTs to enhance immunological biosensor performance (Figure 3).

Figure 3. Construction and operation of immunological biosensor

By using metal mediated self-assembly, they designed vertically aligned arrays of SWNTs (SWNT forest) on pyrolytic graphite electrodes. Anti-HSA, using EDC/NHS, was then covalently bound to the carboxylated ends of the SWNT forest. The electrode was further incubated with a secondary HRP-labelled anti-HSA antibody after catching the HSA target. The HSA target in the test solution can be identified based on the catalytic signal of HRP for hydrogen peroxide. The detection sensitivity, which was around 1 nM, was dramatically improved by the use of SWNT forests. This was probably due to the improved reactivity of electron transfer of HRP encapsulated in SWNT forests.

One of the most relevant clinical tools has been immunological assays. However, existing assay methods, such as ELISA, require large and costly instruments as well as well-trained specialists. For the development of cheap, miniaturized, and compact devices, electrochemical methods are well adapted. As a result, the development of electrochemical immunological biosensors to meet field and point-of-care analysis is highly desirable. It is important to mention that the use of disposable screen-printed electrodes could be crucial towards this goal, comparable to glucose biosensors. In order to carry out high-throughput (HTS) assays, it is also important to establish antibody microarrays based on electrochemistry.

DNA biosensors

There has been tremendous scientific and technological interest in the identification of DNA hybridization events. The rapidly growing interest in chip-based clinical diagnosis has particularly demonstrated this significance. Therefore , a variety of techniques, including optical, acoustic and electronic approaches, have been developed over the years. In past decades, fluorescent detection has dominated state-of-the-art genosensors among them . Electrochemical methods, however, which have proven effective in simple chemical species, especially metal ions, have attracted increasingly growing interested in biologically related species detection applications.

The benefits of electronic detection include: 1) electrochemical detection is typically inexpensive thus enabling highly sensitive and rapid screening; 2) several electroactive labels, e.g. metallocenes, are stable and environmentally insensitive, unlike fluorophores that often have “photo-bleaching” problems; 3) appropriate molecular design and synthesis that generate a variety of derivatives, each with a specific redox potential, have made it possible to label ‘multi-color’; 4) The rapidly established silicon industry has paved the way for the mass production of integrated circuits, making electronic detection particularly appropriate and compatible with microarray-based technologies; 5) The exponential growth of interfacial science and technology has unraveled mysteries in the precise control of surface properties that are one of the key barricades in bioelectronic applications.

At moderate applied voltages, DNA itself is electrochemically silent, while significant interferences are predicted at high voltages that cause DNA bases to be oxidized/reduced (. Millan was the first to suggest sequence-selective DNA target detections based on electroactive hybridization indicators that provide electronic signals and double and single-stranded DNA discrimination. “Sandwich” type detections were suggested in an effort to reduce the high background derived from the minor binding of hybridization indicators to ssDNA. A DNA strand possessing an electroactive label has been introduced to act as the signaling molecule in addition to an immobilized DNA probe. Similarly, with nanoparticle probes, Park and collegues in 2002 have developed an array-based electrical DNA detection that demonstrates high sensitivity and selectivity. A technology based on the relatively high oxidation activity of guanine and its cooperation by exogenous redox catalysts was developed by Thorp one year later. The discrimination of ds/ss is obtained by the fact that guanine has relatively low electron transfer reactivity in duplexes, due to the steric effect. In the detection of PCR products, this method is highly sensitive, but relatively poor in discriminating hybridization events. Moreover, this method is only possible on ITO surfaces so far, because the high oxidation potential still excludes the use of gold.

Despite progress, the development of an all-in-one (i.e. reagentless) sensor that specifically signals target capture is still highly important (i.e., obviating further treatment with either signal molecules or hybridization indicators). A viable means to this end is provided by DNA or RNA aptamers. Aptamers are well-structured DNA or RNA that have high affinity and selectivity for particular targets as well as natural enzymes, thus showing superior robustness to fragile enzymes. They have been a very promising tool for therapy and diagnosis. Until then, for virtually any given target, the well-developed in vitro selection was able to produce aptamers. In view of these benefits, oligonucleotide aptamers are predicted to be the biosensing components of the next generation. An easy, organized hairpin-like DNA with an electroactive label (electronic DNA hairpin) was used by Fan and collegues as the building block to define hybridization events (Figure 4).

Figure 4. Construction and operation of DNA biosensor

Hairpin-like DNA was an incredibly fascinating aptamer that forms the basis of homogeneous hybridization recognition of fluorescent “molecular beacons”. The DNA sequence has been designed so that in the absence of targets, this “beacon” is in the near state while it will be “turned on” when it reaches its particular gene target. The presence of the design of the stem-loop in the structure offers an on/off switch as well as a stringency to differentiate against single DNA hybridization mismatch. A thiolated terminus gives a sticky end to the gold surface of this electronic DNA hairpin, while a ferrocene tag transduces electronic signals at the other end. The initial hairpin localizes the ferrocene proximal to the electrode surface, thus allowing interfacial electron transfer. After hybridization, the formation of the linear duplex structure disrupts the hairpin and forces apart the ferrocene and the electrode. This significant distance change (up to a few nm) effectively blocked the interfacial electron transfer and leads to the diminution of corresponding electrochemical current signals. This strategy offers the opportunity to identify 10 pM DNA targets. More importantly, such a design takes advantage of integrating within a single surface-confined hairpin structure the capturing part (probe sequence) and the signaling part (electroactive species). In contrast to most previously proposed solid-state DNA sensors, this design is therefore effectively reagentless, i.e. no exogenous reagent is required during the recognition process apart from DNA targets. This provides the basis for the development of a portable, continuous DNA analyzer that may be useful for medical and military applications.

A medium for long-range electron transfer (ET) via its base stacking was suggested as the DNA double helix. Although this issue has been discussed for a long time, Barton and colleagues have proven electrochemically that well-oriented gold electrode DNA films enable long-range electron transfer and that such ET is highly sensitive to base stacking pertubations like mismatches. They found that electroactive intercalators like methylene blue (MB) could be effectively reduced by a fully matched DNA duplex-modified electrode. The existence of only a single mismatch, however, converts the wire-like ET medium into an insulator, totally disrupting the ET between the MB and the electrode. Via cyclic voltammetric or coulometric assays, which form the basis of a rapid DNA mutation screening sensor, such a difference can be easily read. Barton and colleagues also demonstrated that electrocatalysis could improve the sensitivity of this strategy. In solution, the addition of ferricyanide constantly pulls electrons from electrochemically reduced MB, amplifying electron flow through the double helix of DNA. This helps in detecting ~108 molecules of DNA with a 30-μm electrode. They have also developed DNA-based sensors to detect DNA-binding proteins in parallel with DNA detection. Some DNA-binding proteins or enzymes are believed to interact with the base pair stacking of DNA, transforming the double helix of DNA from effective ET wires to insulators. They established a sensitive way to electrically assay a variety of DNA-binding proteins based on the comparable sensing strategy. Crucially, these sensors discriminate successfully against proteins that bind to DNA, but they do not disrupt base stacking. This certainly confirms that the signal cut-off on protein binding is due to the alteration of the ET medium relevant to base stacking.

The future of clinical biosensors

Despite the rapid improvement in the development of biosensors, clinical applications of biosensors are still uncommon, with an exception being the glucose monitor. This is in direct contrast to the critical need for point-of-care testing in small clinics. We assume the specifications below are relevant. First, high sensitivity: Improvement of sensitivity is an ever-lasting priority in the development of biosensors. It is clear that the sensitivity criterion ranges from case to case. For example, because glucose levels are high in the blood, one does not need very high sensitivity for glucose detection. This is basically part of the reason why glucose monitors have been successful. However, in many situations, in order to meet the requirements of molecular diagnostics and pathogen detection, it is very important to establish highly sensitive biosensors with optimum single-molecule detection. Second, high selectivity: In the application of biosensors, this may be a significant barricade. Most of the biosensors mentioned in the literature function very well in laboratories, but in real test samples, series problems can be addressed. As a result, in order to prevent non-specific surface adsorption, it is important to establish novel approaches to surface modification. Third, multiplexing is crucial for saving assay time, which is particularly important for laboratory or clinic assays. It is therefore important to establish arrays of high-density electrodes as well as electrochemical instruments that can conduct a large number of assays simultaneously. Forth, in order to increase portability, it is essential to create miniaturized biosensors, thus satisfying the field and point-of-care test requirements. Fifth, it is appropriate to integrate and highly automate an ideal biosensor. A solution to this goal is offered by current lab-on-a-chip technologies (microfluidics). We can expect all these features to be integrated into successful biosensors in the future, and can easily detect minute targets within a short period of time.

Blueprints for Biochips: Design & Operation

The term “biochip” has taken on several meanings. Any device or component introducing biological materials, either extracted from biological species or synthesized in a laboratory on a solid substrate can be considered to be a biochip in the most generic sense. In practical terms, however, both miniaturizations, usually in microarray format, and the possibility of low-cost mass production are often involved in biochips. The electronic nose or artificial nose chip, the electronic tongue, the Polymerase chain reaction chip, the DNA microarray chip (gene chip), the protein chip and the biochemical lab-on-a-chip are some examples which meet these qualifications. In the gene chip and the protein chip, the most dynamic biochip research has been done.

Much attention has been paid, in particular, to biochips integrating conventional biotechnology with semiconductor processing, micro-electro-mechanical systems (MEMS), optoelectronics and digital signal and image acquisition and processing.

Thousands of genes and their derivatives (i.e., RNA and proteins) in a given living organism are generally assumed to act in a complicated and coordinated manner that creates the mystery of life. Traditional methods in molecular biology, however, typically operate on a “one gene in one experiment” basis, which assumes that the throughput is very limited and it is difficult to achieve the “whole picture” of gene function. A new technology, called the DNA microarray, has gained considerable attention among biologists in the last decades. This technology aims to measure the whole genome on a single chip so that, meanwhile, researchers can get a better picture of the interactions between thousands of genes.

A gene or DNA chip corresponds to a two-dimensional array of small reaction cells (100 x 100 μm each) produced using high-speed robotics on a solid substrate. A silicon wafer, a thin sheet of glass, plastic, or a nylon membrane could be the solid substrate. Trillions of polymeric molecules from a particular sequence of single strand DNA fragments are immobilized in each reaction cell (Figure 5).

