Biomass, strain engineering, and fermentation processes for butanol production by solventogenic clostridia

Butanol-isopropanol fermentation with oxygen-tolerant Clostridium beijerinckii XH29

Acetone–butanol–ethanol (ABE) fermentation is a traditional way for solvents production through bioconversion by Clostridium species. It is still a challenge to obtain metabolic engineering strains with high ABE yield. Screening strains with remarkable characteristics from nature and improving ABE yield by mutation are viable approaches. Clostridium beijerinckii XH 0906, a newly isolated strain, produces butanol and isopropanol (BI) as the main end-products (9.1 g/L BI) during fermentation with glucose as the sole carbon source. The screening process for this strain was performed under aerobic conditions rather than anaerobic environment. Thus, it is a robust stain capable of oxygen-tolerant BI fermentation. Furthermore, C. beijerinckii XH 0906 fermented xylose and glucose simultaneously to produce BI. A mutant strain obtained by ultraviolet (UV) mutagenesis, C. beijerinckii XH 29, had improved BI production capacity and could produce 17.0 g/L BI and 18.4 g/L BI using glucose or corn stover hydrolysate, respectively as the carbon source. Interestingly, C. beijerinckii XH 29 also produced up to 19.3 g/L isopropanol through fermentation of a glucose–acetone mix. These results indicate that C. beijerinckii XH 29 is an excellent BI producer with great potential for industrial applications.

A newly isolated strain produces butanol and isopropanol (BI) rather than acetone butanol and ethanol (ABE).

The strain is oxygen-tolerant and robust in the fermentation.

A mutant obtained by ultraviolet mutagenesis produces higher levels of BI than the wild type strain using corn stover as a carbon source.

Production of Hexanol as the Main Product Through Syngas Fermentation by Clostridium carboxidivorans P7

The production of hexanol from syngas by acetogens has gained attention as a replacement for petroleum-derived hexanol, which is widely used in the chemical synthesis and plastic industries. However, acetogenic bacteria generally produce C2 compounds (e.g., acetate and ethanol) as the main products. In this study, the gas fermentation conditions favorable for hexanol production were investigated at different temperatures (30-37°C) and CO gas contents (30-70%) in batch gas fermentation. Hexanol production increased from 0.02 to 0.09 g/L when the cultivation temperature was lowered from 37 to 30°C. As the CO content increased from 30 to 70%, the CO consumption rate and hexanol production (yield, titer, and ratio of C6 compound to total products) increased with the CO content. When 70% CO gas was repeatedly provided by flushing the headspace of the bottles at 30°C, the total alcohol production increased to 4.32 g/L at the expense of acids. Notably, hexanol production (1.90 g/L) was higher than that of ethanol (1.20 g/L) and butanol (1.20 g/L); this is the highest level of hexanol produced in gas fermentation to date and the first report of hexanol as the main product. Hexanol production was further enhanced to 2.34 g/L when 2 g/L ethanol was supplemented at the beginning of 70% CO gas refeeding fermentation. Particularly, hexanol productivity was significantly enhanced to 0.18 g/L/day while the supplemented ethanol was consumed, indicating that the conversion of ethanol to acetyl-CoA and reducing equivalents positively affected hexanol production. These optimized culture conditions (gas fermentation at 30°C and refeeding with 70% CO gas) and ethanol supplementation provide an effective and sustainable approach for bio-hexanol production.

Citrulline deiminase pathway provides ATP and boosts growth of Clostridium carboxidivorans P7

BACKGROUND

Clostridium carboxidivorans P7 is capable of producing ethanol and butanol from inexpensive and non-food feedstock, such as syngas. Achieving improved ethanol and butanol production in the strain for industrial application depends on the energetics and biomass, especially ATP availability.

