Continuous production of 1,3-propanediol using raw glycerol with immobilized Clostridium beijerinckii NRRL B-593 in comparison to suspended culture

Heterologous 1,3-Propanediol Production Using Different Recombinant Clostridium beijerinckii DSM 6423 Strains

1,3-propanediol (1,3-PDO) is a valuable basic chemical, especially in the polymer industry to produce polytrimethylene terephthalate. Unfortunately, the production of 1,3-PDO mainly depends on petroleum products as precursors. Furthermore, the chemical routes have significant disadvantages, such as environmental issues. An alternative is the biobased fermentation of 1,3-PDO from cheap glycerol. Clostridium beijerinckii DSM 6423 was originally reported to produce 1,3-PDO. However, this could not be confirmed, and a genome analysis revealed the loss of an essential gene. Thus, 1,3-PDO production was genetically reinstalled. Genes for 1,3-PDO production from Clostridium pasteurianum DSM 525 and Clostridium beijerinckii DSM 15410 (formerly Clostridium diolis) were introduced into C. beijerinckii DSM 6423 to enable 1,3-PDO production from glycerol. 1,3-PDO production by recombinant C. beijerinckii strains were investigated under different growth conditions. 1,3-PDO production was only observed for C. beijerinckii [pMTL83251_P_pta-ack_1,3-PDO.diolis], which harbors the genes of C. beijerinckii DSM 15410. By buffering the growth medium, production could be increased by 74%. Furthermore, the effect of four different promoters was analyzed. The use of the constitutive thlA promoter from Clostridium acetobutylicum led to a 167% increase in 1,3-PDO production compared to the initial recombinant approach.

The Non-solventogenic Clostridium beijerinckii Br21 Produces 1,3-Propanediol From Glycerol With Butyrate as the Main By-Product

Ever-increasing biofuel production has raised the supply of glycerol, an abundant waste from ethanolic fermentation and transesterification, for biodiesel production. Glycerol can be a starting material for sustainable production of 1,3-propanediol (1,3 PD), a valued polymer subunit. Here, we compare how Clostridium pasteurianum DSMZ 525, a well-known 1,3-PD-producer, and the non-solventogenic Clostridium beijerinckii Br21 perform during glycerol fermentation. Fermentative assays in 80-, 390-, or 1,100-mM glycerol revealed higher 1,3-PD productivity by DSMZ 525 compared to Br21. The highest 1,3-PD productivities by DSMZ 525 and Br21 were obtained in 390 mM glycerol: 3.01 and 1.70 mM h−1, respectively. Glycerol uptake by the microorganisms differed significantly: C. beijerinckii Br21 consumed 41.1, 22.3, and 16.3%, while C. pasteurianum consumed 93, 44.5, and 14% of the initial glycerol concentration in 80, 390, and 1,100 mM glycerol, respectively. In 1,100 mM glycerol, C. beijerinckii Br21 growth was delayed. Besides 1,3-PD, we detected butyrate and acetate during glycerol fermentation by both strains. However, at 80 mM glycerol, C. beijerinckii Br21 formed only butyrate as the by-product, which could help downstream processing of the 1,3-PD fermentation broth. Therefore, C. beijerinckii Br21, an unexplored biocatalyst so far, can be used to convert glycerol to 1,3-PD and can be applied in biofuel biorefineries.

1,3-Propanediol production from glycerol in polyurethane foam containing anaerobic reactors: performance and biomass cultivation and retention

The use of batch and upflow anaerobic reactors filled with polyurethane foam for pure glycerol fermentation was evaluated. The best reactor operational conditions to obtain high yield and productivity of 1,3-propanediol (1,3-PDO) as the main product and the role of the polyurethane foam in the growth and retention of suspended and attached biomass in the reactors were investigated. In the experiment at 30 °C with a batch reactor (700 mL), biomass growth was mostly as immobilized attached cells, and the achieved 1,3-PDO yield was up to 0.58 mol mol-gly^-1. In the experiment (30 °C) with an upflow anaerobic reactor (717 mL), glycerol loading rates (gly-LR) ranging from 6.94 to 15.47 g gly L^-1 day^-1 were applied during a 102-day period. During the operation, average 1,3-PDO yield was 0.47 mol mol-gly^-1, reaching a maximum of 0.51 mol mol-gly^-1 at gly-LR of 13.57 g gly L^-1 day^-1. High 1,3-PDO productivity (5.35 to 5.44 g L^-1 day^-1) was obtained when gly-LR was 13.57 to 15.47 g gly L^-1 day^-1. Comparing the close yield values in both batch and continuous reactors and based on microbial evaluation, it is concluded that most of the 1,3-PDO generated in the continuous reactor was due to the suspended biomass retained by the foam cubes. The Clostridium genus was the predominant 1,3-PDO producer. Good yields and productivities with packed reactors were attributed to polyurethane foam used for mixed culture growth and retention. Consequently, they are worth considering for 1,3-PDO production from pure glycerol.