Figure 5. A schematic illustration of a gene chip

DNA fragments may be either short (about 20 to 25) base sequences (A, T, G, and C) or longer complementary DNA strands (cDNA). In each cell, the unique sequence of bases (e.g. CTATGC…) is preselected or configured depending on the expected use. The probes are also called recognized sequences of single-strand DNA fragments immobilized on the substrate. Double-strand DNA fragments are formed when unknown fragments of single-strand DNA samples, called the target, react (or hybridize) with the probes on the chip, where the target and the probe are complementary according to the base pairing rule (A paired with T, and G paired with C). The target samples are often labeled with tags, such as fluorescents, dyes, or radio-isotope molecules, to facilitate the diagnosis or analysis of the hybridized chip. Each is labeled with its own distinguishable tag when the targets contain more than one type of sample. This type of DNA microarray chip provides a platform where, based on the size of the array, the unknown target or targets can theoretically be defined with very high speed and high throughput by matching the components involved in the research and development of biochip technology with tens of thousands of different types of probes through hybridization in parallel, and the related technical disciplines are indicated in Figure 6. Fundamentally, biochip technology is interdisciplinary; it is important that scientists and engineers from different disciplines cooperate synergistically to push this novel technology from a lab interest to practical devices and systems.

Figure 6. The components and the associated technical disciplines involved in the R&D of biochip technology

DNA microarray

With regard to the property of the arrayed DNA sequence of known identity, there are two variants of the DNA microarray technology:

Type I: probe cDNA (500~5,000 bases long) is immobilized using robot spotting to a solid surface such as glass and exposed either separately or in a mixture to a set of targets. This strategy, “traditionally” referred to as DNA microarray, is largely known to be developed at Stanford University.

Type II: in situ (on-chip) or by conventional synthesis accompanied by on-chip immobilization, an array of oligonucleotide (20~80-mer oligos) or peptide nucleic acid (PNA) probes is synthesized. The array is exposed to hybridized, labeled sample DNA and determines the identity/abundance of complementary sequences. This method, “historically” named DNA chips, was established at Affymetrix INC., which sells its photolithographically manufactured products under the Genechip trademark. Oligonucleotide-based chips are developed by several companies using alternative in-situ synthesis or depositioning technologies.

Depending on the type of molecule immobilized, biochip is made primarily in two formats. CDNA arrays are also referred to as biochips containing PCR products of 200 base pairs to 2KB size immobilized along the length of the molecule by covalently cross linking to the surface of the array. Alternatively, oligonucleotide probes may either be synthesized in situ on the array, or covalent links to the termini may be fixed by pre-synthesized oligos. Genechip engineering includes several different parts, such as manufacturing, sample preparation and hybridization of the target sequence, hybridization results detection, design of the oligonucleotide probe, and hybridization image analysis, and various applications, as seen in Figure 7.

Figure 7. Several important aspects related to Genechip technology

First, according to a particular target, many relevant gene sequences will be selected from the DNA database (single nucleic polymorphism for a specific genes, differential expression for a given group of genes or mutation identification). By determining the sequence and length of each probe and its exact position on the chip, a series of unique oligonucleotide probes will be designed based on the selected sequences. With the spotting method or on-chip synthesis, the synthesis of the DNA microarray can be carried out. The target genes are usually necessary for fluorescence to be amplified and labeled. Selection of appropriate PCR primes, optimization of amplification, and hybridization conditions will be needed in most cases. For the hybridization outcomes on a gene chip, there are several different detection strategies. A traditional approach is a fluorescent detection. For the treatment of such a large amount obtained from a gene chip, data analysis based on the fluorescent images and database configuration is required. The use of PCR products corresponding to the genes as probe molecules is a common platform for preparing microarrays. Biological sources of cDNA libraries offer an effective template for PCR amplification of the probes. This platform is therefore referred to as cDNA Arrays.

The use of oligonucleotide probes instead of PCR products has several benefits. First, they are typical of similar length and can be created in such a way that they have similar properties of hybridization. Second, they may be configured to hybridize against the specific gene region; the PCR product also allows cross-hybridization between homologous genes disturbing members of the same gene family’s gene expression profiles. Furthermore, the need for tedious PCR amplification of the probe molecules is eliminated by oligonucleotide arrays and decreases the risk of error due to clone handling and contamination during transfer.

Microfluidic chip

In recent decades, microfluidic technology has been rapidly developed and provides multitudinous applications in the life sciences. Thanks to the distinct benefits provided by system miniaturization, the microfluidics revolution arose, including high analytical efficiency, increased sensitivity, improved analytical performance, fast multiplexing parallelization, the ability to manage and process reduced reagent volumes and dramatically reduced instrumental footprints.

Microfluidics could simultaneously offer analytical efficiency and high throughput capability as a miniaturization technology, without the lack of accuracy and automation. Microfluidics technology is not only a powerful tool for the fast screening and study of drug development during the drug application process, but also for its miniaturized devices to lower costs and reagent consumption.

Significant progress has been made in developing drug screening components and systems based on microfluidics over the past few years. For drug screening, different types of microfluidic chips are used to improve screening efficiency and decrease costs. Several common types of chip technology are described in the following paragraphs.

Figure 8. Application of microfluidic chip in drug screening.

Droplet microfluidics – In order to perform experiments in continuous or segmented flow, droplet microfluidic technology utilizes liquid droplets compartmentalized by an immiscible fluid as nanoliter to picoliter separate reaction vessels. Such methods show significant advantages, such as reduced sample usage, improved reaction speed and increased efficiency and reproducibility, handling incredibly small volumes with robust composition control.

Based on the sequential process droplet array technique, droplet microfluidic methods may be used for drug combination screening (Figure 8A), to screen various dosing combinations and administration lengths, and to refine the optimum minimally consumed dosing regimen that is important for combined disease situations.

Organ-on-chip – The detailed regulation of microscale structure and flow enables the precise modeling of the microscale structures of organ tissue to be built. Organs-on-chips are biomimetic systems that are micro-engineered and represent essential functional units of living human organs. The functions of multiple organs and tissues, such as the liver, kidneys, lungs and intestines, have been replicated as in vitro models to date. These systems could be used as in vitro models that enable complex biological processes to be simulated and pharmacologically modulated.

The organ chip simulates the human body’s basic processes, by using a number of cells to create a biomimetic chip with similar physiological functions on the chip’s unique structure, which is comparable to the disease’s actual external environment than the typical single-cell culture model.

In order to replicate the complex microarchitecture of cancerous tissue, a microsystem that allows co-culture of breast tumor spheroids with neighboring cells in a compartmentalized 3D microfluidic system has been established to help create the anti-breast cancer drug screening platform (Figure 8B). For the study of cancer cell migration and anti-cancer drug screening, co-culture of multiple tissues with a microfluidic system could be used.

Other microfluidic chips for drug screening – There are several other technologies applied to microfluidic chips for drug screening, in addition to the above-mentioned existing methods, which extend the ideas of researchers. The most significant and integrated aspect of drug development in most pharmaceutical and several biotechnology industries around the world has been an outstanding HTDS system.

With the use of open-access microfluidic tissue array systems  and cell microarray chips, various concentrations and combinations of drugs can be screened. Various configurations and arrays of small culture chambers may be generated by the different design of the chip. Concentration gradient generators can provide an effective liquid concentration gradient, and these devices have been implemented and combined with microfluidic technologies by several research groups to optimize HTDS systems. The diffusive microfluidic mixers in Figure 8C could also recognize a fully automatic HTDS.

Cell array platforms are built using polydimethylsiloxane (PDMS) material in certain microfluidic channels for drug screening. The structure of the chips, though, is difficult and has some disadvantages, such as expensive silicon molds and biomolecular absorption. As a natural extracellular matrix (ECM), poly (ethylene glycol) diacrylate (PEGDA) hydrogel has identical mechanical properties and water content. PEGDA microfluidic hydrogels have been commonly used for cell encapsulation and are permeable to compounds such as water, biomolecules and chemicals. In order to research the combinatorial treatment effect of two drugs, microfluidic devices made of these types of materials and combined with 3D brain cell culture technologies were used (Figure 8D).

The allure of the microfluidic chip is that to perform various functions, it can have multiple designed structures and can be combined to extend its application range with different devices and testing equipment. However, considerable design, manufacturing and optimization efforts are needed. Each model has unique features of its own. It is used not only for drug screening, but for drug testing as well.

Protein microarray

In the research of proteins, protein microarrays are useful tools in an unbiased, high-throughput manner, as they allow up to thousands of individually purified proteins to be characterized in parallel. This technology’s adaptability has made it possible to be used in a wide range of applications, including the study of proteome-wide molecular interactions, the analysis of post-translational alterations, the discovery of new drug targets, and the evaluation of pathogen-host interactions. In addition, the technology has already been shown to be effective in profiling the specificity of antibodies, as well as in identifying new biomarkers for autoimmune diseases and cancers in particular.

Proteins are complex biomolecules with a large spectrum of structures and functions, and as such, studying them in a high-throughput manner is a challenge. Three primary types of protein microarrays exist: functional, analytical, and reverse phase. Functional protein microarrays are assembled in a high-through-put manner with proteins purified/synthesized, allowing hundreds and even thousands of different proteins to be examined in parallel with their biochemical properties. In order to detect or measure complex biological samples, analytical protein microarrays use affinity reagents immobilized on the array. Finally, complex biological samples immobilized on the array are used by reverse phase protein microarrays which use affinity reagents for identification.

Functional protein microarrays are more capable of identifying weak interactions, more flexible for low-abundance proteins, and more capable of analyzing crude samples such as serum, compared to other methods, such as mass spectrometry. In terms of differences in proteome coverage, protein lengths, and production pipelines, several different types of functional protein microarrays have been produced to date.

Development of the Functional Protein Microarray – The whole set of proteins that can be expressed by a genome is the proteome. Typically, the creation of a purified proteome microarray requires the assembly of a genome-wide set of open reading frames (ORFs) cloned into an expression vector, encoded protein expression in cells, high-throughput individual protein purification, and protein immobilization on a microarray.