RESULTS

This study found that exogenous addition of citrulline promoted accumulation of ATP, increased specific growth rate, and reduced the doubling time of C. carboxidivorans P7. In heterotrophic fermentation experiments, the addition of citrulline increased intracellular ATP by 3.39-fold, significantly enhancing the production of total alcohol (ethanol + butanol) by 20%. Moreover, in the syngas fermentation experiments, the addition of citrulline improved the level of intracellular ATP and the biomass by 80.5% and 31.6%, respectively, resulting in an 18.6% and 60.3% increase in ethanol and the alcohol/acid production ratio, respectively.

CONCLUSIONS

This is the first report that citrulline could promote the growth of C. carboxidivorans P7 and increase the level of intracellular ATP, which is of great significance for the use of C. carboxidivorans P7 to synthesize biofuels.

Enhanced sucrose fermentation by introduction of heterologous sucrose transporter and invertase into Clostridium beijerinckii for acetone-butanol-ethanol production

A heterologous pathway for sucrose transport and metabolism was introduced into Clostridium beijerinckii to improve sucrose use for n-butanol production. The combined expression of StSUT1, encoding a sucrose transporter from potato (Solanum tuberosum), and SUC2, encoding a sucrose invertase from Saccharomyces cerevisiae, remarkably enhanced n-butanol production. With sucrose, sugarcane molasses and sugarcane juice as substrates, the C. beijerinckii strain harbouring StSUT1 and SUC2 increased acetone-butanol-ethanol production by 38.7%, 22.3% and 52.8%, respectively, compared with the wild-type strain. This is the first report to demonstrate enhanced sucrose fermentation due to the heterologous expression of a sucrose transporter and invertase in Clostridium. The metabolic engineering strategy used in this study can be widely applied in other microorganisms to enhance the production of high-value compounds from sucrose-based biomass.

Emerging technologies for conversion of sustainable algal biomass into value-added products: A state-of-the-art review

Concerns regarding high energy demand and gradual depletion of fossil fuels have attracted the desire of seeking renewable and sustainable alternatives. Similar to but better than the first- and second-generation biomass, algae derived third-generation biorefinery aims to generate value-added products by microbial cell factories and has a great potential due to its abundant, carbohydrate-rich and lignin-lacking properties. However, it is crucial to establish an efficient process with higher competitiveness over the current petroleum industry to effectively utilize algal resources. In this review, we summarize the recent technological advances in maximizing the bioavailability of different algal resources. Following an overview of approaches to enhancing the hydrolytic efficiency, we review prominent opportunities involved in microbial conversion into various value-added products including alcohols, organic acids, biogas and other potential industrial products, and also provide key challenges and trends for future insights into developing biorefineries of marine biomass.

Recent advances in the valorization of plant biomass

Plant biomass is a highly abundant renewable resource that can be converted into several types of high-value-added products, including chemicals, biofuels and advanced materials. In the last few decades, an increasing number of biomass species and processing techniques have been developed to enhance the application of plant biomass followed by the industrial application of some of the products, during which varied technologies have been successfully developed. In this review, we summarize the different sources of plant biomass, the evolving technologies for treating it, and the various products derived from plant biomass. Moreover, the challenges inherent in the valorization of plant biomass used in high-value-added products are also discussed. Overall, with the increased use of plant biomass, the development of treatment technologies, and the solution of the challenges raised during plant biomass valorization, the value-added products derived from plant biomass will become greater in number and more valuable.

Acetone, butanol, and ethanol production from puerariae slag hydrolysate through ultrasound-assisted dilute acid by Clostridium beijerinckii YBS3

In this study, puerariae slag (PS) was evaluated as a renewable raw material for acetone-butanol-ethanol (ABE) fermentation. To accelerate the hydrolysis of PS, the method of ultrasound-assisted dilute acid hydrolysis (UAAH) was used. With this effort, 0.69 g reducing sugar was obtained from 1 g raw material under the optimal pretreatment condition. Subsequently, the butanol and total solvent production of 8.79 ± 0.16 g/L and 12.32 ± 0.26 g/L were obtained from the non-detoxified diluted hydrolysate, and the yield and productivity of butanol were 0.19 g/g and 0.12 g/L/h, respectively. Additionally, the changes in the structure of PS after different pretreatment methods were observed using SEM and FT-IR. UAAH resulted in more severe and distinct damage to the dense structure of PS. This study suggests that the UAAH is an attainable but effective pretreatment method, thereby is a promising technique for lignocellulose hydrolysis and improve butanol production.