Reclassification of Clostridium diolis Biebl and Spröer 2003 as a later heterotypic synonym of Clostridium beijerinckii Donker 1926 (Approved Lists 1980) emend. Keis et al. 2001

Clostridium diolis shares high similarity based on 16S rRNA gene sequences and fatty acid composition with Clostridium beijerinckii . In this study, the taxonomic status of C. diolis was clarified using genomic and phenotypic approaches. High similarity was detected among C. diolis DSM 15410T, C. beijerinckii DSM 791T and NCTC 13035T, showing average nucleotide identity on blast and in silico DNA–DNA hybridization values over 97 and 85 %, respectively. Results of investigations for substrate utilization and enzyme activity displayed no striking differences between C. diolis DSM 15410T and C. beijerinckii JCM 1390T. Based on the results, we propose the reclassification of Clostridium diolis as a later heterotypic synonym of Clostridium beijerinckii . The type strain is ATCC 25752T (=CIP 104308T=DSM 791T=JCM 1390T=LMG 5716T=NCTC 13035T).

Progress in biocatalysis with immobilized viable whole cells: systems development, reaction engineering and applications

Viable microbial cells are important biocatalysts in the production of fine chemicals and biofuels, in environmental applications and also in emerging applications such as biosensors or medicine. Their increasing significance is driven mainly by the intensive development of high performance recombinant strains supplying multienzyme cascade reaction pathways, and by advances in preservation of the native state and stability of whole-cell biocatalysts throughout their application. In many cases, the stability and performance of whole-cell biocatalysts can be highly improved by controlled immobilization techniques. This review summarizes the current progress in the development of immobilized whole-cell biocatalysts, the immobilization methods as well as in the bioreaction engineering aspects and economical aspects of their biocatalytic applications.

Potential application of glycerol in the production of plant beneficial microorganisms

This review highlights the importance of research for development of biofertilizer and biocontrol products based on the use of glycerol for further process scale-up to industrial microbiology. Glycerol can be used successfully in all stages of production of plant beneficial microorganisms. It serves as an excellent substrate in both submerged and solid-state fermentation processes with free and immobilized microbial cells. Glycerol is also one of the most attractive formulation agents that ensures high cell density and viability including in harsh environmental conditions. Future research is discussed to make this inexpensive material a base for industrial production of plant beneficial microorganisms.

Effective isopropanol-butanol (IB) fermentation with high butanol content using a newly isolated Clostridium sp. A1424

BACKGROUND

Acetone-butanol-ethanol fermentation has been studied for butanol production. Alternatively, to achieve acetone-free butanol production, use of clostridium strains producing butanol and 1,3-propanediol (1,3-PDO) from glycerol, natural and engineered isopropanol-butanol-ethanol (IBE) producers has been attempted; however, residual 1,3-PDO and acetone, low IBE production by natural IBE producers, and complicated gene modification are limitations.

RESULTS

Here, we report an effective isopropanol and butanol (IB) fermentation using a newly isolated Clostridium sp. A1424 capable of producing IB from various substrates with a small residual acetone. Notably, this strain also utilized glycerol and produced butanol and 1,3-PDO. After 46.35 g/L of glucose consumption at pH 5.5-controlled batch fermentation, Clostridium sp. A1424 produced 9.43 g/L of butanol and 13.92 g/L of IB at the productivity of 0.29 and 0.44 g/L/h, respectively, which are the highest values in glucose-based batch fermentations using natural IB producers. More interestingly, using glucose-glycerol mixtures at ratios ranging from 20:2 to 14:8 led to not only acetone-free and 1,3-PDO-free IB fermentation but also enhanced IB production along with a much higher butanol content (butanol/isopropanol ratio of 1.81 with glucose vs. 2.07-6.14 with glucose-glycerol mixture). Furthermore, when the mixture of glucose and crude glycerol at the ratio of 14:8 (total concentration of 35.68 g/L) was used, high butanol/isopropanol ratio (3.44) and butanol titer (9.86 g/L) were achieved with 1.4-fold enhanced butanol yield (0.28 g/g) and productivity (0.41 g/L/h) compared to those with glucose only at pH 5.5.

