Efficient 1,3-propanediol Production by Fed-Batch Culture of Klebsiella Pneumoniae: The Role of pH Fluctuation

Kinetics-based development of two-stage continuous fermentation of 1,3-propanediol from crude glycerol by Clostridium butyricum

BACKGROUND

Glycerol, as a by-product, mainly derives from the conversion of many crops to biodiesel, ethanol, and fatty ester. Its bioconversion to 1,3-propanediol (1,3-PDO) is an environmentally friendly method. Continuous fermentation has many striking merits over fed-batch and batch fermentation, such as high product concentration with easy feeding operation, long-term high productivity without frequent seed culture, and energy-intensive sterilization. However, it is usually difficult to harvest high product concentrations.

RESULTS

In this study, a three-stage continuous fermentation was firstly designed to produce 1,3-PDO from crude glycerol by Clostridium butyricum, in which the first stage fermentation was responsible for providing the excellent cells in a robust growth state, the second stage focused on promoting 1,3-PDO production, and the third stage aimed to further boost the 1,3-PDO concentration and reduce the residual glycerol concentration as much as possible. Through the three-stage continuous fermentation, 80.05 g/L 1,3-PDO as the maximum concentration was produced while maintaining residual glycerol of 5.87 g/L, achieving a yield of 0.48 g/g and a productivity of 3.67 g/(L·h). Based on the 14 sets of experimental data from the first stage, a kinetic model was developed to describe the intricate relationships among the concentrations of 1,3-PDO, substrate, biomass, and butyrate. Subsequently, this kinetic model was used to optimize and predict the highest 1,3-PDO productivity of 11.26 g/(L·h) in the first stage fermentation, while the glycerol feeding concentration and dilution rate were determined to be 92 g/L and 0.341 h-1, separately. Additionally, to achieve a target 1,3-PDO production of 80 g/L without the third stage fermentation, the predicted minimum volume ratio of the second fermenter to the first one was 11.9. The kinetics-based two-stage continuous fermentation was experimentally verified well with the predicted results.

CONCLUSION

A novel three-stage continuous fermentation and a kinetic model were reported. Then a simpler two-stage continuous fermentation was developed based on the optimization of the kinetic model. This kinetics-based development of two-stage continuous fermentation could achieve high-level production of 1,3-PDO. Meanwhile, it provides a reference for other bio-chemicals production by applying kinetics to optimize multi-stage continuous fermentation.

Bioconversion of Glycerol into Lactic Acid by a New Bacterial Strain from the Brazilian Cerrado Soil

A lactic-acid-producing strain was isolated from the Brazilian Cerrado soil (Brazilian savanna). Glycerol, a byproduct of the biodiesel industry, can be converted into various chemical intermediates of industrial value by biotechnological routes. Klebsiella pneumoniae can metabolize glycerol in environments with or without oxygen and bioconvert it into several chemicals with high value-added, such as lactic acid, 3-hydroxypropionic acid and 1,3 propanediol. The wild-type bacterial strain (2GPP) isolated from a soil sample from the Brazilian Cerrado was determined to be a K. pneumoniae complex that was capable of successfully metabolizing glycerol. Fermentations were performed with different temperatures, pH, and inoculum concentrations to evaluate the best lactic acid production. At first, 1,3-propanediol and L-(+)-lactic acid were produced in mini reactors. A lactic acid production of 3.8 g·L−1 and a decrease in 1,3-propanediol output were observed. Thus, by adjusting process variables such as pH and temperature during fermentation, it was possible to maximize the production of lactic acid and decrease the formation of 1,3-propanediol by utilizing experimental design strategies.

Sequential fed-batch fermentation of 1,3-propanediol from glycerol by Clostridium butyricum DL07

The demand for 1,3-propanediol (1,3-PDO) has increased sharply due to its role as a monomer for the synthesis of polytrimethylene terephthalate (PTT). Although Clostridium butyricum is considered to be one of the most promising bioproducers for 1,3-PDO, its low productivity hinders its application on industrial scale because of the longer time needed for anaerobic cultivation. In this study, an excellent C. butyricum (DL07) strain was obtained with high-level titer and productivity of 1,3-PDO, i.e., 104.8 g/L and 3.38 g/(L•h) vs. 94.2 g/L and 3.04 g/(L•h) using pure or crude glycerol as substrate in fed-batch fermentation, respectively. Furthermore, a novel sequential fed-batch fermentation was investigated, in which the next bioreactor was inoculated by C. butyricum DL07 cells growing at exponential phase in the prior bioreactor. It could run steadily for at least eight cycles. The average concentration of 1,3-PDO in eight cycles was 85 g/L with the average productivity of 3.1 g/(L•h). The sequential fed-batch fermentation could achieve semi-continuous production of 1,3-PDO with higher productivity than repeated fed-batch fermentation and would greatly contribute to the industrial production of 1,3-PDO by C. butyricum. KEY POINTS: • A novel C. butyricum strain was screened to produce 104.8 g/L 1,3-PDO from glycerol. • Corn steep liquor powder was used as a cheap nitrogen source for 1,3-PDO production. • A sequential fed-batch fermentation process was established for 1,3-PDO production. • An automatic glycerol feeding strategy was applied in the production of 1,3-PDO.