Smart fermentation engineering for butanol production: designed biomass and consolidated bioprocessing systems

There is a renewed interest in acetone-butanol-ethanol (ABE) fermentation from renewable substrates for the sustainable and environment-friendly production of biofuel and platform chemicals. However, the ABE fermentation is associated with several challenges due to the presence of heterogeneous components in the renewable substrates and the intrinsic characteristics of ABE fermentation process. Hence, there is a need to select optimal substrates and modify their characteristics suitable for the ABE fermentation process or microbial strain. This "designed biomass" can be used to establish the consolidated bioprocessing systems. As there are very few reports on designed biomass, the main objectives of this review are to summarize the main challenges associated with ABE fermentation from renewable substrates and to introduce feasible strategies for designing the substrates through pretreatment and hydrolysis technologies as well as through the establishment of consolidated bioprocessing systems. This review offers new insights on improving the efficiency of ABE fermentation from designed renewable substrates.

Production of n-butanol from cassava bagasse hydrolysate by engineered Clostridium tyrobutyricum overexpressing adhE2: Kinetics and cost analysis

The production of biofuels such as butanol is usually limited by the availability of inexpensive raw materials and high substrate cost. Using food crops as feedstock in the biorefinery industry has been criticized for its competition with food supply, causing food shortage and increased food prices. In this study, cassava bagasse as an abundant, renewable, and inexpensive byproduct from the cassava starch industry was used for n-butanol production. Cassava bagasse hydrolysate containing mainly glucose was obtained after treatments with dilute acid and enzymes (glucoamylases and cellulases) and then supplemented with corn steep liquor for use as substrate in repeated-batch fermentation with engineered Clostridium tyrobutyricum CtΔack-adhE2 in a fibrous-bed bioreactor. Stable butanol production with high titer (>15.0 g/L), yield (>0.30 g/g), and productivity (~0.3 g/L∙h) was achieved, demonstrating the feasibility of an economically competitive process for n-butanol production from cassava bagasse for industrial application.

n-Butanol production from lignocellulosic biomass hydrolysates without detoxification by Clostridium tyrobutyricum Δack-adhE2 in a fibrous-bed bioreactor

Acetone-butanol-ethanol fermentation suffers from high substrate cost and low butanol titer and yield. In this study, engineered Clostridium tyrobutyricum CtΔack-adhE2 immobilized in a fibrous-bed bioreactor was used for butanol production from glucose and xylose present in the hydrolysates of low-cost lignocellulosic biomass including corn fiber, cotton stalk, soybean hull, and sugarcane bagasse. The biomass hydrolysates obtained after acid pretreatment and enzymatic hydrolysis were supplemented with corn steep liquor and used in repeated-batch fermentations. Butanol production with high titer (∼15 g/L), yield (∼0.3 g/g), and productivity (∼0.3 g/L∙h) was obtained from cotton stalk, soybean hull, and sugarcane bagasse hydrolysates, while corn fiber hydrolysate with higher inhibitor contents gave somewhat inferior results. The fermentation process was stable for long-term operation without any noticeable degeneration, demonstrating its potential for industrial application. A techno-economic analysis showed that n-butanol could be produced from lignocellulosic biomass using this novel fermentation process at ∼$2.5/gal for biofuel application.

A Convenient Fluorescence-Based Assay for the Detection of Sucrose Transport and the Introduction of a Sucrose Transporter from Potato into Clostridium Strains

A convenient and effective sucrose transport assay for Clostridium strains is needed. Traditional methods, such as ¹⁴C-sucrose isotope labelling, use radioactive materials and are not convenient for many laboratories. Here, a sucrose transporter from potato was introduced into Clostridium, and a fluorescence assay based on esculin was used for the analysis of sucrose transport in Clostridium strains. This showed that the heterologously expressed potato sucrose transporter is functional in Clostridium. Recombinant engineering of high-level sucrose transport would aid sucrose fermentation in Clostridium strains. The assay described herein provides an important technological platform for studying sucrose transporter function following heterologous expression in Clostridium.