CONCLUSIONS

A newly isolated Clostridium sp. A1424 was able to produce butanol and isopropanol from various carbon sources. The productivity and titer of butanol and total alcohol obtained in this study were higher than the previously reported results obtained using other natural IB producers. Use of the mixture of glucose and glycerol was successful to achieve acetone-free, 1,3-PDO-free, and enhanced IB production with higher yield, productivity, and selectivity of butanol compared to those with glucose only, providing great advantages from the perspective of carbon recovery to alcohols. This notable result could be accomplished by isolating an effective IB producer Clostridium sp. A1424 as well as by utilizing glucose-glycerol mixtures.

Cell immobilization for microbial production of 1,3-propanediol

Cell and enzyme immobilization are often used for industrial production of high-value products. In recent years, immobilization techniques have been applied to the production of value-added chemicals such as 1,3-Propanediol (1,3-PDO). Biotechnological fermentation is an attractive alternative to current 1,3-PDO production methods, which are primarily thermochemical processes, as it generates high volumetric yields of 1,3-PDO, is a much less energy intensive process, and generates lower amounts of environmental organic pollutants. Although several approaches including: batch, fed-batch, continuous-feed and two-step continuous-feed were tested in suspended systems, it has been well demonstrated that cell immobilization techniques can significantly enhance 1,3-PDO production and allow robust continuous production in smaller bioreactors. This review covers various immobilization methods and their application for 1,3-PDO production.

Microbial production of short chain diols

Short chain diols (propanediols, butanediols, pentanediols) have been widely used in bulk and fine chemical industries as fuels, solvents, polymer monomers and pharmaceutical precursors. The chemical production of short chain diols from fossil resources has been developed and optimized for decades. Consideration of the exhausting fossil resources and the increasing environment issues, the bio-based process to produce short chain diols is attracting interests. Currently, a variety of biotechnologies have been developed for the microbial production of the short chain diols from renewable feed-stocks. In order to efficiently produce bio-diols, the techniques like metabolically engineering the production strains, optimization of the fermentation processes, and integration of a reasonable downstream recovery processes have been thoroughly investigated. In this review, we summarized the recent development in the whole process of bio-diols production including substrate, microorganism, metabolic pathway, fermentation process and downstream process.

Reduced catabolic protein expression in Clostridium butyricum DSM 10702 correlate with reduced 1,3-propanediol synthesis at high glycerol loading

Higher initial glycerol loadings (620 mM) have a negative effect on growth and 1,3-propanediol (1,3-PDO) synthesis in Clostridium butyricum DSM 10702 relative to lower initial glycerol concentrations (170 mM). To help understand metabolic shifts associated with elevated glycerol, protein expression levels were quantified by LC/MS/MS analyses. Thirty one (31) proteins involved in conversion of glycerol to 1,3-PDO and other by-products were analyzed by multiple reaction monitoring (MRM). The analyses revealed that high glycerol concentrations reduced cell growth. The expression levels of most proteins in glycerol catabolism pathways were down-regulated, consistent with the slower growth rates observed. However, at high initial glycerol concentrations, some of the proteins involved in the butyrate synthesis pathways such as a putative ethanol dehydrogenase (CBY_3753) and a 3-hydroxybutyryl-CoA dehydrogenase (CBY_3045) were up-regulated in both exponential and stationary growth phases. Expression levels of proteins (CBY_0500, CBY_0501 and CBY_0502) involved in the reductive pathway of glycerol to 1,3-PDO were consistent with glycerol consumption and product concentrations observed during fermentation at both glycerol concentrations, and the molar yields of 1,3-PDO were similar in both cultures. This is the first report that correlates expression levels of glycerol catabolism enzymes with synthesis of 1,3-PDO in C. butyricum. The results revealed that significant differences in the expression of a small subset of proteins were observed between exponential and stationary growth phases at both low and high glycerol concentrations.

