Integration of first- and second-generation ethanol processes is one among the alternate approaches that efficiently address the current socio-economic issues of the bioethanol sector. Edible filamentous fungus capable of utilizing pentoses from lignocelluloses and also possessing biomass application as potential animal feed component was used as the fermentation strain for the integration model. This study presents various fermentation aspects of using edible filamentous fungi in the integrated first and second generation ethanol process model. Fermentation of edible strain of N. intermedia on the integrated first and second-generation ethanol substrate (the mixture of dilute acid pretreated and enzymatically hydrolyzed wheat straw and thin stillage from the first-generation ethanol process), showed an ethanol yield maximum of 0.23 ± 0.05 g/g dry substrate. The growth of fungal pellets in presence of fermentation inhibitors (such as acetic acid, HMF and furfural) resulted in about 11 to 45% increase in ethanol production as compared to filamentous forms, at similar growth conditions in the liquid straw hydrolysate. Fungal cultivations in the airlift reactor showed strong correlation with media viscosity, reaching a maximum of 209.8 ± 3.7 cP and resulting in 18.2 ± 1.3 g/L biomass during the growth phase of fungal pellets. N. intermedia fermentation showed high sensitivity to the dilute acid lignocellulose pretreatment process, with improved fermentation performance at milder acidic concentrations. The rheological examinations showed media viscosity to be the most critical factor influencing the oxygen transfer rate during the N. intermedia fermentation process. Mycelial pellet morphology showed better fermentation efficiency and high tolerance towards fermentation inhibitors.

The conventional materials for constructing bioreactors for ethanol production are stainless and cladded carbon steel because of the corrosive behaviour of the fermenting media. As an alternative and cheaper material of construction, a novel textile bioreactor was developed and examined. The textile, coated with several layers to withstand the pressure, resist the chemicals inside the reactor and to be gas-proof was welded to form a 30 L lab reactor. The reactor had excellent performance for fermentative production of bioethanol from sugar using baker’s yeast. Experiments with temperature and mixing as process parameters were performed. No bacterial contamination was observed. Bioethanol was produced for all conditions considered with the optimum fermentation time of 15 h and ethanol yield of 0.48 g/g sucrose. The need for mixing and temperature control can be eliminated. Using a textile bioreactor at room temperature of 22 °C without mixing required 2.5 times longer retention time to produce bioethanol than at 30 °C with mixing. This will reduce the fermentation investment cost by 26% for an ethanol plant with capacity of 100,000 m³ ethanol/y. Also, replacing one 1300 m³ stainless steel reactor with 1300 m³ of the textile bioreactor in this plant will reduce the fermentation investment cost by 19%.