A fed-batch strategy integrated with mechanical activation improves

92 development of a feasible industrial bioprocess for PR treatment and environmentally. 93 ..... Fluoride and chloride were also detected in signific...
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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

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*Correspondence author

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Tel.: +55-16-2107-2908;

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Fax: +55-16-2107-5754;

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E-mail address: [email protected]

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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.

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The effectiveness of this PR biological solubilization process is driven by the microbial

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production of organic acids that chelate the cations (mainly calcium) bound to

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phosphate. However, the biological solubilization efficiency has been limited by the PR

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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

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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.

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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.

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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

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A detailed characterization of the original and milled samples of IPR was carried

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out in order to understand the physical and chemical nature of the phosphate source

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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,

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PDF2 pattern file #01-089-8934) and apatite (Ca5(PO4)3OH or Ca5(PO4)3F or

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Ca5(PO4)3Cl, PDF2 pattern file #01-086-0740). Minor phases such as kaolinite

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(Al2Si2O5(OH)4) or berlinite (aluminum phosphate, AlPO4, PDF2 pattern file #01-076-

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0228) may also have been present, but the diffraction patterns were not conclusive. The

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presence of a large amount of crystalline quartz phase evidenced the igneous origin of

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this rock 33. All the identified phases were consistent with the chemical analysis results

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shown in Table 1.

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Fluoride and chloride were also detected in significant amounts (Table 1),

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indicating that the apatite phase was probably mostly fluorapatite and/or chlorapatite.

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Mineralogical analysis (Supporting Information, Section 3) suggested that the chloride

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may have all been in the form of KCl, while fluoride was present as fluorapatite

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(Ca5(PO4)3F), considering the higher affinity of F for calcium-based phases

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mineralogical analyses also showed that the phosphate phase contained in this rock was

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about 50% (w/w).

34, 35

. The

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Physical characterization of the IPR samples obtained using different milling

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times was performed by SEM. The micrographs showed that a longer milling time

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resulted in smaller IPR particle size (Supporting Information, Section 1, Fig. S3), while

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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

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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

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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

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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

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Law (Supporting Information, Section 3, Table S1) 36, 37. For this type of PR, the energy

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consumption for milling 1 kg of IPR during 80 min (0.156 kW) would be 2.4-fold

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higher than energy consumed in 10 min (0.065 kW). Therefore, this aspect should also

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be taken into consideration in the overall process development in order to contribute to

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cost reduction and to ensure the sustainability benefits of the final bioproduct.

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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

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cultivated under both SmC (Fig. 1a) and SSC (Fig. 1b) with IPR that had been milled

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for different periods of time (Table 2). For both cultivation methods, there were

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significant increases in P solubilization as the specific surface area increased, with a

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maximum of 70% solubilization achieved under SmC with IPR milled for 80 min.

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Nevertheless, this value was statistically equivalent to the solubilization value achieved

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using the IPR milled for 40 min (Tukey’s test at the 95% confidence level). This

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represented an increase of 90% in P solubilization, compared to the natural IPR. Under

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SSC, the solubilization of P achieved using the same particle size was 61%,

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representing an increase of around 110%, compared to the natural IPR. In addition to

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the positive effect of the smaller size of the IPR, greater P solubilization could have

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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,

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which is generally higher for igneous rocks. However, the optimum milling point had

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not yet been reached, with the solubilization efficiency tending to stabilize with the

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reduction of particle size.

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The results showed that manipulation of the rock phosphate particle size

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significantly enhanced phosphorus solubilization under both SmC and SSC. However,

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the mechanical activation could also have affected other constituent phases of the IPR.

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Therefore, in order to obtain a better understanding of the effect of particle size on the

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solubilization of IPR, evaluation was made of solubilization of the elements Ca, Fe, and

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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

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microbial cultivation process. Nevertheless, it is important to highlight the potential of

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SSC from the environmental and sustainability stand point as well, as an advantage of

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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

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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

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concentrations of soluble Ca were observed in all cases, corresponding to about 1% of

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the total Ca in the IPR. These low values could have been due to the precipitation of

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calcium oxalate following reaction with oxalic acid

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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

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L-1 for all IPR particle sizes, representing 0.7% of the initial amount of Fe. However,

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soluble Al showed a significant increase with IPR particle surface area, especially for

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material milled for more than 20 min. This effect was probably associated with the

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lower pH of the medium induced by the fungal activity. Since the Al phases are fully

316

soluble at pH