Application of Yeast Proteome Microarrays – For the profiling of proteome-wide molecular interactions, functional protein microarrays, especially purified proteome microarrays, are useful and enable detailed, unbiased screening. Researchers have used functional protein microarrays in fundamental research to study protein-protein interactions, protein-lipid interactions, protein-DNA interactions, protein-cell/lysates, small molecule binding, protein-RNA interactions, and PTMs, such as acetylation, SUMOylation, glycosylation, ubiquitylation, phosphorylation, and methylation (Figure 9A-9G). We summarize representative studies in Table I based on the research applications seen in Figure 9.

Figure 9. Application of Functional Protein Microarray

Applications of biochips

The most emerging applications of biochips are included in Table 1.

Biochip in food Biochip detecting genetically modified organisms (gmo’s) in food.
Biochip in diagnostics DNA biochip which revolutionise the way the medical profession performs tests on blood.
Biochip in Tuberculosis epidemic Biochip technology expected to help combat the new variety of drugresistant strains of the disease.
Biochip in cancer Biosensor chip technology provides quick and easy access to critical information regarding DNA damage from cancer-producing compounds and aid in early detection of colon cancer.
Biochip in cancer DNA chips which find genetic differences between people who respond to a drug and those who do not, starting in Phase II, or mid-stage, clinical trials.

Test: LO3 Basic level

Welcome to your LO3-basic level questions

References

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  • Ashley GW, Henise J, Reid R, et al. 2013. Hydrogel drug delivery system with predictable and tunable drug release and degradation rates. Proc. Natl. Acad. Sci. USA, 110: 2318–2323.
  • Bard AJ, Faulkner LR. 2001. Electrochemical Methods. New York: John W Willey & Sons.
  • Benson DE, Conrad DW, de Lorimier RM, et al. 2001. Design of bioelectronic interfaces by exploiting hinge-bending motions in proteins. Science, 293:1641–4.
  • Boon EM, Ceres DM, Drummond TG, et al. 2000. Mutation detection by electrocatalysis at DNA-modified electrodes. Nature Biotech, 18:1096–100.
  • Boon EM, Livingston AL, Chmiel NH, et al. 2003. DNA-mediated charge transport for DNA repair. Proc Natl Acad Sci U S A, 100:12543–7.
  • Boon EM, Salas JE, Barton JK. 2002. An electrical probe of protein-DNA interactions on DNA-modified surfaces. Nat Biotechnol, 20:282-6.
  • Brazill SA, Kim PH, Kuhr WG. 2001. Capillary gel electrophoresis with sinusoidal voltammetric detection: A strategy to allow four-“color” DNA sequencing. Anal Chem, 73:4882–90.
  • Burgstaller P, Girod A, Blind M. 2002. Aptamers as tools for target prioritization and lead identification. Drug Discov Today, 7:1221–8.
  • Choi Y, Hyun E, Seo J, et al. 2015. A microengineered pathophysiological model of early-stage breast cancer. Lab Chip, 15: 3350–3357.
  • Cooper MA, Dultsev FN, Minson T, et al. 2001. Direct and sensitive detection of a human virus by rupture event scanning. Nature Biotechnol, 19:833–7.
  • Dai Z, Yan F, Yu H, et al. 2004. Novel amperometric immunosensor for rapid separation-free immunoassay of carcinoembryonic antigen. J Immuno Methods, 287:13–20.
  • Das, H.K. 2005. “Functional Gernomics using Microarrays Technology.” Text book of Biotechnology, pp .1276-1288, Wiley Dreamtech Publisher.
    Drummond TG, Hill MG, Barton JK. 2003. Electrochemical DNA sensors. Nat Biotechnol, 21:1192–9.
  • Fan C, Plaxco KW, Heeger AJ. 2003. Electrochemical interrogation of conformational changes as a reagentless method for the sequence-specific detection of picomolar DNA. Proc Natl Acad Sci U S A, 100:9134–7.
  • Fan C, Plaxco KW, Heeger AJ. 2005. Biosensors based on binding-modulated donor-acceptor distances. Trends Biotechnol, 23:186–92.
  • Fan Y, Nguyen DT, Akay Y, et al. 2016. Engineering a brain cancer chip for high-throughput drug screening. Sci. Rep., 6: 25062.
  • Fritz J, Cooper EB, Gaudet S, et al. 2002. Electronic detection of DNA by its intrinsic molecular charge. Proc Natl Acad Sci U S A, 99:14142–6.
  • Gao Z, Binyamin G, Kim H-H, et al. 2002. Electrodeposition of redox polymers and co-electrodeposition of enzymes by coordinative crosslinking. Angew Chem Int Ed, 41:810–13.
  • Gaylord BS, Heeger AJ, Bazan GC. 2002. DNA detection using watersoluble conjugated polymers and peptide nucleic acid probes. Proc Nat Acad Sci U S A, 99:10954.
  • Griffiths AD, Tawfik DS. 2000. Man-made enzymes – from design to in vitro compartmentalisation. Curr Opin Biotech, 11:338–53.
  • Heeger AJ. 2000. Nobel Lecture: Semiconducting and Metallic polymers: The fourth generation of polymeric materials [online]. URL: http:// wwwnobelse.
  • Hook F, Ray A, Norden B, et al. 2001. Characterization of PNA and DNA immobilization and subsequent hybridization with DNA using acoustic- shear-wave attenuation measurements. Langmuir, 17:8305–12.
  • Hsiung LC, Chiang CL, Wang CH, et al. 2011. Dielectrophoresis-based cellular microarray chip for anticancer drug screening in perfusion microenvironments. Lab Chip, 11: 2333–2342.
  • Li Z, Su W, Zhu Y, et al. 2017. Drug absorption related nephrotoxicity assessment on an intestine-kidney chip. Biomicrofluidics, 11: 034114.
    Lin D, Li P, Lin J, et al. 2017. Orthogonal screening of anticancer drugs using an open-access microfluidic tissue array system. Anal. Chem., 89: 11976–11984.
  • Liu J, Zhang Y, Jiang M, et al. 2017. Electrochemical microfluidic chip based on molecular imprinting technique applied for therapeutic drug monitoring. Biosens. Bioelectron., 91: 714–720.
  • Moore CD, Ajala O.Z, Zhu H. 2016. Applications in high-content functional protein microarrays. Curr. Opin. Chem. Biol., 30: 21–27.
  • Palecek E, Jelen F. 2002. Electrochemistry of nucleic acids and development of DNA sensors. Crit Rev Anal Chem, 32:261–70.
  • Palecek E. 2004. Surface-attached molecular beacons light the way for DNA sequencing. Trends Biotechnol, 22:55–8.
  • Park SJ, Taton TA and Mirkin CA. 2002. Array-based electrical detection of DNA with nanoparticle probes. Science, 295:1503–6.
  • Patolsky F, Lichtenstein A, Willner I. 2001. Detection of single-base DNA mutations by enzyme-amplified electronic transduction. Nature Biotech, 19:253–7.
  • Patolsky F, Weizmann Y, Wilner I. 2004. Long-range electrical contacting of redox enzymes by SWCNT connectors. Angew Chem Int Ed, 43:2113–17.
  • S. Mi, Z. Du, Y. Xu, et al. 2016. Microfluidic co-culture system for cancer migratory analysis and anti-metastatic drugs screening. Sci. Rep., 6: 35544.
  • Schuster GB. 2000. Long-range charge transfer in DNA: transient structural distortions control the distance dependence. Acc Chem Res, 33:253-60. Sullivan CKO. 2002. Aptasensors–the future of biosensing? Anal Bioanal Chem, 372:44–8.
  • Stone HA, Stroock AD, Ajdari A. 2004. Engineering flows in small devices: microfluidics toward a lab-on-a-chip. Annu. Rev. Fluid Mech., 36: 381–411.
    Sugiura S, Hattori K, Kanamori T. 2010. Microfluidic serial dilution cell-based assay for analyzing drug dose response over a wide concentration range. Anal. Chem., 82: 8278–8282.
  • Taton TA, Mirkin CA, Letsinger RL. 2000. Scanometric DNA array detection with nanoparticle probes. Science, 289:1757–60.
  • Thorp HH. 2003. Reagentless detection of DNA sequences on chemically modified electrodes. Trends Biotechnol, 21:522–4.
  • Umek RM, Lin SW, Vielmetter J, et al. 2001. Electronic detection of nucleic acids–A versatile platform for molecular diagnostics. J Mol Diag, 3:74–84.
  • Van Hove AH, Antonienko E, Burke K, et al. 2015. Temporally tunable, enzymatically responsive delivery of proangiogenic peptides from poly (ethylene glycol) hydrogels. Adv. Healthc. Mater., 4: 2002–2011.
  • Whitesides GM, Grzybowski B. 2002. Self-assembly at all scales. Science, 295:2418–21.
  • Willner I. 2002. Biomaterials for sensors, fuel cells, and circuitry. Science, 298:2407.
  • Wosnick JH, Swager TM. 2000. Molecular photonic and electronic circuitry for ultra-sensitive chemical sensors. Curr Opin Chem Biol, 4:715–20.
  • Xiao Y, Patolsky F, Katz E, et al. 2003. Plugging into enzymes: nanowiring of redox enzymes by a gold nanoparticle. Science, 299:1877–81.
  • Xu H, Wu H, Huang F, et al. 2005. Magnetically assisted DNA assays: High selectivity using conjugated polymers for amplified fluorescent transduction. Nucleic Acids Res, 33:e83.
  • Yu CJ, Wan YJ, Yowanto H, et al. 2001. Electronic detection of single-base mismatches in DNA with ferrocene-modified probes. J Am Chem Soc, 123:11155–61.
  • Yu X, Kim SN, Papadimitrakopoulos F, et al. 2005. Protein immunosen- sor using single-wall carbon nanotube forests with electrochemical detection of enzyme labels. Mol Biosyst, 1:70–8.
  • Adams DA, Brus L, Chidsey CED, et al. 2003. Charge transfer on the nanoscale: current status. J Phys Chem B, 107: 6668-97.
  • Ashley GW, Henise J, Reid R, et al. 2013. Hydrogel drug delivery system with predictable and tunable drug release and degradation rates. Proc. Natl. Acad. Sci. USA, 110: 2318–2323.
  • Bard AJ, Faulkner LR. 2001. Electrochemical Methods. New York: John W Willey & Sons.
  • Benson DE, Conrad DW, de Lorimier RM, et al. 2001. Design of bioelectronic interfaces by exploiting hinge-bending motions in proteins. Science, 293:1641–4.
  • Boon EM, Ceres DM, Drummond TG, et al. 2000. Mutation detection by electrocatalysis at DNA-modified electrodes. Nature Biotech, 18:1096–100.
  • Boon EM, Livingston AL, Chmiel NH, et al. 2003. DNA-mediated charge transport for DNA repair. Proc Natl Acad Sci U S A, 100:12543–7.
  • Boon EM, Salas JE, Barton JK. 2002. An electrical probe of protein-DNA interactions on DNA-modified surfaces. Nat Biotechnol, 20:282-6.
  • Brazill SA, Kim PH, Kuhr WG. 2001. Capillary gel electrophoresis with sinusoidal voltammetric detection: A strategy to allow four-“color” DNA sequencing. Anal Chem, 73:4882–90.
  • Burgstaller P, Girod A, Blind M. 2002. Aptamers as tools for target prioritization and lead identification. Drug Discov Today, 7:1221–8.
  • Choi Y, Hyun E, Seo J, et al. 2015. A microengineered pathophysiological model of early-stage breast cancer. Lab Chip, 15: 3350–3357.
  • Cooper MA, Dultsev FN, Minson T, et al. 2001. Direct and sensitive detection of a human virus by rupture event scanning. Nature Biotechnol, 19:833–7.
  • Dai Z, Yan F, Yu H, et al. 2004. Novel amperometric immunosensor for rapid separation-free immunoassay of carcinoembryonic antigen. J Immuno Methods, 287:13–20.
  • Das, H.K. 2005. “Functional Gernomics using Microarrays Technology.” Text book of Biotechnology, pp .1276-1288, Wiley Dreamtech Publisher.
    Drummond TG, Hill MG, Barton JK. 2003. Electrochemical DNA sensors. Nat Biotechnol, 21:1192–9.
  • Fan C, Plaxco KW, Heeger AJ. 2003. Electrochemical interrogation of conformational changes as a reagentless method for the sequence-specific detection of picomolar DNA. Proc Natl Acad Sci U S A, 100:9134–7.
  • Fan C, Plaxco KW, Heeger AJ. 2005. Biosensors based on binding-modulated donor-acceptor distances. Trends Biotechnol, 23:186–92.
  • Fan Y, Nguyen DT, Akay Y, et al. 2016. Engineering a brain cancer chip for high-throughput drug screening. Sci. Rep., 6: 25062.
  • Fritz J, Cooper EB, Gaudet S, et al. 2002. Electronic detection of DNA by its intrinsic molecular charge. Proc Natl Acad Sci U S A, 99:14142–6.
  • Gao Z, Binyamin G, Kim H-H, et al. 2002. Electrodeposition of redox polymers and co-electrodeposition of enzymes by coordinative crosslinking. Angew Chem Int Ed, 41:810–13.
  • Gaylord BS, Heeger AJ, Bazan GC. 2002. DNA detection using watersoluble conjugated polymers and peptide nucleic acid probes. Proc Nat Acad Sci U S A, 99:10954.
  • Griffiths AD, Tawfik DS. 2000. Man-made enzymes – from design to in vitro compartmentalisation. Curr Opin Biotech, 11:338–53.
  • Heeger AJ. 2000. Nobel Lecture: Semiconducting and Metallic polymers: The fourth generation of polymeric materials [online]. URL: http:// wwwnobelse.
  • Hook F, Ray A, Norden B, et al. 2001. Characterization of PNA and DNA immobilization and subsequent hybridization with DNA using acoustic- shear-wave attenuation measurements. Langmuir, 17:8305–12.
  • Hsiung LC, Chiang CL, Wang CH, et al. 2011. Dielectrophoresis-based cellular microarray chip for anticancer drug screening in perfusion microenvironments. Lab Chip, 11: 2333–2342.
  • Li Z, Su W, Zhu Y, et al. 2017. Drug absorption related nephrotoxicity assessment on an intestine-kidney chip. Biomicrofluidics, 11: 034114.
    Lin D, Li P, Lin J, et al. 2017. Orthogonal screening of anticancer drugs using an open-access microfluidic tissue array system. Anal. Chem., 89: 11976–11984.
  • Liu J, Zhang Y, Jiang M, et al. 2017. Electrochemical microfluidic chip based on molecular imprinting technique applied for therapeutic drug monitoring. Biosens. Bioelectron., 91: 714–720.
  • Moore CD, Ajala O.Z, Zhu H. 2016. Applications in high-content functional protein microarrays. Curr. Opin. Chem. Biol., 30: 21–27.
  • Palecek E, Jelen F. 2002. Electrochemistry of nucleic acids and development of DNA sensors. Crit Rev Anal Chem, 32:261–70.
  • Palecek E. 2004. Surface-attached molecular beacons light the way for DNA sequencing. Trends Biotechnol, 22:55–8.
  • Park SJ, Taton TA and Mirkin CA. 2002. Array-based electrical detection of DNA with nanoparticle probes. Science, 295:1503–6.
  • Patolsky F, Lichtenstein A, Willner I. 2001. Detection of single-base DNA mutations by enzyme-amplified electronic transduction. Nature Biotech, 19:253–7.
  • Patolsky F, Weizmann Y, Wilner I. 2004. Long-range electrical contacting of redox enzymes by SWCNT connectors. Angew Chem Int Ed, 43:2113–17.
  • S. Mi, Z. Du, Y. Xu, et al. 2016. Microfluidic co-culture system for cancer migratory analysis and anti-metastatic drugs screening. Sci. Rep., 6: 35544.
  • Schuster GB. 2000. Long-range charge transfer in DNA: transient structural distortions control the distance dependence. Acc Chem Res, 33:253-60. Sullivan CKO. 2002. Aptasensors–the future of biosensing? Anal Bioanal Chem, 372:44–8.
  • Stone HA, Stroock AD, Ajdari A. 2004. Engineering flows in small devices: microfluidics toward a lab-on-a-chip. Annu. Rev. Fluid Mech., 36: 381–411.
    Sugiura S, Hattori K, Kanamori T. 2010. Microfluidic serial dilution cell-based assay for analyzing drug dose response over a wide concentration range. Anal. Chem., 82: 8278–8282.
  • Taton TA, Mirkin CA, Letsinger RL. 2000. Scanometric DNA array detection with nanoparticle probes. Science, 289:1757–60.
  • Thorp HH. 2003. Reagentless detection of DNA sequences on chemically modified electrodes. Trends Biotechnol, 21:522–4.
  • Umek RM, Lin SW, Vielmetter J, et al. 2001. Electronic detection of nucleic acids–A versatile platform for molecular diagnostics. J Mol Diag, 3:74–84.
  • Van Hove AH, Antonienko E, Burke K, et al. 2015. Temporally tunable, enzymatically responsive delivery of proangiogenic peptides from poly (ethylene glycol) hydrogels. Adv. Healthc. Mater., 4: 2002–2011.
  • Whitesides GM, Grzybowski B. 2002. Self-assembly at all scales. Science, 295:2418–21.
  • Willner I. 2002. Biomaterials for sensors, fuel cells, and circuitry. Science, 298:2407.
  • Wosnick JH, Swager TM. 2000. Molecular photonic and electronic circuitry for ultra-sensitive chemical sensors. Curr Opin Chem Biol, 4:715–20.
  • Xiao Y, Patolsky F, Katz E, et al. 2003. Plugging into enzymes: nanowiring of redox enzymes by a gold nanoparticle. Science, 299:1877–81.
  • Xu H, Wu H, Huang F, et al. 2005. Magnetically assisted DNA assays: High selectivity using conjugated polymers for amplified fluorescent transduction. Nucleic Acids Res, 33:e83.
  • Yu CJ, Wan YJ, Yowanto H, et al. 2001. Electronic detection of single-base mismatches in DNA with ferrocene-modified probes. J Am Chem Soc, 123:11155–61.
  • Yu X, Kim SN, Papadimitrakopoulos F, et al. 2005. Protein immunosen- sor using single-wall carbon nanotube forests with electrochemical detection of enzyme labels. Mol Biosyst, 1:70–8.