Metabolic engineering of Clostridium carboxidivorans for enhanced ethanol and butanol production from syngas and glucose

Clostridium carboxidivorans can convert CO₂, CO and H₂ to ethanol and n-butanol; however, its industrial application is limited by the lack of tools for metabolic pathway engineering. In this study, C. carboxidivorans was successfully engineered to overexpress aor, adhE2, and fnr together with adhE2 or aor. In glucose fermentation, all engineered strains showed higher alcohol yields compared to the wild-type. Strains overexpressing aor showed CO₂ re-assimilation during heterotrophic growth. In syngas fermentation, compared to the wild-type, the strain overexpressing adhE2 produced ∼50% more ethanol and the strain overexpressing adhE2 and fnr produced ∼18% more butanol and ∼22% more ethanol. Interestingly, both strains showed obvious acid re-assimilation, with <0.15 g/L total acid remaining at the end of fermentation. Overexpressing fnr with adhE2 enhanced butanol production compared to only adhE2. This is the first report of overexpressing homologous and heterologous genes in C. carboxidivorans for enhancing alcohols production from syngas and glucose.

Butanol production from lignocellulosic biomass: revisiting fermentation performance indicators with exploratory data analysis

After just more than 100 years of history of industrial acetone-butanol-ethanol (ABE) fermentation, patented by Weizmann in the UK in 1915, butanol is again today considered a promising biofuel alternative based on several advantages compared to the more established biofuels ethanol and methanol. Large-scale fermentative production of butanol, however, still suffers from high substrate cost and low product titers and selectivity. There have been great advances the last decades to tackle these problems. However, understanding the fermentation process variables and their interconnectedness with a holistic view of the current scientific state-of-the-art is lacking to a great extent. To illustrate the benefits of such a comprehensive approach, we have developed a dataset by collecting data from 175 fermentations of lignocellulosic biomass and mixed sugars to produce butanol that reported during the past three decades of scientific literature and performed an exploratory data analysis to map current trends and bottlenecks. This review presents the results of this exploratory data analysis as well as main features of fermentative butanol production from lignocellulosic biomass with a focus on performance indicators as a useful tool to guide further research and development in the field towards more profitable butanol manufacturing for biofuel applications in the future.

Co-production of solvents and organic acids in butanol fermentation by Clostridium acetobutylicum in the presence of lignin-derived phenolics

Co-production of solvents (butanol, acetone, and ethanol) and organic acids (butyrate and acetate) by Clostridium acetobutylicum using lignocellulosic biomass as a substrate could further enlarge the application scope of butanol fermentation. This is mainly because solvents and organic acids could be used for production of fine chemicals such as butyl butyrate, butyl oleate, etc. However, many phenolic fermentation inhibitors are formed during the pretreatment process because of lignin degradation. The present study investigated the effects of five typical lignin-derived phenolics on the biosynthesis of solvents and organic acids in C. acetobutylicum ATCC 824. Results obtained in 100 mL anaerobic bottles indicated that butanol concentration was enhanced from 10.29 g L⁻¹ to 11.36 g L⁻¹ by the addition of 0.1 g L⁻¹ vanillin. Subsequently, a pH-control strategy was proposed in a 5 L anaerobic fermenter to alleviate the “acid crash” phenomenon and improve butanol fermentation performance, simultaneously. Notably, organic acid concentration was enhanced from 6.38 g L⁻¹ (control) to a high level of 9.21–12.57 g L⁻¹ with vanillin or/and vanillic acid addition (0.2 g L⁻¹) under the pH-control strategy. Furthermore, the butyrate/butanol ratio reached the highest level of 0.80 g g⁻¹ with vanillin/vanillic acid co-addition, and solvent concentration reached 13.85 g L⁻¹, a comparable level to the control (13.69 g L⁻¹). The effectiveness and robustness of the strategy for solvent and organic acid co-production was also verified under five typical phenolic environments. In conclusion, these results suggest that the proposed process strategy would potentially promote butanol fermentative products from renewable biomass.