Statistical Optimization of 1,3-Propanediol (1,3-PD) Production from Crude Glycerol by Considering Four Objectives: 1,3-PD Concentration, Yield, Selectivity, and Productivity

This study investigated the biological conversion of crude glycerol generated from a commercial biodiesel production plant as a by-product to 1,3-propanediol (1,3-PD). Statistical analysis was employed to derive a statistical model for the individual and interactive effects of glycerol, (NH₄)₂SO₄, trace elements, pH, and cultivation time on the four objectives: 1,3-PD concentration, yield, selectivity, and productivity. Optimum conditions for each objective with its maximum value were predicted by statistical optimization, and experiments under the optimum conditions verified the predictions. In addition, by systematic analysis of the values of four objectives, optimum conditions for 1,3-PD concentration (49.8 g/L initial glycerol, 4.0 g/L of (NH₄)₂SO₄, 2.0 mL/L of trace element, pH 7.5, and 11.2 h of cultivation time) were determined to be the global optimum culture conditions for 1,3-PD production. Under these conditions, we could achieve high 1,3-PD yield (47.4%), 1,3-PD selectivity (88.8%), and 1,3-PD productivity (2.1/g/L/h) as well as high 1,3-PD concentration (23.6 g/L).

High-level De novo biosynthesis of arbutin in engineered Escherichia coli

Arbutin is a hydroquinone glucoside compound existing in various plants. It is widely used in pharmaceutical and cosmetic industries owing to its well-known skin-lightening property as well as anti-oxidant, anti-microbial, and anti-inflammatory activities. Currently, arbutin is usually produced by plant extraction or enzymatic processes, which suffer from low product yield and expensive processing cost. In this work, we established an artificial pathway in Escherichia coli for high-level production of arbutin from simple carbon sources. First, a 4-hydroxybenzoate 1-hydroxylase from Candida parapsilosis CBS604 and a glucosyltransferase from Rauvolfia serpentina were characterized by in vitro enzyme assays. Introduction of these two genes into E. coli led to the production of 54.71mg/L of arbutin from glucose. Further redirection of carbon flux into arbutin biosynthesis pathway by enhancing shikimate pathway genes enabled production of 3.29g/L arbutin, which is a 60-fold increase compared with the initial strain. Final optimization of glucose concentration added in the culture medium was able to further improve the titer of arbutin to 4.19g/L in shake flasks experiments, which is around 77-fold higher than that of initial strain. This work established de novo biosynthesis of arbutin from simple carbon sources and provided a generalizable strategy for the biosynthesis of shikimate pathway derived chemicals. The high titer achieved in our engineered strain also indicates the potential for industrial scale bio-manufacturing of arbutin.

Biological valorization of pure and crude glycerol into 1,3-propanediol using a novel isolate Lactobacillus brevis N1E9.3.3

The aim of the study was to evaluate a novel onsite enrichment approach to isolate a crude glycerol utilizing facultative anaerobic bacteria. An onsite enrichment in natural conditions resulted an isolate, Lactobacillus brevis N1E9.3.3, that can utilize glycerol and produce 1,3-propanediol with a yield of 0.89g1,3-PDO/gGlycerol and productivity of 0.78g1,3-PDO/l/h at pH-8.5 under anaerobic conditions. Batch fermentation experiments with glycerol-glucose co-fermentation strategy was carried out to evaluate the production of 1,3-propanediol and other byproducts. The effect of other carbon sources as co-substrate was also evaluated. At the optimized condition, 18.6g/l 1,3-propanediol was monitored when biodiesel industry generated crude glycerol and 2.5% glucose were used as the substrate.

