Determination of reactor operation for the microbial hydroxylation of toluene in a two-liquid phase process

Continuous cyclohexane oxidation to cyclohexanol using a novel cytochrome P450 monooxygenase from Acidovorax sp. CHX100 in recombinant P. taiwanensis VLB120 biofilms

The applications of biocatalysts in chemical industries are characterized by activity, selectivity, and stability. One key strategy to achieve high biocatalytic activity is the identification of novel enzymes with kinetics optimized for organic synthesis by Nature. The isolation of novel cytochrome P450 monooxygenase genes from Acidovorax sp. CHX100 and their functional expression in recombinant Pseudomonas taiwanensis VLB120 enabled efficient oxidation of cyclohexane to cyclohexanol. Although initial resting cell activities of 20 U gCDW (-1) were achieved, the rapid decrease in catalytic activity due to the toxicity of cyclohexane prevented synthetic applications. Cyclohexane toxicity was reduced and cellular activities stabilized over the reaction time by delivering the toxic substrate through the vapor phase and by balancing the aqueous phase mass transfer with the cellular conversion rate. The potential of this novel CYP enzyme was exploited by transferring the shake flask reaction to an aqueous-air segmented flow biofilm membrane reactor for maximizing productivity. Cyclohexane was continuously delivered via the silicone membrane. This ensured lower reactant toxicity and continuous product formation at an average volumetric productivity of 0.4 g L tube (-1) h(-1) for several days. This highlights the potential of combining a powerful catalyst with a beneficial reactor design to overcome critical issues of cyclohexane oxidation to cyclohexanol. It opens new opportunities for biocatalytic transformations of compounds which are toxic, volatile, and have low solubility in water.

Redox biocatalysis and metabolism: molecular mechanisms and metabolic network analysis

Whole-cell biocatalysis utilizes native or recombinant enzymes produced by cellular metabolism to perform synthetically interesting reactions. Besides hydrolases, oxidoreductases represent the most applied enzyme class in industry. Oxidoreductases are attributed a high future potential, especially for applications in the chemical and pharmaceutical industries, as they enable highly interesting chemistry (e.g., the selective oxyfunctionalization of unactivated C-H bonds). Redox reactions are characterized by electron transfer steps that often depend on redox cofactors as additional substrates. Their regeneration typically is accomplished via the metabolism of whole-cell catalysts. Traditionally, studies towards productive redox biocatalysis focused on the biocatalytic enzyme, its activity, selectivity, and specificity, and several successful examples of such processes are running commercially. However, redox cofactor regeneration by host metabolism was hardly considered for the optimization of biocatalytic rate, yield, and/or titer. This article reviews molecular mechanisms of oxidoreductases with synthetic potential and the host redox metabolism that fuels biocatalytic reactions with redox equivalents. The tools discussed in this review for investigating redox metabolism provide the basis for studies aiming at a deeper understanding of the interplay between synthetically active enzymes and metabolic networks. The ultimate goal of rational whole-cell biocatalyst engineering and use for fine chemical production is discussed.

Miniaturized test system for soil respiration induced by volatile pollutants

A miniaturized method based on 96-well microtitre plates was developed and used to study respiration in pristine and contaminated soils following addition of volatile substrates. Small soil samples were exposed to fuel components, which were volatilized from spatially separate reservoirs of 2,2,4,4,6,8,8-heptamethylnonane (HMN) as an organic carrier. Respiration was determined as CO(2) production by means of a pH-indicator and bicarbonate-containing agar, or as (14)CO(2) evolution from (14)C-labelled substrates. Substrate concentrations inducing maximum microbial activity or inhibition were determined and CO(2) production profiles examined by multivariate analysis. When high concentrations of fuel components were applied, distinction of hydrocarbon exposed soils from unexposed soil was achieved within 6 h of incubation. With low concentrations, adequate distinction was achieved after 24 h, probably as a result of community adaptation. Nutrient limitation was identified with the (14)C method for toluene, and the optimal N and P amendment determined. Further potential applications of this rapid and inexpensive method are outlined.

