Methods, compositions, and systems for steeping, propagation and fermentation, particularly large-scale operations for production of starch and ethanol and fermentation product streams are provided. Addition of mycotoxin mitigating enzymes or microorganisms expressing mycotoxin mitigating enzymes to steeping, propagation, and/or fermentation tanks, and/or to post-fermentation product streams, mitigates mycotoxin levels in fermentation co-products obtained from mycotoxin contaminated feedstocks.

The invention pertains to a method for synthesizing a product of interest by culturing a microalgal cell obtained from a subterranean habitat for producing the product of interest. The microalgal cell obtained from a subterranean habitat can be cultured in the dark, in light, in low nutrition, or nutrient rich conditions for at least a portion of production cycle. A combination of these conditions can be used to specifically manipulate a microalgal cell culture to produce a product of interest. The product of interest can be a water-soluble carotenoid, for example, a water-soluble carotenoid produced by culturing an algae belonging to the genus Haematococcus or a capsular exopolysaccharide produced by culturing an algae belonging to the genus Parachlorella. Compositions containing the water-soluble carotenoid, for example, as sunscreen and compositions containing the exopolysaccharide, for example, as moisturizing cream are also described.

The invention pertains to a method for synthesizing a product of interest by culturing a microalgal cell obtained from a subterranean habitat for producing the product of interest. The microalgal cell obtained from a subterranean habitat can be cultured in the dark, in light, in low nutrition, or nutrient rich conditions for at least a portion of production cycle. A combination of these conditions can be used to specifically manipulate a microalgal cell culture to produce a product of interest. The product of interest can be a water-soluble carotenoid, for example, a water-soluble carotenoid produced by culturing an algae belonging to the genus Haematococcus or a capsular exopolysaccharide produced by culturing an algae belonging to the genus Parachlorella. Compositions containing the water-soluble carotenoid, for example, as sunscreen and compositions containing the exopolysaccharide, for example, as moisturizing cream are also described.

The invention provides for the optimal utilization of gas by a fermentation process, whereby the various components within the gas stream are separated to increase the efficiency of the microorganisms. The invention is capable of tailoring the composition of the gas being used by the fermentation process so as to enhance the production of various products. The invention is capable of applying such controlled separation and utilization of gas to produce different products in two parallel fermentation processes. The invention is also capable of applying such controlled separation and utilization of gas to produce one product in a first fermentation process, which may be converted to a different product in a second fermentation process. The invention is additionally capable of mitigating culture inhibition.

The invention relates to a method for producing a solid transformation product of a substrate comprising the following steps: ⋅preparing a substrate of biomass comprising carbohydrates and proteinaceous matter that originates from soya bean, rape seed, or mixtures thereof, optionally in further mixture with carbohydrates and proteinaceous matter originating from fava beans, peas, sunflower seeds, lupine, cereals, and/or grasses, ⋅mixing said substrate with an enzyme preparation or a combination of enzyme preparations and adding water in an amount which provides an initial incubation mixture having a water content from 30 to 70% by weight, and a ratio of wet bulk density to dry bulk density from 0.60 to 1.45 in the resulting mixture; ⋅incubating said initial incubation mixture for 0.15-72 hours at a temperature of 20-70° C.; and thereafter recovering wet solid transformation product from the incubated mixture; further comprising that the incubating step is performed as a continuous plug-flow process in a vertical, non-agitated incubation tank with inlet means for said mixture and additives and outlet means for said solid transformation product.

The invention relates to a method for producing a solid transformation product of a substrate comprising the following steps: ⋅preparing a substrate of biomass comprising carbohydrates and proteinaceous matter that originates from soya bean, rape seed, or mixtures thereof, optionally in further mixture with carbohydrates and proteinaceous matter originating from fava beans, peas, sunflower seeds, lupine, cereals, and/or grasses, ⋅mixing said substrate with an enzyme preparation or a combination of enzyme preparations and adding water in an amount which provides an initial incubation mixture having a water content from 30 to 70% by weight, and a ratio of wet bulk density to dry bulk density from 0.60 to 1.45 in the resulting mixture; ⋅incubating said initial incubation mixture for 0.15-72 hours at a temperature of 20-70° C.; and thereafter recovering wet solid transformation product from the incubated mixture; further comprising that the incubating step is performed as a continuous plug-flow process in a vertical, non-agitated incubation tank with inlet means for said mixture and additives and outlet means for said solid transformation product.

A method of preparing includes storing cut crop material in an accumulation having an oxygen barrier. The cut crop material ferments within the accumulation to form a silage material. After the fermentation of the silage material, the silage material is mechanically macerated with a macerator, and then fed to ruminant animals.

A method of preparing includes storing cut crop material in an accumulation having an oxygen barrier. The cut crop material ferments within the accumulation to form a silage material. After the fermentation of the silage material, the silage material is mechanically macerated with a macerator, and then fed to ruminant animals.

“Green” methods of preparing oxygenated products, animal feed, and fertilizer are disclosed. Desired oxygenated products include, but are not limited to, ethanol, acetic acid, butyrate, butanol, propionate, propanol, or any combination thereof. The methods use synthesis gas (syngas), which can be produced from processing of coal, natural gas, and/or biomass. The syngas contains some combination of hydrogen, carbon monoxide, and/or carbon dioxide. The method entails blending the syngas with purge (tail) gases from industrial processes and/or with hydrogen gas, e.g., produced from renewable sources. The resulting mixture is a H.sub.2-enriched syngas that is fermented by microorganisms that are well suited to ferment hydrogen-rich gases. Byproducts from the method can also be recovered. The disclosure also provides methods of preparing material fertilizer and animal feed, respectively. By repurposing purge gases so they are not emitted into the environment and/or using hydrogen from renewable sources, the disclosed methods are environmentally-friendly.

The invention herein is directed to pig waste silage, which is derived from the conversion of pig waste, a fermentable sugar source, and lactic acid fermentable culture, thereby pig waste is transformed into a nitrogen-rich, crude protein concentrate ingredient, suitable for consumption by cattle, sheep, and goat diets. The pig waste silage of the invention herein is a crude protein source that can lower operational costs for cattle and other ruminant producers, by using less protein-based grains, as well as reduction in greenhouse gas emissions, through a better and more efficient digestion of ruminants, based on physiological principles.