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A fed-batch strategy integrated with mechanical activation improves the solubilization of phosphate rock by Aspergillus niger Rodrigo Klaic, Fabio Plotegher, Caue Ribeiro, Teresa Zangirolami, and Cristiane S. Farinas ACS Sustainable Chem. Eng., Just Accepted Manuscript • DOI: 10.1021/acssuschemeng.8b00885 • Publication Date (Web): 16 Jul 2018 Downloaded from http://pubs.acs.org on July 17, 2018
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A fed-batch strategy integrated with mechanical activation improves
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the solubilization of phosphate rock by Aspergillus niger
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Rodrigo Klaica,b, Fabio Ploteghera, Caue Ribeiroa,c, Teresa C. Zangirolamib, Cristiane S.
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Farinasa,b,*
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a
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Brazil
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b
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Washington Luiz, km 235, 13565-905, São Carlos, SP, Brazil
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c
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Luiz, km 235, 13565-905, São Carlos, SP, Brazil
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c
Embrapa Instrumentação, Rua XV de Novembro 1452, 13560-970, São Carlos, SP,
Graduate Program of Chemical Engineering, Federal University of São Carlos, Rod.
Graduate Program of Chemistry, Federal University of São Carlos, Rod. Washington
19 20 21
*Correspondence author
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Tel.: +55-16-2107-2908;
23
Fax: +55-16-2107-5754;
24
E-mail address:
[email protected] 25
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ABSTRACT
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Solubilization of phosphate rock (PR) by microorganisms is an environmentally
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sustainable alternative to chemical processing for production of phosphate fertilizers.
29
The effectiveness of this PR biological solubilization process is driven by the microbial
30
production of organic acids that chelate the cations (mainly calcium) bound to
31
phosphate. However, the biological solubilization efficiency has been limited by the PR
32
solids content of cultivation systems, and is still low for practical applications. Here, we
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propose a fed-batch strategy coupled with mechanical activation to improve the
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biological solubilization of PR by Aspergillus niger. An initial systematic study of the
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effect of the particle size of Itafós phosphate rock (IPR), a low reactivity phosphate
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mineral (P2O5, 20%), on the biological solubilization of P revealed that the particle size
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played a key role in IPR solubilization. Increases of available phosphate of up to 57%
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under submerged cultivation and 45% for solid-state culture were observed for rocks
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that had been milled for only 10 min. A fed-batch procedure was proposed in order to
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increase the solids content while maintaining the P-solubilization efficiency, resulting in
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a remarkable increase of 78% in P-solubilization, compared to the conventional process.
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This proposed strategy could potentially contribute to the future development of
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biotechnological processes for the large-scale industrial production of phosphate
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fertilizers that are environmentally sustainable.
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KEYWORDS: Phosphate rock, Biofertilizer, Biological solubilization, Aspergillus
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niger, Organic acids, Fed-batch.
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INTRODUCTION
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Phosphorus (P) is a key nutrient for plants that is usually supplied in the form of
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soluble fertilizers produced by expensive chemical treatments of phosphate rock (PR),
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leading to several environmental concerns
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technologies have been developed to process PR 3 and to obtain new fertilizers products
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for a sustainable agriculture
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soluble P fertilizer is the use of P-solubilizing microorganisms (PSMs) to solubilize PR
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in biotechnological processes 1, 2, 6, 7. The P-solubilizing activity of PSMs is determined
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mainly by their ability to produce and release metabolites such as organic acids that
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chelate cations (principally calcium) bound to phosphate
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especially noted for their high rates of growth and organic acid production
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Aspergillus niger has been widely recognized as a potential PSM 8, 12, 13.
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1, 2
. To overcome these limitations, different
4, 5
. An innovative and attractive alternative for obtaining
8-10
. Aerobic fungi are 11
, and
Recent studies concerning biotechnological routes for PR solubilization have 14-16
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discussed the selection of PSMs using different screening methods
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process conditions (including C and N sources, initial pH, inoculum size, and duration
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of cultivation)
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cultivation 8, 13, 21-23. Among the organic acids, citric, oxalic and tartaric acid have been
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shown to promote a PR solubilization comparable to the one achieved using the
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conventional sulfuric acid 22, 24-26. In previous work by our group, we found that the PR
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particle size can also influence phosphate solubilization, with gains of over 60% for
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solid-state culture and 115% for submerged culture
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depending on the type of rock (sedimentary or igneous).
