Pilot-scale biorefinery for the production of purified biopolymers based on hydrothermal treatment in flow-through reactor cycles.

[Display omitted] • Multi-bed operation with cycles enhances the efficiency of hydrothermal treatment. • Start-up & bed shifting highly affects final concentration and process steadiness. • Carrot discards produced high purity hemicelluloses and pectins up to 80.4 kDa. • Ultrafiltration/diafiltration remove up to 100% of low molecular weight components. • Molecular weight increased up to 16.7 times and polydispersity reduced 13.5 times. Purified solid fractions of hemicellulose and pectin biopolymers with different molecular weight were produced on a pilot-scale from discarded carrots. The pulp was subjected to hydrothermal extraction on a pilot plant operating in cycles of three flow-through reactors in series at 140 and 180 °C. Two operational modes of start-up (with and without water pre-filling) were tested, showing that it influences the final hydrolysate concentration and the stability of the system. Free sugars, arabinogalactan hemicellulose and homogalacturonan pectin were produced at maximum recoveries of 379.5 g/kg dry pulp, 81.0 g/kg dry pulp and 5.35 g/kg dry pulp, respectively, with the extraction of arabinogalactan reaching a yield of 96.1 % (w/w). The extracted biopolymers were separated and purified through ultrafiltration and diafiltration cycles using a multi-membrane system (30, 10, 1 kDa). Ultrafiltration and especially diafiltration allowed going from extracts with molecular weight, polydispersity and purity values of 14.77 kDa, 19.2 and 22.2 % w/w (140 °C extract) and 8.08 kDa, 18.2 and 14.9 % w/w (180 °C extract), to fractions with values of 80.36 kDa, 67.77 kDa, 9.85 kDa, 5.23 kDa and 3.86 kDa (molecular weight), 1.3 – 3.8 (polydispersity), and 64.5 – 100 % w/w (purity). The five fractions were freeze-dried and spray-dried. The pilot-scale system allowed the production of purified biopolymer fractions of high purity, different average molecular weight, and in sufficient quantity for their subsequent transformation into products such as biodegradable films. [ABSTRACT FROM AUTHOR]