Environmental benefit from modern biotechnology and ICT applications

B A S I C   L E V E L

Recent updates on the legislation on renewable energy Directive (EU) 2018/2001 of the European Parliament and of the Council of 11 December 2018 on the promotion of the use of energy from renewable sources.

Contents

 

Renewable energy: biotechnology for biogas and bioethanol production

Recent updates on the legislation on renewable energy à Directive (EU) 2018/2001 of the European Parliament and of the Council of 11 December 2018 on the promotion of the use of energy from renewable sources. The 2030 climate and energy framework includes EU-wide targets and policy objectives for the period from 2021 to 2030. The key targets are:

– Reduce CO2 emissions (from 1990 levels) by 40%

– Increase renewable energy sources by 32%

– Improve energy efficiency by 32,5%

Biogas

Biogas is the mixture of gases produced by the breakdown of organic matter in the absence of oxygen (anaerobically), primarily consisting of methane and carbon dioxide. Biogas can be produced from raw materials such as agricultural waste, manure, municipal waste, plant material, sewage, green waste or food waste. Biogas is a renewable energy source (Fig. 1). Biogas is considered to be a renewable resource because its production-and-use cycle is continuous, and it generates no net carbon dioxide. As the organic material grows, it is converted and used. It then regrows in a continually repeating cycle. From a carbon perspective, as much carbon dioxide is absorbed from the atmosphere in the growth of the primary bio-resource as is released, when the material is ultimately converted to energy.

Fig. 1. Renewable energy

Biogas is produced by anaerobic digestion with methanogenic or anaerobic organisms, which digest organic materials inside a closed system, or fermentation of biodegradable materials. This closed system is called an anaerobic digester or a biodigester.

Biogas is primarily methane (CH4) and carbon dioxide (CO2) and may have small amounts of hydrogen sulfide (H2S), and moisture (Fig. 2). After purification from H2S and moisture, the biogas can be used to produce electricity and thermal energy. In this way, biogas can be used in a in a co-generation system (a kind of gas engine) to convert the energy in the gas into electricity and heat.