Effects of culture conditions on the kinetic behavior of 1,3-propanediol fermentation by Clostridium butyricum with a kinetic model

The effects of culture conditions on the kinetic behavior of 1,3-propanediol (PD) fermentation were investigated with a kinetic model. First, with initial glycerol concentration (S0) increasing, μmax and PD inhibition increased. Glycerol assimilation was harder and a little glycerol was consumed on cell maintenance at high S0. Second, with yeast extract concentration increasing, PD inhibition decreased. However, μmax decreased and glycerol assimilation became harder. It seems that the stimulus effect of yeast extract resulted from decreased PD inhibition. Glycerol amount consumed on cell maintenance also decreased. Third, with temperature decreasing, μmax and PD inhibition decreased. Glycerol assimilation was harder and a little more glycerol was consumed on cell maintenance at low temperature. Fourth, with pH increasing, μmax and PD inhibition decreased. Glycerol assimilation was harder and much more glycerol was consumed on cell maintenance at pH 6.5 and 7.5 than 7.0. This work facilitates further fermentation process optimization.

Utilization of excess NADH in 2,3-butanediol-deficient Klebsiella pneumoniae for 1,3-propanediol production

AIMS

To utilize excess NADH for 1,3-propanediol production by 2,3-butanediol-deficient mutants, the effect of dhaT overexpression in two distinct 2,3-butanediol-deficient mutants was investigated.

METHODS AND RESULTS

Two 2,3-butanediol-deficient mutants, KG1-3 (blocking of the 2,3-butanediol pathway only) and KG1-5 (blocking of both of 2,3-butanediol and lactate pathways) were constructed. Our results showed that although the intracellular redox balance (NADH/NAD(+)) was extremely high at the end of fermentation for both mutants, the status of intracellular redox in KG1-5 was maintained at a normal level following the first stage of fermentation. Analysis of cell growth and metabolite formation confirmed the inhibition of excess lactate in 2,3-butanediol pathway-deficient mutants. Furthermore, dhaT was overexpressed in two 2,3-butanediol-deficient mutants (KG1-3T and KG1-5T). In KG1-5T, the intracellular redox balance was restored to normal and 1,3-propanediol production increased. The yield of 1,3-propanediol from glycerol in KG1-5T was also restored to a normal level of 0·6.

CONCLUSIONS

The excess NADH in both the 2,3-butanediol- and lactate-deficient mutants can be used by overexpresstion of dhaT.

SIGNIFICANCE AND IMPACT OF STUDY

The metabolic flux tended to increase lactate production by the abolishment of the 2,3-butanediol pathway in Klebsiella pneumoniae, and the high accumulation of lactate prevented the cell from using excess NADH, thereby inhibiting cell growth and 1,3-propanediol production.

Biosynthesis of 1,3-propanediol from glycerol with Lactobacillus reuteri: effect of operating variables

Chemical synthesis of 1,3-propanediol (1,3-PD) is environmentally unfriendly and hence its microbial production is preferred, especially for biomedical, cosmetic and textile applications. In this work, production of 1,3-PD by co-fermentation of glucose and glycerol by Lactobacillus reuteri was investigated under different cultivation conditions such as aeration, acetate concentration and different molar ratios of glucose/glycerol. The final concentration of 1,3-PD and yield attained under unaerated conditions was close to that obtained under anaerobic conditions. Addition of acetate in the initial medium at 5 g/l increased the productivity of 1,3-PD but above this concentration it was found to be inhibitory. Batch reactor experiments showed that the molar ratio of glucose and glycerol in the medium affected the fermentation pattern. The effect of molar ratios was further investigated in fed-batch fermentation and the optimum ratio was found to be 1.5. In repeated fed-batch fermentation with co-feeding of glucose and glycerol in the molar ratio of 1.5, 1,3-PD concentration reached up to 65.3 g/l, which is the highest 1,3-PD concentration reported so far for this strain. The yield (0.97 mol/mol) based on glycerol utilized also approached the theoretical value (1 mol/mol).

Treatment of effluents from a membrane bioreactor by nanofiltration using tubular membranes

Production of bioproducts is associated with the generation of considerable amounts of effluents from the bioreactors used. Application of the nanofiltration process was proposed for the treatment of these effluents in order to separate both inorganic and organic solutes. Composition of the fermentation broth precludes the utilization of traditional spiral-wound modules (high turbidity) for the solutes separation in the NF process. The tubular module with AFC30 membranes applied in this work enables such a possibility. Transport and separation characteristics of the NF membrane were determined for the reference solutions containing components present in the effluents generated during the fermentation of glycerol with the use of bacteria.