17-21
, as well as
and quantification of the organic acids produced in the microbial
12
. However, this effect can vary
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The biological solubilization process is still strongly limited by the PR solids
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content in the cultivation system, since there is a negative correlation between the
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amount of P solubilized and the P yield with increasing PR doses
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challenge in achieving an economically and industrially feasible process is to develop a
27, 28
. Therefore, the
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strategy to solubilize all the available phosphate in PR at high solids contents. This
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strategy could contribute to the development of a commercial bioproduct in the form of
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a liquid biofertilizer with high P concentration, which could be used for direct
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application in agriculture. The effectiveness of liquid biofertilizers has been
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demonstrated previously in the fertirrigation of Trifolium repens plants, which resulted
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in a significant improvement in plant growth and increased P uptake 29. However, novel
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bioprocess engineering strategies focusing on ways to make this process industrially
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competitive remain to be further investigated.
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Therefore, here we propose a fed-batch strategy coupled to mechanical activation
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to simultaneously increase the biological solubilization of PR and the effective solids
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content. Itafós phosphate rock (IPR), an igneous rock, was selected as a model of a very
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low solubility phosphate source typically rejected for industrial fertilizer production,
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despite its high phosphate content (P2O5, 20%), due to its difficult chemical processing
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and high associated costs. The findings indicated that biological solubilization using
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fed-batch addition of solids, with optimization of PR size and bioprocess conditions
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(microorganism, pH, and biomass), was more efficient than using sequential or
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conventional biological solubilization modes. These results could contribute to the
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development of a feasible industrial bioprocess for PR treatment and environmentally
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sustainable fertilizer production.
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MATERIALS AND METHODS
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Itafós phosphate rock
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The Itafós phosphate rock (IPR) was kindly donated by ITAFÓS in Arraias
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(Tocantins State, Brazil). The IPR was dried at 110 ºC for 48 h in order to reduce the
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humidity content and was then ground for periods of 2.5, 5, 10, 20, 40, and 80 min in an
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orbital mill (Model CT-251, Servitec) consisting of a porcelain jar and alumina balls 12, 4 ACS Paragon Plus Environment
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30
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further physical-chemical characterizations and for use in the solubilization
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experiments.
. After treatment, the materials were stored in dry boxes at room temperature for
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Characterization of Itafós phosphate rock (IPR)
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X-ray diffraction (XRD) analyses of the IPR samples were performed using a
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LabX XRD-6000 diffractometer (Shimadzu, Japan) operated with Cu-Kα radiation (λ =
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1.54056 Å), voltage of 30 kV, and current of 30 mA. The diffractograms were recorded
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for 2θ from 5° to 55°, using a continuous scanning speed of 2° min-1. X-ray
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fluorescence (XRF) employing the lithium tetraborate fusion technique was used to
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analyze the ten commonest oxides found in the ores. In addition, fluorine and carbon
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were determined using specific ion analysis and infrared spectroscopy, respectively. The
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morphology of the IPR samples was observed by field emission gun scanning electron
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microscopy (FEG-SEM), using a JSM-6701F FEG microscope (JEOL, Japan). Images
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were acquired using an acceleration voltage of 2 kV and secondary electron detection.
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Total surface area measurements of the IPR samples were made by isothermal nitrogen
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adsorption, using a Micromeritics ASAP 2020 instrument and the 5-point B.E.T.
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(Brunauer–Emmett–Teller) method. The particle size was estimated by assuming that
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all particles have a spherical shape and using the equation D = 6/ρ (SSA), which relates
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the mean diameter (D) to its density (ρ) and specific surface area (SSA) 30.
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Microorganism
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The filamentous fungus Aspergillus niger C was obtained from the Embrapa Food
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Technology collection (Rio de Janeiro, RJ, Brazil). This A. niger strain was selected in a
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previous work as a potential candidate for rock phosphate solubilization
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suspensions of the fungal strain were kept at -18 °C in a solution of water with glycerol
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. Spore
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(10 wt.%) and NaCl (0.9 wt.%). Spores were germinated at 30 °C in Petri dishes
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containing potato dextrose agar. After 96 h, a suspension of grown spores was harvested
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by adding distilled water. The spore concentration was determined using a Neubauer
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chamber.