Lignin-derived phenolics enhance solvent and organic acid biosynthesis in butanol fermentation by Clostridium acetobutylicum ATCC 824.

Enhancement of sucrose metabolism in Clostridium saccharoperbutylacetonicum N1-4 through metabolic engineering for improved acetone-butanol-ethanol (ABE) fermentation

This work investigated sucrose metabolism in C. saccharoperbutylacetonicum. Inactivation of sucrose catabolism operon resulted in 28.9% decrease in sucrose consumption and 44.1% decrease in ABE production with sucrose as sole carbon source. Interestingly, a large amount of colloid-like polysaccharides were generated in the mutant, which might be due to inefficient intracellular sucrose metabolism. Deletion of transcriptional repressor gene successfully alleviated CCR and enhanced ABE production by 24.7%. Additional overexpression of endogenous sucrose pathway further elevated sucrose consumption and enhanced ABE production by 17.2%, 45.7%, or 22.5% compared to wild type with sucrose, mixed sugars or sugarcane juice as substrate, respectively. The engineered strain could be a robust platform for efficient biofuel production from inexpensive sucrose-based carbon sources.

The draft genome sequence of Clostridium sp. strain LJ4 with high furan and phenolic derivates' tolerances occurring from lignocellulosic hydrolysates

The genome of a wild-type solventogenic Clostridium sp. strain LJ4 that could directly convert undetoxified lignocellulosic hydrolysate to butanol and tolerate high concentration of furan and phenolic derivates occurring in the lignocellulosic hydrolysate is described. 16S rDNA gene sequencing and analysis indicated that it is closely related to Clostridium acetobutylicum. The genome size of strain LJ4 is 3.90 Mp, which has a G + C content of 30.72% and encodes 2711 proteins. It also has one 0.19 Mp plasmid with 181 predicted encoding proteins. Alcohol dehydrogenases (ADs) and a nicotinamide adenine dinucleotide phosphate (NADPH)-dependent flavin mononucleotide (FMN) reductase were identified, which may play key roles in inhibitors' resistance in lignocellulosic hydrolysate.

Consolidated processing of biobutanol production from food wastes by solventogenic Clostridium sp. strain HN4

In this study, biobutanol production from glucose, starch and food waste by newly identified Clostridium sp. strain HN4 was comprehensively investigated, which is capable of secreting amylase indigenously for the following acetone-butanol-ethanol fermentation. With pH adjustment, strain HN4 could produce 5.23 g/L of butanol from 60 g/L of starch with secretion of 1.95 U/mL amylase through consolidated bioprocessing. Further supplementation of 3 g/L of CaCO₃ and 0.5% non-ionic surfactant of Tween 80 could stimulate both amylase activities and the final butanol titer, leading to 17.64 g/L of butanol with yield of 0.15 g/g. Fed batch fermentation integrated with in situ removal could further improve the butanol titer to 35.63 g/L with yield of , representing the highest butanol production and yield from food waste. These unique features of Clostridium sp. strain HN4 could open the door to the possibility of cost-effective biobutanol production from food waste on a large scale.