Methane from biogas (after elimination of CO2) can be used as a fuel and for any heating purpose. Biogas can therefore be cleaned and upgraded to natural gas standards, when it becomes bio-methane.

Biogas can be produced from a vast variety of raw materials (feedstocks). The biggest role in the biogas production process is played by microbes feeding on the biomass (details in the related power point). Materials suitable for biogas production include:

Fig. 2. Main biogas components

  • biodegradable waste from enterprises and industrial facilities, such as surplus lactose from the production of lactose-free dairy products
  • spoiled food from shops
  • biowaste generated by consumers
  • sludge from wastewater treatment plants
  • manure and field biomass from agriculture

The material is typically delivered to the biogas plant’s reception pit by lorry or waste management vehicle. A delivery of solid matter such as biowaste will next undergo crushing to make its consistency as even as possible. At this point, water containing nutrients obtained from a further stage in the production process is also mixed with the feedstock to take the rate of solid matter down to only around one-tenth of the total volume.

Fig. 3. Scheme of a biogas plant

This is also when any unwanted non-biodegradable waste, such as packaging plastic of out-of-date food waste from shops, is separated from the mixture. This waste is taken to a waste treatment facility where it is used to generate heat and electricity. Biomass that has passed through slurrification is combined with biomass delivered in the form of slurry to the biogas plant and pumped into the pre-digester tank where enzymes secreted by bacteria break down the biomass into an even finer consistency. A scheme of a biogas plant is presented in Fig. 3.

The residual solids and liquids created in biogas production are referred to as digestate. This digestate goes into a post-digester reactor and from there further into storage tanks. Digestates are well suited for uses such as fertilization of fields. Digestates can also be centrifuged to separate the solid and liquid parts.

Solid digestates is used as fertilizers in agriculture or in landscaping and can also be turned into gardening soil through a process of maturation involving composting.

Digestates are centrifuged to obtain process water for the slurrification of biowaste at the beginning of the process. This helps reduce the use of clean water. The centrifuged liquid is rich in nutrients, particularly nitrogen, that can be separated further using methods such as stripping technology and used as fertilizers or nutrient sources in industrial processes. Methane that can possibly be obtained from different by-products/waste is shown in Fig. 4.

Stages in biogas production. Anaerobic digestion is a multiple-stage process in which hydrolysis is one of the main steps. During hydrolysis the complex insoluble substrate macromolecules are hydrolysed into simpler and more soluble intermediates by bacteria.

Fig. 4. Biomethane potential of different by-products

A large number of microbial species, acting in concert, are capable of utilising organic substrates such as carbohydrates, proteins and lipids to produce volatile fatty acids (VFAs), which can be converted to methane and carbon dioxide by methanogenic microorganisms. Bacteria excrete enzymes that hydrolyse the particulate substrate to small transportable molecules, which can pass through the cell membrane. Once inside the cell, these simple molecules are used to provide energy and to synthesize cellular components. Polysaccharides are converted to simple sugars; hydrolysis of cellulose by cellulase enzymes yields glucose; hemicellulose degradation results in monosaccharides such as xylose, glucose, galactose, pentoses, arabinose and mannose, while starch is converted to glucose by amylase enzymes. A scheme of the process and examples of microorganisms involved is depicted below (Fig. 5).

Methanogens are Archea. They can live in different habitats and are an heterogeneous group of microorganisms. They lack cell nuclei and are therefore prokaryotes. Archaea were initially classified as bacteria, receiving the name archaebacteria (in the Archaebacteria kingdom), but this term has fallen out of use. Archaeal cells have unique properties separating them from the other two domains, Bacteria and Eukaryota. Archaea are further divided into multiple recognized phyla. Classification is difficult because most have not been isolated in a laboratory and have been detected only by their gene sequences in environmental samples. Archaea and bacteria are generally similar in size and shape, although a few archaea have very different shapes. Despite this morphological similarity to bacteria, archaea possess genes and several metabolic pathways that are more closely related to those of eukaryotes, notably for the enzymes involved in transcription and translation. Other aspects of archaeal biochemistry are unique, such as their reliance on ether lipids in their cell membranes. Archaea use more energy sources than eukaryotes: these range from organic compounds, such as sugars, to ammonia, metal ions or even hydrogen gas. Salt-tolerant archaea (the Haloarchaea) use sunlight as an energy source, and other species of archaea fix carbon, but unlike plants and cyanobacteria, no known species of archaea does both. Archaea reproduce asexually by binary fission, fragmentation, or budding; unlike bacteria, no known species of Archaea form endospores. The first observed archaea were extremophiles, living in extreme environments, such as hot springs and salt lakes with no other organisms. Improved molecular detection tools led to the discovery of archaea in almost every habitat, including soil, oceans, and marshlands. Archaea are particularly numerous in the oceans, and the archaea in plankton may be one of the most abundant groups of organisms on the planet. Archaea are a major part of Earth’s life. They are part of the microbiota of all organisms. In the human microbiome, they are important in the gut, mouth, and on the skin. Their morphological, metabolic, and geographical diversity permits them to play multiple ecological roles: carbon fixation; nitrogen cycling; organic compound turnover; and maintaining microbial symbiotic and syntrophic communities, methane formation.

Substrates for methanogenesis are a large array and they are listed below.

Fig. 6. Substrates for methanogenesis

Bioethanol

The use of bioethanol in Europe will be described and the main microorganisms used for bioethanol production (yeasts and bacteria) will be presented and their performances compared.

Fig. 7. Ethanol vs bioethanol production

Ethanol is widely used as a solvent, reagent, in the food industry and automotive fuel (Fig. 7 and 8). The production of ethanol by fermentation is based on the use of raw materials, microorganisms and technologies different from those used for the production of alcoholic beverages (wine and beer) in order to have the maximum yield in ethanol in the shortest time and with the lowest costs. 95% of the world actual ethanol production is BIOETHANOL (sugar fermentation process), whereas only 5% is manufactured by the chemical process of reacting ethylene with steam.

Fig. 8. Bioethanol use on the EU market

 Bioethanol is the principle fuel used as a petrol substitute for road transport vehicles. Ethanol or ethyl alcohol (C2H5OH) is a clear colourless liquid, it is biodegradable, low in toxicity and causes little environmental pollution if spilt. Ethanol burns to produce carbon dioxide and water. Ethanol is a high octane fuel and has replaced lead as an octane enhancer in petrol. By blending ethanol with gasoline we can also oxygenate the fuel mixture so it burns more completely and reduces polluting emissions. Ethanol fuel blends are widely sold in the United States. The most common blend is 10% ethanol and 90% petrol (E10). Vehicle engines require no modifications to run on E10 and vehicle warranties are unaffected also. Only flexible fuel vehicles can run on up to 85% ethanol and 15% petrol blends (E85).

The main sources of sugar required to produce ethanol come from fuel or energy crops. These crops are grown specifically for energy use and include corn, maize and wheat crops (1st generation bioethanol), waste straw, willow and popular trees, forest and agricultural waste, residues from pulp production, solid urban waste (2nd generation bioethanol), third-generation bioethanol has been derived from algal biomass including microalgae and macroalgae (Fig. 9).

Fig. 9. First, second and thirg generation

Benefits of Bioethanol. Bioethanol has a number of advantages over conventional fuels. It comes from a renewable resource i.e. crops and not from a finite resource and the crops it derives from can grow well in Europe (like cereals, sugar beet and maize). Another benefit over fossil fuels is the greenhouse gas emissions. The road transport network accounts for 22% of all greenhouse gas emissions and through the use of bioethanol, some of these emissions will be reduced as the fuel crops absorb the CO2 they emit through growing. Also, blending bioethanol with petrol will help extend the life of the diminishing oil supplies and ensure greater fuel security, avoiding heavy reliance on oil producing nations. By encouraging bioethanol’s use, the rural economy would also receive a boost from growing the necessary crops. Bioethanol is also biodegradable and far less toxic that fossil fuels. In addition, by using bioethanol in older engines can help reduce the amount of carbon monoxide produced by the vehicle thus improving air quality. Another advantage of bioethanol is the ease with which it can be easily integrated into the existing road transport fuel system. In quantities up to 5%, bioethanol can be blended with conventional fuel without the need of engine modifications.

Biothanol can be produced from biomass by the hydrolysis and sugar fermentation processes. Biomass wastes contain a complex mixture of carbohydrate polymers from the plant cell walls as cellulose, hemi cellulose and lignin. In order to produce sugars from the biomass, the biomass is pre-treated with acids or enzymes in order to reduce the size of the feedstock and to disrupt the plant structure. The cellulose and the hemi cellulose portions are broken down (hydrolysed) by enzymes or dilute acids into sucrose sugar that is then fermented into ethanol. The lignin which is also present in the biomass is normally used as a fuel for the ethanol production plants boilers.

There are three principle methods of extracting sugars from biomass: concentrated acid hydrolysis, dilute acid hydrolysis and enzymatic hydrolysis. The first one works by adding 70-77% sulphuric acid to the biomass that has been dried to a 10% moisture content. The acid is added in the ratio of 1.25 acid to 1 biomass and the temperature is controlled to 50 °C. Water is then added to dilute the acid to 20-30% and the mixture is again heated to 100 °C for 1 hour. The gel produced from this mixture is then pressed to release an acid sugar mixture and a chromatographic column is used to separate the acid and sugar mixture. The dilute acid hydrolysis process is one of the oldest, simplest and most efficient methods of producing ethanol from biomass. Dilute acid is used to hydrolyse the biomass to sucrose. The first stage uses 0.7% sulphuric acid at 190 °C to hydrolyse the hemi cellulose present in the biomass. The second stage is optimised to yield the more resistant cellulose fraction. This is achieved by using 0.4% sulphuric acid at 215 °C. The liquid hydrolates are then neutralised and recovered from the process. Instead of using acid to hydrolyse the biomass into sucrose, we can use enzymes to break down the biomass in a similar way.