Process implementation aspects for biocatalytic hydrocarbon oxyfunctionalization

Oxidoreductases catalyze a large variety of regio-, stereo-, and chemoselective hydrocarbon oxyfunctionalizations, reactions, which are important in industrial organic synthesis but difficult to achieve by chemical means. This review summarizes process implementation aspects for the in vivo application of the especially versatile enzyme class of oxygenases, capable of specifically introducing oxygen from molecular oxygen into a large range of organic molecules. Critical issues such as reaching high enzyme activity and specificity, product degradation, cofactor recycling, reactant toxicity, and substrate and oxygen mass transfer can be overcome by biochemical process engineering and biocatalyst engineering. Both strategies provide a growing toolset to facilitate process implementation, optimization, and scale-up. Major advances were achieved via heterologous overexpression of oxygenase genes, directed evolution, metabolic engineering, and in situ product removal. Process examples from industry and academia show that the combined use of different concepts enables efficient oxygenase-based whole-cell catalysis of various commercially interesting reactions such as the biosynthesis of chiral compounds, the specific oxyfunctionalization of complex molecules, and also the synthesis of medium-priced chemicals. Better understanding of the cell metabolism and future developments in both biocatalyst and bioprocess engineering are expected to promote the implementation of many and various industrial biooxidation processes.

Use of the two-liquid phase concept to exploit kinetically controlled multistep biocatalysis

The two-liquid phase concept was used to develop a whole cell biocatalytic system for the efficient multistep oxidation of pseudocumene to 3,4-dimethylbenzaldehyde. Recombinant Escherichia coli cells were employed to express the Pseudomonas putida genes encoding xylene monooxygenase, which catalyzes the multistep oxygenation of one methyl group of toluene and xylenes to corresponding alcohols, aldehydes, and acids. A fed-batch based two-liquid phase bioconversion was established with bis(2-ethylhexyl)- phthalate as organic carrier solvent and a phase ratio of 0.5; the product formation pattern, the impact of the nutrient feeding strategy, and the partitioning behavior of the reactants were studied. On the basis of the favorable conditions provided by the two-liquid phase system, engineering of the initial pseudocumene concentration allowed exploiting the complex kinetics of the multistep reaction for the exclusive production of 3,4-dimethyl- benzaldehyde. Further oxidation of the product to 3,4-dimethylbenzoic acid could be inhibited by suitable concentrations of pseudocumene or 3,4-dimethylbenzyl alcohol. The optimized biotransformation setup includes a completely defined medium with high iron content and a nutrient feeding strategy that avoids severe glucose limitation as well as high inhibitory glucose levels. Using such a system on a 2-liter scale, we were able to produce, within 14.5 h, 30 g of 3,4-dimethylbenzaldehyde as predominant reactant in the organic phase and reached a maximal productivity of 1.6 g per liter liquid volume per hour. The present study implicates that the two-liquid phase concept is an efficient tool to exploit the kinetics of multistep biotransformations in general.

Membrane-facilitated bioproduction of 3-methylcatechol in an octanol/water two-phase system

Bioproduction of 3-methylcatechol from toluene by Pseudomonas putida MC2 was studied in the presence of an additional 1-octanol phase. This solvent was used to supply the substrate and extract the product, in order to keep the aqueous concentrations low. A hollow-fibre membrane kept the octanol and aqueous phase separated to prevent phase toxicity towards the bacterium. Volumetric production rates increased approximately 40% as compared to two-phase 3-methylcatechol production with direct phase contact. Preliminary investigations on downstream processing of 3-methylcatechol showed that 1 M of sodium hydroxide selectively extracted the disodium salt of 3-methylcatechol into an aqueous phase.

Integrated bioproduction and extraction of 3-methylcatechol

Pseudomonas putida MC2 is a solvent-tolerant strain that accumulates 3-methylcatechol. In aqueous media, 10 mM of 3-methylcatechol was produced and production was limited by 3-methylcatechol toxicity to the biocatalyst. Production levels increased by introduction of a second, organic phase that provides the substrate toluene and extracts the product from the culture medium. Octanol was shown to be an appropriate second phase with respect to tolerance of the strain for this solvent and with respect to partitioning of both substrate and product. Per unit of overall reactor volume (octanol and water), best results were obtained with 50% (v/v) of octanol: an overall 3-methylcatechol concentration of 25 mM was reached with 96% of the product present in the octanol phase. These product concentrations are much higher than in aqueous media without organic solvent, indicating that biocatalysis in an organic/aqueous two-phase system is an improved set-up for high production levels of 3-methylcatechol.

