Photoautotrophic production of poly-hydroxybutyrate – First detailed cost estimations

Large-scale cultivation of Synechocystis sp. PCC6803 for the production of Poly(3-hydroxybutyrate) and its potential applications in the manufacturing of bulk and medical prototypes

Polyhydroxyalkanoates (PHAs) are biopolymers produced by microorganisms under nutrient limiting conditions and in the presence of excess carbon source. PHAs have gained popularity as a sustainable alternative to traditional plastics. However, large scale production of PHAs is economically challenging due to the relatively high costs of organic carbon. Alternative options include using organisms capable of phototrophic or mixotrophic growth. This study aimed at the production of poly(3-hydroxybutyrate) P(3HB), a type of PHA, at pilot scale using the freshwater cyanobacterium Synechocystis sp. PCC6803. First, to identify optimal conditions for P(3HB) production from Synechocystis sp. PCC6803, different supplemental carbon source concentrations and salinity levels were tested at laboratory scale. The addition of 4 g/L acetate with no added NaCl led to P(3HB) accumulation of 10.7 % dry cell weight on the 28th day of cultivation. Although acetate additions were replicated in an outdoor 400 L serpentine photobioreactor, P(3HB) content was lower, implying uncontrolled conditions impact on biopolymer production efficiency. An optimized P(3HB) extraction methodology was developed to remove pigments, and the biopolymer was characterized and subjected to 3D printing (fused deposition modelling) to confirm its processability. This study thus successfully led to the large-scale production of P(3HB) using sustainable and environmentally friendly cyanobacterial fermentation.

Polyhydroxyalkanoate recovery overview: properties, characterizations, and extraction strategies

Due to their excellent properties, polyhydroxyalkanoates are gaining increasing recognition in the biodegradable polymer market. These biogenic polyesters are characterized by high biodegradability in multiple environments, overcoming the limitation of composting plants only and their versatility in production. The most consolidated techniques in the literature or the reference legislation for the physical, chemical and mechanical characterisation of the final product are reported since its usability on the market is still linked to its quality, including the biodegradability certificate. This versatility makes polyhydroxyalkanoates a promising prospect with the potential to replace fossil-based thermoplastics sustainably. This review analyses and compares the physical, chemical and mechanical properties of poly-β-hydroxybutyrate and poly-β-hydroxybutyrate-co-β-hydroxyvalerate, indicating their current limitations and strengths. In particular, the copolymer is characterised by better performance in terms of crystallinity, hardness and workability. However, the knowledge in this area is still in its infancy, and the selling prices are too high (9-18 $ kg-1). An analysis of the main extraction techniques, established and in development, is also included. Solvent extraction is currently the most widely used method due to its efficiency and final product quality. In this context, the extraction phase of the biopolymer production process remains a major challenge due to its high costs and the need to use non-halogenated toxic solvents to improve the production of good-quality bioplastics. The review also discusses all fundamental parameters for optimising the process, such as solubility and temperature.

Comparative assessment of environmental impacts of 1st generation (corn feedstock) and 3rd generation (carbon dioxide feedstock) PHA production pathways using life cycle assessment

Polyhydroxyalkanoates (PHA) are bio-based and biodegradable alternatives to conventional plastic types and have the potential to reduce the environmental impacts along the life cycle. In comparison to already established production routes for PHA (heterotrophic production) based on renewable feedstock like glucose (first generation feedstock), novel production routes, such as the photoautotrophic production of PHA based on CO₂ as feedstock (third generation feedstock) could offer new perspectives with regard to the reduction in the environmental impacts. To quantify the environmental impacts of PHA produced via photoautotrophic and heterotrophic production pathways, life cycle assessment (LCA) methodology based on ISO 14040/44 was applied, thus conducting a first of its kind comparative study for PHA based on third generation feedstock. The results show that the photoautotrophic production of PHA has advantages in comparison to heterotrophic PHA based on glucose originating from corn as feedstock in all the assessed environmental impact categories, thus showing the environmental potential of novel production routes for bioplastics. Additionally, the results of the LCA show that the chloroform-based extraction method, commonly used in the downstream processes of both the technologies, has a significant contribution of environmental impacts in the production of PHA. Therefore, the reduction of chloroform loss during the extraction process can reduce its environmental impact. Our results indicate that PHA production from CO₂ using the photoautotrophic production route is a promising technology with regard to the environmental impacts when compared to the heterotrophic production based on glucose feedstock.

Systematizing Microbial Bioplastic Production for Developing Sustainable Bioeconomy: Metabolic Nexus Modeling, Economic and Environmental Technologies Assessment

The excessive usage of non-renewable resources to produce plastic commodities has incongruously influenced the environment's health. Especially in the times of COVID-19, the need for plastic-based health products has increased predominantly. Given the rise in global warming and greenhouse gas emissions, the lifecycle of plastic has been established to contribute to it significantly. Bioplastics such as polyhydroxy alkanoates, polylactic acid, etc. derived from renewable energy origin have been a magnificent alternative to conventional plastics and reconnoitered exclusively for combating the environmental footprint of petrochemical plastic. However, the economically reasonable and environmentally friendly procedure of microbial bioplastic production has been a hard nut to crack due to less scouted and inefficient process optimization and downstream processing methodologies. Thereby, meticulous employment of computational tools such as genome-scale metabolic modeling and flux balance analysis has been practiced in recent times to understand the effect of genomic and environmental perturbations on the phenotype of the microorganism. In-silico results not only aid us in determining the biorefinery abilities of the model microorganism but also curb our reliance on equipment, raw materials, and capital investment for optimizing the best conditions. Additionally, to accomplish sustainable large-scale production of microbial bioplastic in a circular bioeconomy, extraction, and refinement of bioplastic needs to be investigated extensively by practicing techno-economic analysis and life cycle assessment. This review put forth state-of-the-art know-how on the proficiency of these computational techniques in laying the foundation of an efficient bioplastic manufacturing blueprint, chiefly focusing on microbial polyhydroxy alkanoates (PHA) production and its efficacy in outplacing fossil based plastic products.