Microbial recycling of glycerol to biodiesel

The sustainable supply of lipids is the bottleneck for current biodiesel production. Here microbial recycling of glycerol, byproduct of biodiesel production to biodiesel in engineered Escherichia coli strains was reported. The KC3 strain with capability of producing fatty acid ethyl esters (FAEEs) from glucose was used as a starting strain to optimize fermentation conditions when using glycerol as sole carbon source. The YL15 strain overexpressing double copies of atfA gene displayed 1.7-fold increase of FAEE productivity compared to the KC3 strain. The titer of FAEE in YL15 strain reached to 813 mg L(-1) in minimum medium using glycerol as sole carbon source under optimized fermentation conditions. The titer of glycerol-based FAEE production can be significantly increased by both genetic modifications and fermentation optimization. Microbial recycling of glycerol to biodiesel expands carbon sources for biodiesel production.

Scale-up and kinetic modeling for bioethanol production

Bioethanol was produced from acidic hydrolysate of rice hulls using recombinant Escherichia coli KO11. Two different issues (scale-up and kinetic modeling) were evaluated simultaneously and concomitantly for bioethanol production. During the step-wise scale-up process from 100 mL shaken flask to 10 L stirred-tank bioreactor, the constant Reynolds number and the constant impeller tip speed were evaluated as scale-up methodologies under laboratory conditions. It was determined that the volumetric bioethanol productivity was 88% higher in 10 L bioreactor in comparison to the value of 0.21 g L(-1) h(-1) in shaken flask. The modified Monod and Luedeking-Piret models provided an accurate approach for the modeling of the experimental data. Ethanol concentration reached the maximum level of 29.03 g/L, which was 5% higher than the value of model prediction in 10 L bioreactor. The findings of this research could contribute to the industrial scale productions especially from lignocellulosic raw materials.

Microbial utilization of crude glycerol for the production of value-added products

Energy fuels for transportation and electricity generation are mainly derived from finite and declining reserves of fossil hydrocarbons. Fossil hydrocarbons are also used to produce a wide range of organic carbon-based chemical products. The current global dependency on fossil hydrocarbons will not be environmentally or economically sustainable in the long term. Given the future pessimistic prospects regarding the complete dependency on fossil fuels, political and economic incentives to develop carbon neutral and sustainable alternatives to fossil fuels have been increasing throughout the world. For example, interest in biodiesel has undergone a revival in recent times. However, the disposal of crude glycerol contaminated with methanol, salts, and free fatty acids as a by-product of biodiesel production presents an environmental and economic challenge. Although pure glycerol can be utilized in the cosmetics, tobacco, pharmaceutical, and food industries (among others), the industrial purification of crude glycerol is not economically viable. However, crude glycerol could be used as an organic carbon substrate for the production of high-value chemicals such as 1,3-propanediol, organic acids, or polyols. Microorganisms have been employed to produce such high-value chemicals and the objective of this article is to provide an overview of studies on the utilization of crude glycerol by microorganisms for the production of economically valuable products. Glycerol as a by-product of biodiesel production could be used a feedstock for the manufacture of many products that are currently produced by the petroleum-based chemical industry.

Use of ceramic-based cell immobilization to produce 1,3-propanediol from biodiesel-derived waste glycerol with Klebsiella pneumoniae

AIMS

The feasibility of the continuous production of a valuable bioplastic raw material, namely 1,3-propanediol (1,3-PDO) from biodiesel by-product glycerol, using immobilized cells was investigated. In addition, the effect of hydraulic retention time (HRT) was also analysed.

METHODS AND RESULTS

Ceramic balls and ceramic rings were used for the immobilization of a locally isolated strain; Klebsiella pneumoniae (GenBank no. 27F HM063413). HRT of 1 h is the best one in terms of volumetric production rate (g 1,3-PDO l(-1) h(-1)). The results indicated that ceramic-based cell immobilization achieved a 2-fold higher production rate (10 g 1,3-PDO l(-1) h(-1)) in comparison with suspended cell system (4·9 g 1,3-PDO l(-1) h(-1)).

CONCLUSIONS

Continuous cultures with immobilized cells revealed that 1,3-PDO production was more effective and more stable than suspended culture systems. Furthermore, cell immobilization had also obvious benefits especially for resistance of the production for extreme conditions (high organic loading rates, cell washouts). The results were important for understanding the significance of continuous immobilization process among other well-known 1,3-PDO fermentation processes.

SIGNIFICANCE AND IMPACT OF THE STUDY

This work is a promising process for further studies, as the immobilized micro-organism was able to reach high volumetric production rates at short HRT, it has an important role in tolerating and converting glycerol during fermentation. Therefore, HRT is a very significant operational parameter (P value <0·05) directly affecting the bioreactor performance and production rate.