Enhanced 1,3-propanediol production by a newly isolated Citrobacter freundii strain cultivated on biodiesel-derived waste glycerol through sterile and non-sterile bioprocesses

The production of 1,3-propanediol (PD) by a newly isolated Citrobacter freundii strain [FMCC-B 294 (VK-19)] was investigated. Different grades of biodiesel-derived glycerol were employed. Slightly lower PD biosynthesis was observed in batch experiments only when crude glycerol from waste-cooking oil trans-esterification was utilized and only at elevated initial substrate concentrations employed. Batch bioreactor cultures revealed the capability of the strain to tolerate elevated amounts of substrate (glycerol up to 170 g/L) and produce quantities of PD in such high substrate concentrations. Nevertheless, maximum PD quantities (45.9 g/L) were achieved at lower initial glycerol concentrations (∼100 g/L) employed, suggesting some inhibition exerted due to the increased initial substrate concentrations. In order to improve PD production, a fed-batch fermentation was carried out and 68.1g/L of PD were produced (the highest PD quantity achieved by C. freundii strains so far) with yield per glycerol consumed ∼0.40 g/g and volumetric productivity 0.79 g/L/h. Aiming to perform a more economical and eco-friendlier procedure, batch and fed-batch fermentations under completely non-sterile conditions were carried out. During non-sterilized fed-batch process, 176 g/L of raw glycerol were converted to 66.3g/L of PD, suggesting the potentiality of the non-sterile fermentation by C. freundii FMCC-B 294.

Microbial 2,3-butanediol production: a state-of-the-art review

2,3-butanediol is a promising bulk chemical due to its extensive industry applications. The state-of-the-art nature of microbial 2,3-butanediol production is reviewed in this paper. Various strategies for efficient and economical microbial 2,3-butanediol production, including strain improvement, substrate alternation, and process development, are reviewed and compared with regard to their pros and cons. This review also summarizes value added derivatives of biologically produced 2,3-butanediol and different strategies for downstream processing. The future prospects of microbial 2,3-butanediol production are discussed in light of the current progress, challenges, and trends in this field. Guidelines for future studies are also proposed.

An effective and simplified fed-batch strategy for improved 2,3-butanediol production by Klebsiella oxytoca

Substrate concentration in 2,3-butanediol (2,3-BD) fermentation could not be controlled well in traditional feeding strategies, such as constant, impulse, and exponential feeding strategies. In the present study, fermentative 2,3-BD production by Klebsiella oxytoca was investigated under different batch and fed-batch strategies. The glucose-feedback fed-batch strategy was proved to be not effective for economical 2,3-BD production for the inability of timely feeding, leading that the bacteria reused 2,3-BD as carbon source for cell growth. Based on the phenomena that the byproducing acids caused the pH declining and the requirement of maintaining the pH at a proper level for both cell growth and 2,3-BD accumulation, an improved strategy of pH-stat fed-batch culture with glucose and sodium hydrate fed at the same time was established. Thus, the residual glucose concentration could be controlled through the adjustment of pH automatically. At last, efficient 2,3-BD production was fulfilled under this fed-batch strategy, and the highest 2,3-BD concentration, productivity, and yield were 127.9 g/l, 1.78 g/(l•h), and 0.48 g/g (2,3-BD/glucose), respectively, compared to 98.5 g/l, 1.37 g/(l•h), and 0.43 g/g obtained in glucose-feedback fed-batch strategy. This feeding strategy was simple and easy to operate and could be feasible for industrial 2,3-BD production in the future.

Enhanced 1,3-propanediol production by supply of organic acids and repeated fed-batch culture

In fed-batch culture of Klebsiella pneumoniae, 1,3-propanediol production was growth associated, while the by-products, including lactic acid and ethanol, increased sharply as the cells grew slowly. When the fed-batch culture was supplied with a mixture of organic acids including citrate, fumarate and succinate, cell growth and 1,3-propanediol production increased significantly, whereas the by-products, especially lactic acid and ethanol, decreased sharply. High concentrations of PDO and acetate inhibited cell growth and PDO production. To improve the PDO production, repeated fed-batch culture with addition of the organic acid mixture was performed in a 5-l reactor. The fed-batch culture was repeated five times, and the 1,3-propanediol yield and concentration reached above 0.61 mol mol(-1) and 66 g l(-1), respectively, in 20 h for each cycle. Furthermore, the PDO productivity reached above 3.30 g l(-1) h(-1) in each cycle, which was much higher than that of the original fed-batch culture.