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Submerged culture (SmC)
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In the microbial cultivations under submerged culture, the pre-culture was
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initiated in 500 mL Erlenmeyer flasks by adding a volume of spore suspension
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calculated to give a concentration of 1.2x107 spores per mL of the nutrient medium. The
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nutrient medium was adapted from the medium described by Pikvoskaya
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contained (w/v): glucose, 1%; (NH4)2SO4, 0.5%; NaCl, 0.2%; MgSO4.7H2O, 0.1%;
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KCl, 0.2%; MnSO4.H2O, 0.002%; FeSO4.7H2O, 0.002%; yeast extract, 0.5%. A 100 mL
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volume of the nutrient medium was used in each experiment. The incubation for the
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pre-culture step was carried out for 48 h in an orbital shaker incubator, at 30 °C and 220
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rpm. Solubilization of P was initiated by transferring a volume of pre-culture suspension
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corresponding to 10% (v/v) to 100 mL of culture medium with the same composition,
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with agitation for 96 h in an orbital shaker incubator at 30 °C and 220 rpm. In this
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cultivation step, IPR was added at 5 g L-1 as the source of insoluble phosphate. After
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this period, the resulting suspension was vacuum-filtered using Whatman No. 1 filter
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paper, followed by centrifugation for 20 min at 12000 rpm and 20 °C. This clear
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supernatant was used for the measurements of soluble P, pH, titratable acidity, and
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microbial biomass, as described in the following sections. All experiments were carried
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out in triplicate and the data were calculated as means ± standard deviations. A
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schematic diagram of this experimental procedure is shown in the Supporting
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Information (Section 1, Fig. S1).
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and
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Solid-state culture (SSC)
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Sugarcane bagasse (SB) ground to a particle size of 2 mm was used as the solid
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substrate for SSC. The experiments were carried out in 250 mL Erlenmeyer flasks, with
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5 g of SB in each experiment. After sterilization at 120 °C for 20 min, the medium
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containing SB and IPR was inoculated with 1.2x107 spores per g of substrate. The initial
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moisture content of the SB was adjusted to 80% (w/v) by using the nutrient solution
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(Pikovskaya medium
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fermentation was performed at 30 °C for 96 h. After the cultivation period, the sample
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was homogenized in 50 mL of distilled water (shaking the suspension at 200 rpm for 60
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min). The resulting material was vacuum-filtered using Whatman No. 1 filter paper and
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was then centrifuged for 20 min at 12000 rpm and 20 °C. Soluble P in the clear
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supernatant was determined by the colorimetric method described in the following
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section. All experiments were carried out in triplicate and the data were calculated as
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means ± standard deviations. A schematic diagram of this experimental procedure is
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shown in the Supporting Information (Section 1, Fig. S1).
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, as previously described for the submerged culture), and the
169 170
Sequential solubilization
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A. niger was cultivated under submerged culture, without the presence of IPR, for
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144 h, followed by removal of the biomass by filtration and centrifugation. The culture
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medium extract obtained was then used for solubilization of the IPR for a further 24 h,
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at 30 °C and 220 rpm, resulting in a total process time of 168 h. The medium was
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filtered and centrifuged to remove the IPR particles, and the phosphorus solubilized in
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the liquid fraction was determined. This strategy was evaluated using solids contents of
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5, 10, and 15 g L-1. All experiments were carried out in triplicate.
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Simultaneous solubilization with fed-batch addition of solids
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For solubilization with fed-batch addition of solids, A. niger was cultivated under
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SmC for 48 h, in the absence of IPR, after which the IPR was added at predetermined
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times (48, 72, 96, and 120 h). At each time, a solids content of 2.5 g L-1 was added, up
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to a final solids content of 10 g L-1. This strategy was only performed with the solids
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content of 10 g L-1. After 168 h, the medium was filtered and centrifuged to remove the
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fungal biomass and PR particles, and the phosphorus solubilized in the liquid fraction
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was determined. All experiments were carried out in triplicate.
187 188 189
Determination of soluble phosphorus The soluble P content was determined using a colorimetric method adapted from 32
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Murphy and Riley
. Briefly, a 5 mL aliquot of the clear supernatant sample was
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reacted with 2 mL of ascorbic acid solution (0.4 mol L-1), 0.2 mL of citric acid (0.03
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mol L-1), and 2 mL of a reagent consisting of 25 mL of a sulfuric acid solution (4.7 mol
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L-1), 5.5 mL of ammonium molybdate solution (0.08 mol L-1), and 0.6 mL of antimony
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and potassium tartrate solution (0.05 mol L-1). This mixture was reacted at 50 °C for 15
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min, forming a phosphoantimonylmolybdenum blue complex. The concentration of the
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complex was determined by UV-Vis spectrometry at a wavelength of 880 nm.