Corn, one of the most agricultural source to obtain ethanol, can be processed into ethanol by either the dry milling or the wet milling process. In the wet milling process, the corn kernel is steeped in warm water, this helps to break down the proteins and release the starch present in the corn and helps to soften the kernel for the milling process. The corn is then milled to produce germ, fibre and starch products. The germ is extracted to produce corn oil and the starch fraction undergoes centrifugation and saccharifcation to produce gluten wet cake. The ethanol is then extracted by the distillation process. The wet milling process is normally used in factories producing several hundred million gallons of ethanol every Year. The dry milling process involves cleaning and breaking down the corn kernel into fine particles using a hammer mill process. This creates a powder with a course flour type consistency. The powder contains the corn germ, starch and fibre. In order to produce a sugar solution the mixture is then hydrolysed or broken down into sucrose sugars using enzymes or a dilute acid. The mixture is then cooled and yeast is added in order to ferment the mixture into ethanol.

Sugar Fermentation Process

The hydrolysis process breaks down the cellulostic part of the biomass or corn into sugar solutions that can then be fermented into ethanol. Yeast is added to the solution, which is then heated. The yeast contains an enzyme called invertase, which acts as a catalyst and helps to convert the sucrose sugars into glucose and fructose.

Fig. 10. Yeast alcoholic fermentation

The main features of microorganism to be used in the industrial production of ethanol are:

–  high yields of molar conversion of sugar (moles of ethanol produced/moles of sugar consumed)

– high production rate (moles of ethanol produced/time × volume of culture)  mol/Lh  or g/Lh

– high ethanol yields in weight (grams of produced ethanol/volumes of culture, ≥ 120 g/L)     g/L

– high tolerance to ethanol

– as low as possible production of side products derived from side fermentations (e.g. glycerol)

Yeasts for bioethanol fermentation: Microorganisms such as yeasts play an essential role in bioethanol production by fermenting a wide range of sugars to ethanol. They are used in industrial plants due to valuable properties in ethanol yield (>90.0% theoretical yield), ethanol tolerance (>40.0 g/L), ethanol productivity (>1.0 g/L/h), growth in simple, inexpensive media and undiluted fermentation broth with resistance to inhibitors and retard contaminants from growth condition. As the main component in fermentation, yeasts affect the amount of ethanol yield. Saccharomyces cerevisiae is the most widely used yeast. Since thousands of years ago, S. cerevisiae have been used in alcohol production especially in the brewery and wine industries. It keeps the distillation cost low as it gives a high ethanol yield, a high productivity and can withstand high ethanol concentration. Nowadays, yeasts are used to generate fuel ethanol from renewable energy sources. Some yeast strains belonging to the species Pichia stipitis, S. cerevisiae and Kluyveromyces fagilis were reported as good ethanol producers from different types of sugars. S. cerevisiae tolerates a wide range of pH thus making the process less susceptible to infection. Baker’s yeast was traditionally used as a starter culture in ethanol production due to its low cost and easy availability. However, baker’s yeast and other S. cerevisiae strains were unable to compete with wild-type yeast which caused contamination during industrial processes. Stressful conditions like an increase in ethanol concentration, temperature, osmotic stress and bacterial contamination are the reasons why the yeast cannot survive during the fermentation. Flocculent yeasts were also used during biological fermentation for ethanol production as it facilitates downstream processing, allows operation at high cell density and gives higher overall productivity. It reduces the cost of cells recovery as it separates easily from the fermentation medium without centrifugation. There are common challenges to yeasts during sugar fermentation which are rise in temperature (35–45 °C) and ethanol concentration (over 20%). Yeasts growth rate and metabolism increase as the temperature increases until it reaches the optimum value. Increase in ethanol concentration during fermentation can cause inhibition to microorganism growth and viability. Inability of S. cerevisiae to grow in media containing high level of alcohol leads to the inhibition of ethanol production. The other problems in bioethanol fermentation by yeast are the ability to ferment pentose sugars. S. cerevisiae is the most commonly used in bioethanol production. However, it can only ferment hexoses but not pentoses. Only some yeasts from genera Pichia, Candida, Schizosaccharomyces and Pachysolen are capable of fermenting pentoses to ethanol. The efficiency of ethanol production on an industrial scale will be increased by using yeasts that are tolerant to inhibitors. The common challenges of yeasts can be overcome by using ethanol-tolerant and thermotolerant yeast. Ethanol-tolerant and thermotolerant strains which can resist stresses can be isolated from natural resources such as soil, water, plants and animals. Ethanol fermentation at high temperature is a beneficial process as it selects thermo-tolerant microorganisms and does not require cooling costs and cellulase. For example, K. marxianus is thermotolerant yeast which is capable of co-fermenting both hexose and pentose sugars and can survive the temperature of 42–45 °C.

Zymomonas mobilis for bioethanol fermentation: Zymomonas mobilis is a Gram negative, facultative anaerobic, non-sporulating, polarly-fagellated, rod-shaped bacterium. It is the only species of the genus Zymomonas. It has notable bioethanol-producing capabilities, which surpass yeast in some aspects. It was originally isolated from alcoholic beverages like the African palm wine, the Mexican pulque, and also as a contaminant of cider and beer (cider sickness and beer spoilage) in European countries. Zymomonas mobilis degrades sugars to pyruvate using the Entner-Doudoroff pathway. The pyruvate is then fermented to produce ethanol and carbon dioxide as the only products (analogous to yeast). The advantages of Z. mobilis over S. cerevisiae with respect to producing bioethanol are:

  • higher sugar uptake and ethanol yield (up to 2.5 times higher),
  • lower biomass production,
  • higher ethanol tolerance up to 16% (v/v),
  • does not require controlled addition of oxygen during the fermentation.

However, in spite of these attractive advantages, several factors prevent the commercial usage of Z. mobilis in cellulosic ethanol production. The foremost hurdle is that its substrate range is limited to glucose, fructose and sucrose. Wild-type Z. mobilis cannot ferment C5 sugars like xylose and arabinose which are important components of lignocellulosic hydrolysates. Unlike E. coli and yeast, Z. mobilis cannot tolerate toxic inhibitors present in lignocellulosic hydrolysates such as acetic acid and various phenolic compounds. Concentration of acetic acid in lignocellulosic hydrolysates can be as high as 1.5% (w/v), which is well above the tolerance threshold of Z. mobilis. Engineered Z. mobilis could overcome its inherent deficiencies and therefore expanded its substrate range to include C5 sugars like xylose and arabinose. Acetic acid resistant strains of Z. mobilis have been developed by rational metabolic engineering efforts, mutagenesis techniques or adaptive mutation. Mpreover, an extensive adaptation process was used to improve xylose fermentation in Z. mobilis. By adapting a strain in a high concentration of xylose, significant alterations of metabolism occurred. One noticeable change was reduced levels of xylitol, a byproduct of xylose fermentation which can inhibit the strain’s xylose metabolism. An interesting characteristic of Z. mobilis is that its plasma membrane contains hopanoids, pentacyclic compounds similar to Eukaryotic sterols. This allows it to have an extraordinary tolerance to ethanol in its environment, around 13%.

A comparison between production of bioethanol by S. cerevisiae and Z. mobilis is shown in Fig. 11.

Fig. 11. Comparison between different microbial agents operating the bioethanol

Biotechnology for the remediation of contaminated sites

Wastewater

Fig. 12. Water location and use

Water is a resource to be protected. Please find below the main location where freshwater is located on earth and some of the reasons why water is slowly running out. Almost 70 % of the water today is consumed for agriculture, about one-quarter for commercial uses, and roughly 10% is utilized for domestic purposes. Therefore, the main sector that uses water is agriculture/farming. Agricultural water is mainly used for irrigation as well as pesticide and fertilizer applications and for animal farming. There are three sources for agriculture water: i) Groundwater from underground wells; ii) surface water that is derived from open canals, streams, irrigation ditches, and diverted from reservoirs; iii) rainwater which is usually collected in barrels, tubs, and large cisterns. Water is often poisoned. The main causes of poisoning are: domestic use of water (organic matter, surfactants….), agriculture and industrial use of water (fertilizers and pesticides, water deriving from industrial processes), atmosphere (contamination of rainwater by toxic substances present in the atmosphere, deriving from industries, airplanes, motor vehicle engines).

Directive 2000/60/EC of the European Parliament established a framework for Community actions in the field of water policy. This legislation establishes a framework for the protection of inland surface waters, coastal waters and groundwater. The objectives of the directive are:

– the safeguard against further deterioration;

– the improvement of the state of the ecosystems;

– the promotion of sustainable water use;

– the reduction of groundwater pollution;

– the reduction of discharges;

– mitigation of the effects of floods and droughts.

The depuration of wastewater is obtained through different treatments that are often applied in sequences: primary, secondary (biological), tertiary treatments as indicated in the picture) (Fig. 13 and 14).

Fig. 13 (above ) and 14 (below). Primary, secondary and tertiary treatment for the biological depuration of wastewater

Fig. 15. Aerobic oxidation tank

The activated sludge process is one of the most commonly used for secondary wastewater treatment of civil and industrial origin. It is a suspended-growth biological treatment process, using a dense microbial culture in suspension to biodegrade organic material under aerobic conditions and forming spontaneously a biological floc (referred to as activated sludge). Diffused or mechanical aeration maintains the aerobic environment in the reactor. Typical retention times are 5-14 hours in conventional units rising to 24-72 in low rate systems. The activated sludge process depends on aerobic biological action (Fig. 15). The microorganisms break down the complex organic substances into simple molecules including water and CO2. This process results in the removal of soluble and suspended organic matter from wastewater. The growth of microorganisms in the presence of dissolved oxygen removes the majority of pollutant matter; in turn, protozoa grow and feed on these organisms. The resulting balance is of a living culture in suspended form in the activated sludge flocs. The main elements of the system include an aeration tank (secondary treatment) in which the wastewater is thoroughly mixed with continuously activated sludge and oxygen. From this part of the process, it passes into a clarifier tank (secondary sedimentation), where the settled sludge is removed from the purified water to be recycled by the return activated sludge pumps. For this system to work, two requirements must be met: the aeration device must be capable of both transferring oxygen from the atmosphere to the liquid, and distributing this oxygen throughout the wastewater to the suspended living microorganism. This type of system is suited for low-strength waste, typically on the order of 50-200 mg L−1 BOD. Pre- or post-treatment of wastewater may also be applied. After the aeration basin, the mixture of microorganisms and wastewater (mixed liquor) flows into a settling basin or clarifier where the sludge is allowed to settle. Some of the sludge volume is continuously recirculated from the clarifier, as Returned Activated Sludge, back to the aeration basin to ensure adequate amounts of microorganisms are maintained in the aeration tank. The microorganisms are again mixed with incoming wastewater where they are reactivated to consume organic nutrients. Then the process starts again.

