A sustainable bioprocessing system leveraging gas fermentation and bipolar membrane electrodialysis system for direct recovery of acetic acid

[Display omitted] •Demonstrated integrating gas fermentation with BPMED system.•Continues CO2 fermentation with methanol supplement.•High purity acetate extraction with direct acetic acid production were obtained.•The integrated BPMED system saved 13 % cost reduction than ED system.•The integrated BPMED system saved 5 % CO2 emission than ED system. This study examined the integration of gas fermentation with bipolar membrane electrodialysis (BPMED) for sustainable production of acetic acid and bases, focusing on medium recycling and ion-exchange membrane optimisation. Gas fermentation was performed using an acetogenic microbe, Eubacterium callanderi KIST612, in a custom-designed gas bioreactor. The BPMED system was operated under specific voltage conditions to evaluate the proton and hydroxyl ion generation, ion concentration, and residual ratios. Gas fermentation consistently generated acetate with a stable CO2 consumption rate (0.167 mmol gcell−1) and an increased rate of conversion of carbon into biochemicals via methanol. The BPMED system efficiently produced acetic acid (acetate extraction rate of 99.72 %–99.82 %) and hydroxide ions (from 8 to 18 V), with operational challenges identified at higher voltage levels (≥20 V). The BPMED process, which includes additional membranes and exhibits a lower acetate flux than the ED process, had remarkable cost-effectiveness, surpassing the ED integration process by 17.6 %. This economic advantage was paralleled by a significant environmental benefit, where the BPMED process reduced carbon dioxide emissions by 7.4 % compared with the ED process. These results suggest that integrating gas fermentation with BPMED is a viable and sustainable approach for acetic acid production.