197 198
Determination of soluble calcium, aluminum, and iron
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The amounts of calcium (Ca), iron (Fe), and aluminum (Al) released were
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determined by flame atomic absorption spectroscopy (FAAS), using a Perkin Elmer
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PinAAcle 900T instrument operated in flame atomization mode. The analytical
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conditions for Ca were a wavelength of 422.67 nm, slit width of 0.7 nm, and flame
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mixture of synthetic air at 10 L min-1 and acetylene at 2.7 L min-1. The conditions for Al
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were a wavelength of 309.27 nm, slit width of 0.7 nm, and flame mixture of nitrous 8 ACS Paragon Plus Environment
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oxide at 6 L min-1 and acetylene at 7.5 L min-1. The conditions for Fe were a
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wavelength of 248.33 nm, slit width of 0.2 nm, and flame mixture of synthetic air at 10
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L min-1 and acetylene at 2.5 L min-1.
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Determination of organic acids
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The concentrations of gluconic, oxalic, and citric acids were determined using a
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Waters HPLC system equipped with W515 pumps, W717 injector, and W486 UV
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reader. An Aminex HPX-87H column (Bio-Rad) was employed, with 5 mM sulfuric
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acid solution as the isocratic mobile phase, at a flow rate of 0.6 mL min-1. The injector
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and column temperatures were 4 °C and 65 °C, respectively. The organic acids were
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detected at 210 nm. Gluconic, oxalic, and citric acid standards were obtained from
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Sigma-Aldrich (organic acid kit). All the experiments were performed in triplicate and
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the data were calculated as means ± standard deviations.
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Determination of pH, titratable acidity, and microbial dry mass
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The pH of the medium was measured with a glass electrode and titratable acidity
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was determined by titrating a sample containing 10 mL of acid extract with 0.1 M
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NaOH solution, using about three drops of a solution of phenolphthalein (1 wt.%) as
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indicator. The microbial biomass was determined as the dry weight after drying at 70 °C
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for 48 h.
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RESULTS AND DISCUSSION
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Characterization of Itafós phosphate rock
228
A detailed characterization of the original and milled samples of IPR was carried
229
out in order to understand the physical and chemical nature of the phosphate source
230
used in the bioprocess. The X-ray diffractograms (Supporting Information, Section 1, 9 ACS Paragon Plus Environment
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Fig. S2) revealed crystalline phase constituents corresponding to alpha-quartz (SiO2,
232
PDF2 pattern file #01-089-8934) and apatite (Ca5(PO4)3OH or Ca5(PO4)3F or
233
Ca5(PO4)3Cl, PDF2 pattern file #01-086-0740). Minor phases such as kaolinite
234
(Al2Si2O5(OH)4) or berlinite (aluminum phosphate, AlPO4, PDF2 pattern file #01-076-
235
0228) may also have been present, but the diffraction patterns were not conclusive. The
236
presence of a large amount of crystalline quartz phase evidenced the igneous origin of
237
this rock 33. All the identified phases were consistent with the chemical analysis results
238
shown in Table 1.
239
Fluoride and chloride were also detected in significant amounts (Table 1),
240
indicating that the apatite phase was probably mostly fluorapatite and/or chlorapatite.
241
Mineralogical analysis (Supporting Information, Section 3) suggested that the chloride
242
may have all been in the form of KCl, while fluoride was present as fluorapatite
243
(Ca5(PO4)3F), considering the higher affinity of F for calcium-based phases
244
mineralogical analyses also showed that the phosphate phase contained in this rock was
245
about 50% (w/w).
34, 35
. The
246
Physical characterization of the IPR samples obtained using different milling
247
times was performed by SEM. The micrographs showed that a longer milling time
248
resulted in smaller IPR particle size (Supporting Information, Section 1, Fig. S3), while
249
short milling times (such as 2.5 min) only resulted in de-agglomeration. An effect on
250
particle size only occurred after 5 min of grinding, when the first submicron particles
251
became apparent. These observations are supported by the results of the surface area
252
and particle size (Table 2), showing that the specific surface area of the sample milled
253
for 2.5 min was approximately the same as that of the original sample. However, the
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specific surface area increased by about 70% for the material milled for 10 min and
255
more than 3-fold for the material milled for 80 min.