Advances in enzyme technology--UK contributions

Enzyme technology has been a recognised part of bioprocess engineering since its inception in the 1950s and 1960s. In this article the early history of enzyme technology is discussed and the subsequent developments in enzyme isolation, enzyme modification and process technology are described. These creative developments have put enzyme technology in a position of huge potential to contribute to environmentally compatible and cost effective means of industrial chemical synthesis. Recent developments in protein modification to produce designer enzymes are leading a new wave of enzyme application.

The use of oxygen uptake rate measurements to control the supply of toxic substrate: toluene hydroxylation by Pseudomonas putida UV4

During toluene hydroxylation, catalyzed by Pseudomonas putida UV4 one molecule of oxygen is added to the aromatic ring to produce the dihydroxylated (non-aromatic) ring structure, toluene cis-glycol. Toluene, which is toxic to the cells at aqueous phase concentration above ( approximately 2.4 mmol), is fed to the reactor. A feed-back control system based on oxygen uptake rate measurements was used to control the feed rate, and thus maintain the aqueous phase toluene concentration in the desired range for zero order kinetics.

Design of a control system for biotransformation of toxic substrates: toluene hydroxylation by Pseudomonas putida UV4

Using the hydroxylation of toluene to toluene cis-glycol by Pseudomonas putida UV4 as an example, the design of a feed-back control system for the addition of a toxic, poorly water-soluble substrate to a fed-batch biotransformation is described. In kinetic studies the reaction followed Michaelis-Menten behavior until toxic toluene concentrations were reached (2.4 mM), above which irreversible denaturation of the biocatalyst was observed. An algorithm, based on a system mass balance, was used to maintain the aqueous phase toluene concentration in the desired range for zero order kinetics. The mass balance required accurate and rapid analysis of the product and reactant in both the liquid and the vapor phase. Various analytical methods were considered and the effect of the sampling and analysis time on the response of the control system was examined.

Medium chain length alkane solvent-cell transfer rates in two-liquid phase, pseudomonas oleovorans cultures

The oxidation of medium chain length alkanes and alkenes (C6 to C12) by Pseudomonas oleovorans and related, biocatalytically active recombinant organisms, in two-liquid phase cultures can be used for the biochemical production of several interesting fine chemicals. The volumetric productivities that can be attained in two-liquid phase systems can be, in contrast to aqueous fermentations, limited by the transport of substrates from an apolar phase to the cells residing in the aqueous phase and by toxic effects of apolar solvents on microbial cells. We have assessed the impact of these possible limitations on attainable productivities in two-liquid phase fermentations operated with mcl-alkanes. Pseudomonas oleovorans grows well in two-liquid phase media containing a bulk n-octane phase as the sole carbon source. However, cells are also damaged, typically resulting in a cell lysis rate of about 0.08 to 0. 10 h-1. These rates could be lowered by 50 to 70% to 0.03 h-1 and substrate yields increased from 0.55 to 0.85 g g-1 by diluting octane in non-metabolizable long-chain hydrocarbon solvents. Transfer rates of medium chain length (mcl) alkanes from the apolar phase to the cells were determined by following growth and the rate at which carbon-containing metabolites accumulated in the different phases of the cultures. mcl-Alkane solvent-cell transfer rates of at least 79, 64, and 18 mmol per liter of aqueous medium per hour were determined for n-heptane, n-octane, and n-decane, respectively. Rates of up to 30 mmol L-1 h-1 were observed under octane-limiting conditions in systems where the apolar substrate was dissolved to concentrations below 3% (v/v) in hexadecene. Based on low power input experiments, we estimated the maximum obtainable mass transfer rates in large scale processes to be in the range of 13 mmol L-1 h-1 for decane and higher than 45 mmol L-1 h-1 for octane and heptane. The results indicate that high solvent to cell mass transfer rates and minimized cell damage will enable high production rates in two-liquid phase bioprocesses, justifying ongoing efforts to attain high densities of catalytically, highly active cells in such systems. Copyright 1998 John Wiley & Sons, Inc.

Partitioning bioreactors

A very wide range of methods has recently been employed to selectively partition fermentation products, substrates, or other metabolites to achieve an overall improvement in bioprocess performance. Techniques ranging from extraction and gas stripping to electrokinetic methods have been used to favorably influence the microenvironment of cells being cultivated in bioreactors. Virtually all types of cells, including animal cells, have benefitted by such selective partitioning and very high value fermentation products, such as monoclonal antibodies and secondary metabolites, have been produced using this process concept.