The activated sludge process, under proper conditions, is very efficient. It removes 85 to 95 percent of the solids and reduces the biochemical oxygen demand (BOD) about the same amount. The efficiency of this system depends on many factors, including wastewater climate and characteristics. Toxic wastes that enter the treatment system can disrupt the biological activity. Wastes heavy in soaps or detergents can cause excessive frothing and thereby create aesthetic or nuisance problems. In areas where industrial and sanitary wastes are combined, industrial wastewater must often be pretreated to remove the toxic chemical components before it is discharged into the activated sludge treatment process. Nevertheless, microbiological treatment of wastewater is by far the most natural and effective process for removing wastes from water.

Microbial populations in activated sludges: The microbial community partecipating to the biological depuration process forms floc agglomerates which are called activated sludges. The activated sludge of a of a secondary treatment plant is a microbial culture that develops around organic and inorganic particles and that metabolizes the organic matter present in wastewater. Activated sludge flocs tend to settle down in the “secondary” sedimentation phase because of gravity. Several groups of microorganisms are responsible for the depuration process:

Bacteria are primarily responsible for removing organic nutrients from the wastewater. They also develop a sticky layer of slime around the cell wall that enables them to clump together to form bio-solids or sludge that is then separated from the liquid phase. The successful removal of wastes from the water depends on how efficiently the bacteria consume the  organic  material  and  on  the ability of the bacteria to stick together, form floc, and settle out of the bulk  fluid. The flocculation (clumping) characteristics of the microorganisms inactivated sludge enable them to amass to form solid masses large enough to settle to the bottom of the settling basin.

FUNGI are also heterotrophic organisms helping in the degradation of organic matter.

Protozoa play a critical role in the treatment process by removing and digesting free swimming dispersed bacteria and other suspended particles. This improves the clarity of the wastewater effluent. Like bacteria, some protozoa need oxygen, some require very little oxygen, and a few can survive without oxygen. The types of protozoa present are classified as follows:

Amoebae à Little effect on treatment & die off as amount of food decreases

Flagellate à Feed primarily on soluble organic nutrients

Ciliates à Clarify water by removing suspended bacteria.

Rotifers and Nematods are multi-cellular organisms which are larger than most protozoa and do not basically remove organic material from the wastewater. Although they can eat bacteria, they also feed on algae and protozoa. A dominance of metazoa is usually found in longer age systems; namely, lagoon treatment systems. Although their contribution in the activated sludge treatment system is small, their presence does indicate treatment system conditions.

In addition to activated sludge plants, there are other types of secondary wastewater treatment processes. Some of them can be IMMOBILIZED CELLS PROCESSES, as indicated in Fig. 16.

Fig. 16. Immobilized cell tecnologies for the depuration of wastewater

Percolating filters are a biological purification technology through microorganisms that develop, in an aerobic environment, on appropriate support materials, through which sewage percolates.The percolating filter tank is filled with inert, natural or synthetic materials (e.g. stones) through which wastewater is fed from above. The DEPURATION PHASES include: 1) Primary treatments to prevent obstruction of the bed; 2) Formation of the biofilm  (3-4 mm thick); 3) Cell detachment from biofilm and setting-up of the biofilm again; 4) Final sedimentation. The main advantages of this technology are the low cost of set-up and maintenance and the fact that they can tolerate variation of the organic load of the influent. The main drawbacks include the large areas for the set-up and the problems of bad odours. Biocircles are a modified version of the percolating filters, in which the surfaces bearing the biofilm rotates around an axis, half immersed in the liquid to be treated; the rotation allows the oxygenation of the biomass adhered to the disc. Anaerobic systems work well when the entering flow rate is low and the organic load entering the system is sufficiently high. The required depuration efficiency is not high (anaerobic microorganisms are characterized by a lower growth rate and a slower metabolism with respect to aerobic ones, so the organic matter is not completely degraded). These conditions are typical of some industrial wastewater, anaerobic reactors do not work well for the treatment of large scale civil effluents.

Another important system for the depuration of wastewater is phytodepuration (Fig. 17), which is a: purification technology characterised by biological treatments, in which plants growing in water-saturated soil develop a key role helped by the direct action of the bacteria that colonize the root system and rootstock.

Fig. 17. General features of phytodepuration.

These treatments are seen both as alternatives as well as support to traditional systems based on biological processes and chemical and physical reactions. The term “Wetlands” indicates “Phytodepuration” systems of wastewaters designed to artificially create the same ecological conditions that are naturally established in watery areas. “Phytodepuration” systems engineered, designed and built to reproduce natural self-depurative processes in a controllable environment. In comparison to natural wetlands, phytodepuration systems allow for the choice of the site, the flexibility in the dimension, control of hydraulic flows and retention times. Phytodepurifyng functions can be preferred and additionally exploited with opportune strategies, like the choice of plant species and substratum and control of the flow of water. With Phytodepuration systems, pollutants are removed through a combination of chemical, physical and biological processes. The most effective processes are sedimentation, precipitation, adsorption, assimilation from plants and microbial activity. Phytodepuration technology adds the medium’s adsorbing ability to the traditional biological oxidation depurative treatment (filtering action by plant roots that also provide a large surface suitable for developing microbial masses involved in the treatment) and removal of nutriments due to their growth. Different strategies are described In Fig. 18:

Fig. 18. Different phytodepuration strategies

Floating macrophytes, including water hyacinth (Eichhornia crassipes), are dominant invasive organisms in tropical aquatic systems and they may play an important role in modifying the gas exchange between water and the atmosphere. Hydrophytes are plants which live in water and adjust with their surroundings. They either remain fully submerged in the water or most of their body parts remain under the water. In the picture you can distinguish different examples of emergent hydrophyte system.

Contaminated soils

What are xenobiotic compounds (Fig. 19)?

Fig. 19. Definition of xenobiotics

Which fate can they have in the environment (Fig. 20)?

Fig. 20. Fate of xenobiotics in the environment

Xenobiotics are not necessarily molecules extrinsic to the biosphere, but they can also be natural molecules present in non-natural concentrations in the environment. They are not necessarily toxic molecules, but, generally, they are recalcitrant to the biodegradation.

Antropogenic molecules can derive from different sources:

1) Petrochemical industry: – fuels(aliphatic and aromatic hydrocarbon mixtures), – pure chemicals for the chemical and pharmaceutical industry (alcohols, ethers, esters, aldehydes,  frequently substituted with Cl– ,amino or nitro groups

2) Pulp and paper industries: use wood as raw material and produce pulp, paper and other cellulose-based products. – the bleaching of paper with chlorine-based products produces halogenated molecules including chloro-lignin

3) Synthetic plastic industry: styrene, vinyl chloride, solvents, cross-linking agents to produce polymers.

4) Pesticide industry: benzene and heterocyclic derivatives, urea, organophosphorus compounds

5) Pharmaceutical and cosmetic industry

6) Textile industry: reagents to produce synthetic fibers, detergents to soften fibers and pesticides for insect/moth control

7) Paint industry

8) domestic use of chemicals (personal hygiene products, cleaning products, ….)

A typical example of natural molecules present in non-natural concentrations is olive mill wastewater: they derive from olive milling to produce olive oil, but they have an high COD (see below) and need to be treated before being discarded in the environment.

Several questions have to answered before deciding whether a contaminated soil can be subjected to a bioremediation treatment. The first aspect to be considered is if we are referring to a chronic contaminated soil or a recent sudden contamination has occurred. In the first case, we can take some time to decide what to do, study in depth the situation, do some preliminary laboratory test and decide the best strategy. In the seconf case, we have to act promptly following the experiences that have been collected for the same contaminants and the same soils.

Please read the questions that need to be answered before DECIDING THE STRATEGY TO APPLY (Fig. 21).

Fig. 21. How to decide which bioremediation strategy is the best one for your

A large array of bioremediation technologies can be used for the decontamination of contaminated sites (Fig. 22).

Fig. 22. In situ and ex situ bioremediation technologies

 IN SITU means that the soil is not removed from its original location and is treated in the same location where the contamination occurred.

 NATURAL ATTENUATION: within this term “a variety of physical, chemical, or biological processes” are included. These processes, under favorable conditions, act without human intervention to reduce the concentration, the toxicity and the mobility of contaminants in soil or groundwater. These in situ processes include biodegradation. A precise monitoring of the process is done, in order to make sure that the soil is remediated. The use of natural attenuation is often proposed as a remedial solution for benzene, toluene, ethylbenzene, and xylene (BTEX). More recently, natural attenuation has been proposed for chlorinated solvents, nitroaromatics, heavy metals, and other contaminants for which the scientific understanding and field experience are robust enough. Natural attenuation is applied when there is solid evidence that natural attenuation processes are transforming the contaminants to harmless products.

BIOAUGMENTATION: it is the addition of microbial cultures in order to speed up the rate of degradation of a contaminant. Indigenous microorganisms present in the contaminated areas may already be able to break down the contaminants, but their action may be inefficient and slow. Bioaugmentation requires studying the indigenous varieties present in the location to determine if biostimulation is possible. The same indigenous bacterial cultures can be isolated, cultivated and implemented into the location to boost the degradation of the contaminants. If the indigenous variety do not have the metabolic capability to perform the remediation process, exogenous varieties with different degradation pathways can be introduced.

biostimulation: is the addition of nutritional supplements for the indigenous microbiota to promote its metabolism. Usually, it refers to the addition of rate limiting nutrients like phosphorus, nitrogen, oxygen, electron donors to severely polluted sites to stimulate the existing bacteria to degrade the hazardous and toxic contaminants. The addition of these nutrients improves the degradation potential of the indigenous microorganisms. Among all the bioremediation techniques, biostimulation is considered to be the most efficient method for remediation of hydrocarbons, especially petroleum products and its derivatives. This is mostly due to the easy availability of carbon source which is one of the rate-limiting nutrients required by the indigenous microorganisms for their metabolic activities from the petroleum contaminants. In addition to the mentioned rate limiting nutrients, implementation of other nutrients rich organic matter can also trigger the remediation process extensively. In this context, it has been shown that the addition of bio solids (nutrient rich organic matter) obtained from the treatment of domestic sewage and inorganic fertilisers, rich in nitrogen and phosphorus, can improve and speed up the degradation rate of petroleum hydrocarbons.