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Another important aspect to consider is the energy consumption required in such
257
milling process, as this energy could add to the overall process cost. In order to evaluate
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that, the energy consumption for milling the IPR was estimated according to the Bond
259
Law (Supporting Information, Section 3, Table S1) 36, 37. For this type of PR, the energy
260
consumption for milling 1 kg of IPR during 80 min (0.156 kW) would be 2.4-fold
261
higher than energy consumed in 10 min (0.065 kW). Therefore, this aspect should also
262
be taken into consideration in the overall process development in order to contribute to
263
cost reduction and to ensure the sustainability benefits of the final bioproduct.
264 265
Effect of particle size on P solubilization
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Fig. 1 shows the effect of the IPR particle size on P solubilization using A. niger
267
cultivated under both SmC (Fig. 1a) and SSC (Fig. 1b) with IPR that had been milled
268
for different periods of time (Table 2). For both cultivation methods, there were
269
significant increases in P solubilization as the specific surface area increased, with a
270
maximum of 70% solubilization achieved under SmC with IPR milled for 80 min.
271
Nevertheless, this value was statistically equivalent to the solubilization value achieved
272
using the IPR milled for 40 min (Tukey’s test at the 95% confidence level). This
273
represented an increase of 90% in P solubilization, compared to the natural IPR. Under
274
SSC, the solubilization of P achieved using the same particle size was 61%,
275
representing an increase of around 110%, compared to the natural IPR. In addition to
276
the positive effect of the smaller size of the IPR, greater P solubilization could have
277
resulted from enhanced interaction between the rock particles and the organic acids
278
produced by A. niger.
279
These results indicated that the milling time had a greater influence in the case of 12
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igneous rocks, compared to sedimentary rocks, since in earlier work
we showed that
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rock (a sedimentary rock). This behavior was directly related to the rock friability,
283
which is generally higher for igneous rocks. However, the optimum milling point had
284
not yet been reached, with the solubilization efficiency tending to stabilize with the
285
reduction of particle size.
286
The results showed that manipulation of the rock phosphate particle size
287
significantly enhanced phosphorus solubilization under both SmC and SSC. However,
288
the mechanical activation could also have affected other constituent phases of the IPR.
289
Therefore, in order to obtain a better understanding of the effect of particle size on the
290
solubilization of IPR, evaluation was made of solubilization of the elements Ca, Fe, and
291
Al present in the IPR. In addition, production of the main organic acids was quantified
292
for all the grinding times. Since SmC was more effective than SSC for phosphate
293
solubilization, and considering that SmC and SSC showed similar features during the
294
solubilization processes, in the next experiments only SmC was used as a model
295
microbial cultivation process. Nevertheless, it is important to highlight the potential of
296
SSC from the environmental and sustainability stand point as well, as an advantage of
297
SSC is the possibility to use solid substrates consisting of agro-industrial lignocellulosic
298
residues as sources of carbon and energy for microbial growth and promotion of PR
299
solubilization 38.
300 301
Effect of particle size on Ca, Fe, and Al solubilization and organic acid production
302
Table 3 shows the organic acids (citric, oxalic, and gluconic) and soluble Ca, Fe,
303
and Al produced after 96 h of SmC cultivation using the different particle sizes. Low
304
concentrations of soluble Ca were observed in all cases, corresponding to about 1% of
305
the total Ca in the IPR. These low values could have been due to the precipitation of
306
calcium oxalate following reaction with oxalic acid
307
levels of Ca and oxalic acid in the solution. This hypothesis was in agreement with the
8, 22
, which would decrease the
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low amount of oxalic acid detected in the medium after the solubilization process.
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Nevertheless, the concentration of soluble Ca increased slightly with higher surface area
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of the IPR.
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The release of Fe during the solubilization process was minimal, at around 0.5 mg
312
L-1 for all IPR particle sizes, representing 0.7% of the initial amount of Fe. However,
313
soluble Al showed a significant increase with IPR particle surface area, especially for
314
material milled for more than 20 min. This effect was probably associated with the
315
lower pH of the medium induced by the fungal activity. Since the Al phases are fully
316
soluble at pH