Exploiting endogenous CRISPR-Cas system for multiplex genome editing in Clostridium tyrobutyricum and engineer the strain for high-level butanol production

Although CRISPR-Cas9/Cpf1 have been employed as powerful genome engineering tools, heterologous CRISPR-Cas9/Cpf1 are often difficult to introduce into bacteria and archaea due to their severe toxicity. Since most prokaryotes harbor native CRISPR-Cas systems, genome engineering can be achieved by harnessing these endogenous immune systems. Here, we report the exploitation of Type I-B CRISPR-Cas of Clostridium tyrobutyricum for genome engineering. In silico CRISPR array analysis and plasmid interference assay revealed that TCA or TCG at the 5'-end of the protospacer was the functional protospacer adjacent motif (PAM) for CRISPR targeting. With a lactose inducible promoter for CRISPR array expression, we significantly decreased the toxicity of CRISPR-Cas and enhanced the transformation efficiency, and successfully deleted spo0A with an editing efficiency of 100%. We further evaluated effects of the spacer length on genome editing efficiency. Interestingly, spacers ≤ 20 nt led to unsuccessful transformation consistently, likely due to severe off-target effects; while a spacer of 30-38 nt is most appropriate to ensure successful transformation and high genome editing efficiency. Moreover, multiplex genome editing for the deletion of spo0A and pyrF was achieved in a single transformation, with an editing efficiency of up to 100%. Finally, with the integration of the alcohol dehydrogenase gene (adhE1 or adhE2) to replace cat1 (the key gene responsible for butyrate production and previously could not be deleted), two mutants were created for n-butanol production, with the butanol titer reached historically record high of 26.2 g/L in a batch fermentation. Altogether, our results demonstrated the easy programmability and high efficiency of endogenous CRISPR-Cas. The developed protocol herein has a broader applicability to other prokaryotes containing endogenous CRISPR-Cas systems. C. tyrobutyricum could be employed as an excellent platform to be engineered for biofuel and biochemical production using the CRISPR-Cas based genome engineering toolkit.

The chemostat metabolite spectra of alkaline mixed culture fermentation under mesophilic, thermophilic, and extreme-thermophilic conditions

Alkaline mixed culture fermentation (MCF) is a promising technology for reducing organic waste and producing biochemicals. However, chemostat metabolite spectra that are necessary for constructing a model and analyzing factors are seldom reported. In the present study, the effects of pH on the metabolites distribution in mesophilic (35 °C), thermophilic (55 °C), and extreme-thermophilic (70 °C) alkaline MCF were demonstrated. A chemical oxygen demand balance above 80% was achieved, and the main metabolites included acetate, ethanol, propionate, lactate, and formate. The yields of ethanol and formate increased as pH was increased from 7.5 to higher pH under mesophilic and thermophilic conditions, while the yields of acetate, lactate, and/or propionate decreased. The yields of ethanol, acetate, and formate increased under extreme-thermophilic conditions as pH was increased from 7.5 to 9.0, whereas lactate and hydrogen yields decreased. Low biomass yield under thermophilic and extreme-thermophilic conditions benefited higher metabolite production and minimized the accumulation of sludge.

High-efficient n-butanol production by co-culturing Clostridium acetobutylicum and Saccharomyces cerevisiae integrated with butyrate fermentative supernatant addition

Butanol is not only an important chemical intermediate and solvent in pharmaceutical and cosmetics industries, but also considered as an advanced biofuel. Although species of the natural host Clostridium have been engineered, butanol titers in the anaerobe seem to be limited by its intolerance to butanol less than 13 g/L. Here we aimed to develop a technology for enhancing butanol production by a co-culture system with butyrate fermentative supernatant addition. First, when adding 4.0 g/L butyrate into the acetone-butanol-ethanol (ABE) fermentation broth with single-shot at 24 h, the "acid crash" phenomenon occurred and the ABE fermentation performance deteriorated. Subsequently, we found that adding certain amino acids could effectively enhance butyrate re-assimilation, butanol tolerance and titer (from 11.1 to 14.8 g/L). Additionally, in order to decrease the raw material cost, butyrate fermentative supernatant produced by Clostridium tyrobutyricum was applied to butanol production in the Clostridium acetobutylicum/Saccharomyces cerevisiae co-culture system, instead of adding synthetic butyrate. Final butanol and total ABE concentrations reached higher levels of 16.3 and 24.8 g/L with increments of 46.8 and 37.8%, respectively. These results show that the proposed fermentation strategy has great potential for efficiently butanol production with an economic approach.