BIOVENTING: also referred to as “Bioenhanced Soil Venting”, it is an in situ technology based on the natural stimulation of the indigenous biological activity with the introduction of oxygen through an air fluid; it is successfully applied to any aerobically biodegradable organic substance, in particular for the remediation of sites polluted by petroleum derivatives. The intake of air is at low flow rate as it is only designed to provide the oxygen needed to support microbial activity. Inside the polluted area, toxic compounds are removed from the air flow while organic compounds are biodegraded aerobically. The air is injected directly through one or more wells connected with vacuum pumps which provides the forced circulation of the air in the unsaturated contaminated soil. Passive bioventilation systems are also applied which exploit the natural exchange of air to transport oxygen, a one-way valve is installed on top of the external vent that allows air to enter only when the pressure inside the contaminated soil is higher than atmospheric.

Fig. 23. Phytoremediation technology 

PHYTOREMEDIATION: It is the treatment of contaminated soil with the use of plants to clean up soil contaminated with hazardous contaminants (Fig. 23). It is more properly defined as “the use of green plants and the associated microorganisms, along with proper soil amendments and agronomic techniques to either contain, remove or render toxic environmental contaminants harmless”, because plants act in synergy with rhizospheric microorganisms that, very often, strongly collaborate with plants in the realization of the process. Phytoremediation is proposed as a cost-effective plant-based approach of environmental remediation that takes advantage of the ability of plants to concentrate elements and compounds from the environment and to detoxify various compounds. The concentrating effect results from the ability of certain plants called hyperaccumulators to bioaccumulate chemicals. The remediation effect is quite different. Toxic heavy metals cannot be degraded, but organic pollutants can be and are generally the major targets for phytoremediation. Several field trials confirmed the feasibility of using plants for environmental cleanup.

EX SITU means that the soil is removed from its original location and treated very close to the site where the contamination has occurred (on site) or far away (off site).

 

LANDFARMING: it is a full-scale bioremediation technology, which requires excavation and placement of the contaminated soils, sediments, or sludges in a site where they can be treated; this is typically an on site remediation technology used to enhance the microbial degradation of hazardous compounds. Usually, liners and plastic covers are employed to control leaching of contaminants underground in order to avoid contamination of aquifers. Soil conditions are often controlled to optimize the rate of contaminant degradation, in particular:

  • Moisture content (usually by irrigation or spraying).
  • Aeration (by tilling the soil with a predetermined frequency, the soil is mixed and aerated).
  • pH (buffered near neutral pH by adding crushed limestone or agricultural lime).
  • Other amendments (e.g., soil bulking agents, nutrients, etc.).

Contaminated soil is usually treated in lifts that are up to 1 meter thick. When the desired level of treatment is achieved, the lift is removed and a new one is placed. Very often only the top of the remediated lift is removed, then the new lift is constructed by adding more contaminated soil to the remaining material and mixed. This serves to inoculate the freshly added material with an actively degrading microbial culture, and can reduce treatment times. This technique has been successfully used for years in the management and disposal of oily sludge and other petroleum refinery wastes. Generally, the higher the molecular weight of the target molecule (i.e., the more rings within a polycyclic aromatic hydrocarbon), the slower the degradation rate. Also, the more chlorinated or nitrated the compound, the more difficult it is to be degraded. Factors that may limit the applicability and effectiveness of the process include: (a) large space requirements; (b) the conditions advantageous for biological degradation of contaminants cannot be reached, which increases the length of time to complete remediation, particularly for recalcitrant compounds; (c) inorganic contaminants are not biodegraded; (d) the potential of large amounts of particulate matter released by operations; and (e) the presence of metal ions may be toxic to microbes and may leach from the contaminated soil into the ground. Land farming, combined with other biological treatments, is widely used and has been successfully applied to many waste types, especially for disposal of oily sludge and other petroleum refinery wastes.

COMPOSTING: Composting is a process that works to speed up the natural decay of organic material by providing the ideal conditions for microorganisms to thrive (Fig. 24). The end-product of this concentrated decomposition process is nutrient-rich product (compost) that can help crops, garden plants and trees to grow.

Fig. 24. Composting

Compost bioremediation refers to the use of a biological system of micro-organisms in a mature, cured compost to sequester or break down contaminants in water or soil. Micro-organisms consume contaminants in soils, ground and surface waters, and air. The contaminants are digested, metabolized, and transformed into humus and inert by-products, such as carbon dioxide, water, and salts. Compost bioremediation has proven effective in degrading or altering many types of contaminants, such as chlorinated and non-chlorinated hydrocarbons, wood-preserving chemicals, solvents, heavy metals, pesticides, petroleum products, and explosives. Compost used in bioremediation is referred to as “tailored” or “designed” compost in that it is specially made to treat specific contaminants at specific sites. The ultimate goal in any remediation project is to return the site to its pre-contamination condition, which often includes revegetation to stabilize the treated soil. In addition to reducing contaminant levels, compost advances this goal by facilitating plant growth. In this role, compost provides soil conditioning and also provides nutrients to a wide variety of vegetation.

BIOREACTORS: the treatment of a contaminated soil in a bioreactor is the finest remediation technology although it is the most expensive (Fig. 25).

Fig. 25. Example of soil treatment in a biorector

It is an ex situ off site technology: the soil, after its removal from the original site, can be treated far away from its original location. The soil is treated in slurry phase inside a bioreactor made of different materials (glass, steel, concrete or other materials) and all the parameters of the remediation process are monitored and controlled to make the process as effective as possible (pH, redox potential, temperature, concentration of the pollutant(s), presence of degradation metabolites). Microorganisms can therefore work in their optimal conditions. The treatment of a contaminated soil in a bioreactor is usually applied for soils contaminated by particularly recalcitrant molecules that are difficultly removed by other remediation technologies (e.g. highly chlorinated molecule).

STRENGTHS and WEAKNESSES of bioremediation technologies

STRENGHTS

– Reduced costs with respect to chemical and physical strategies (lower energy costs);

– Reduced environmental impact: the soil can be re-used in situ;

– The problem (i.e. the contamination) is solved (pollutants disappear, they are not simply moved from one site to another);

– Acceptability by the public opinion.

WEAKNESSES

– Problems of the bioavailability  of pollutants;

– Problems in case pollutants are more than one;

– Problems of adequate environmental conditions (pH, temperature, oxygen availability).

Test: LO7 Basic level

Welcome to your LO7BL TRAINING MATERIAL

References

  • Meegoda JN, Li B, Patel K, Wang LB. 2018. A review of the processes, parameters, and optimization of anaerobic digestion. International journal of environmental research and public health, 15(10): 2224
  • Wang P, Wang H, Qiu Y, Ren L, Jiang B. 2018. Microbial characteristics in anaerobic digestion process of food waste for methane production–A review. Bioresource technology, 248: 29-36
  • Azhar S HM, Abdulla R, Jambo SA, Marbawi H, Gansau JA, Faik AAM, Rodrigues KF. 2017. Yeasts in sustainable bioethanol production: A review. Biochemistry and Biophysics Reports, 10: 52-61
  • Prasad RK, Chatterjee S, Mazumder PB, Gupta SK, Sharma S, Vairale MG, .Gupta DK. 2019. Bioethanol production from waste lignocelluloses: A review on microbial degradation potential. Chemosphere, 231: 588-606
  • Sivagami K, Sakthivel KP, Nambi IM. 2018. Advanced oxidation processes for the treatment of tannery wastewater. Journal of environmental chemical engineering, 6(3): 3656-3663
  • Krzeminski P, Tomei MC, Karaolia P, Langenhoff A, Almeida CMR, Felis E, Fatta-Kassinos D. 2019. Performance of secondary wastewater treatment methods for the removal of contaminants of emerging concern implicated in crop uptake and antibiotic resistance spread: A review. Science of the Total Environment, 648: 1052-1081
  • Abatenh E, Gizaw B, Tsegaye Z, Wassie M. 2017. The role of microorganisms in bioremediation-A review. Open Journal of Environmental Biology, 2(1): 038-046
  • Wan X, Lei M, Chen T. 2020. Review on remediation technologies for arsenic-contaminated soil. Frontiers of Environmental Science & Engineering, 14(2): 1-14.
  • Meegoda JN, Li B, Patel K, Wang LB. 2018. A review of the processes, parameters, and optimization of anaerobic digestion. International journal of environmental research and public health, 15(10): 2224
  • Wang P, Wang H, Qiu Y, Ren L, Jiang B. 2018. Microbial characteristics in anaerobic digestion process of food waste for methane production–A review. Bioresource technology, 248: 29-36
  • Azhar S HM, Abdulla R, Jambo SA, Marbawi H, Gansau JA, Faik AAM, Rodrigues KF. 2017. Yeasts in sustainable bioethanol production: A review. Biochemistry and Biophysics Reports, 10: 52-61
  • Prasad RK, Chatterjee S, Mazumder PB, Gupta SK, Sharma S, Vairale MG, .Gupta DK. 2019. Bioethanol production from waste lignocelluloses: A review on microbial degradation potential. Chemosphere, 231: 588-606
  • Sivagami K, Sakthivel KP, Nambi IM. 2018. Advanced oxidation processes for the treatment of tannery wastewater. Journal of environmental chemical engineering, 6(3): 3656-3663
  • Krzeminski P, Tomei MC, Karaolia P, Langenhoff A, Almeida CMR, Felis E, Fatta-Kassinos D. 2019. Performance of secondary wastewater treatment methods for the removal of contaminants of emerging concern implicated in crop uptake and antibiotic resistance spread: A review. Science of the Total Environment, 648: 1052-1081
  • Abatenh E, Gizaw B, Tsegaye Z, Wassie M. 2017. The role of microorganisms in bioremediation-A review. Open Journal of Environmental Biology, 2(1): 038-046
  • Wan X, Lei M, Chen T. 2020. Review on remediation technologies for arsenic-contaminated soil. Frontiers of Environmental Science & Engineering, 14(2): 1-14.