The survivor strain: isolation and characterization of Phormidium yuhuli AB48, a filamentous phototactic cyanobacterium with biotechnological potential

Despite their recognized potential, current applications of cyanobacteria as microbial cell factories remain in early stages of development. This is partly due to the fact that engineered strains are often difficult to grow at scale. This technical challenge contrasts with the dense and highly productive cyanobacteria populations thriving in many natural environments. It has been proposed that the selection of strains pre-adapted for growth in industrial photobioreactors could enable more productive cultivation outcomes. Here, we described the initial morphological, physiological, and genomic characterization of Phormidium yuhuli AB48 isolated from an industrial photobioreactor environment. P. yuhuli AB48 is a filamentous phototactic cyanobacterium with a growth rate comparable to Synechocystis sp. PCC 6803. The isolate forms dense biofilms under high salinity and alkaline conditions and manifests a similar nutrient profile to Arthrospira platensis (Spirulina). We sequenced, assembled, and analyzed the P. yuhuli AB48 genome, the first closed circular isolate reference genome for a member of the Phormidium genus. We then used cultivation experiments in combination with proteomics and metabolomics to investigate growth characteristics and phenotypes related to industrial scale cultivation, including nitrogen and carbon utilization, salinity, and pH acclimation, as well as antibiotic resistance. These analyses provide insight into the biological mechanisms behind the desirable growth properties manifested by P. yuhuli AB48 and position it as a promising microbial cell factory for industrial-scale bioproduction[221, 1631].

Process optimization of the polyhydroxybutyrate production in the cyanobacteria Synechocystis sp. and Synechococcus sp

The effect of four parameters (acetate, NaCl, inorganic carbon and days in darkness) affecting the polyhydroxybutyrate (PHB) production were tested and optimized for Synechococcus sp. and Synechocystis sp. using a Box-Behnken design. The optimal conditions for Synechocystis sp. were found to be 1.2 g L^-1 of acetate, 4 gC L^-1 of NaHCO₃, 18 g L^-1 of NaCl and 0 days in darkness. For Synechococcus sp., equal acetate concentration and days in darkness, and lower inorganic carbon and NaCl concentrations than those for Synechocystis sp. were needed (0.05 g L^-1 inorganic carbon and 9 g L^-1 NaCl). Optimal conditions were scaled up to 3 L photobioreactors. Using Synechocystis sp., 5.6 %_dcw of PHB was obtained whether adding or not acetate. In opposition, a maximum of 26.1 %_dcw by using acetate was reached with Synechococcus sp. These results provide an easy method to optimize the cultivation conditions to enhance PHB production with cyanobacteria.

PHB Producing Cyanobacteria Found in the Neighborhood-Their Isolation, Purification and Performance Testing

Cyanobacteria are a large group of prokaryotic microalgae that are able to grow photo-autotrophically by utilizing sunlight and by assimilating carbon dioxide to build new biomass. One of the most interesting among many cyanobacteria cell components is the storage biopolymer polyhydroxybutyrate (PHB), a member of the group of polyhydroxyalkanoates (PHA). Cyanobacteria occur in almost all habitats, ranging from freshwater to saltwater, freely drifting or adhered to solid surfaces or growing in the porewater of soil, they appear in meltwater of glaciers as well as in hot springs and can handle even high salinities and nutrient imbalances. The broad range of habitat conditions makes them interesting for biotechnological production in facilities located in such climate zones with the expectation of using the best adapted organisms in low-tech bioreactors instead of using "universal" strains, which require high technical effort to adapt the production conditions to the organism's need. These were the prerequisites for why and how we searched for locally adapted cyanobacteria in different habitats. Our manuscript provides insight to the sites we sampled, how we isolated and enriched, identified (morphology, 16S rDNA), tested (growth, PHB accumulation) and purified (physical and biochemical purification methods) promising PHB-producing cyanobacteria that can be used as robust production strains. Finally, we provide a guideline about how we managed to find potential production strains and prepared others for basic metabolism studies.

Leptolyngbya sp. NIVA-CYA 255, a Promising Candidate for Poly(3-hydroxybutyrate) Production under Mixotrophic Deficiency Conditions

Cyanobacteria are a promising source for the sustainable production of biodegradable bioplastics such as poly(3-hydroxybutyrate) (PHB). The auto-phototrophic biomass formation is based on light and CO₂, which is an advantage compared to heterotrophic PHB-producing systems. So far, only a handful of cyanobacterial species suitable for the high-yield synthesis of PHB have been reported. In the present study, the PHB formation, biomass, and elemental composition of Leptolyngbya sp. NIVA-CYA 255 were investigated. Therefore, a three-stage cultivation process was applied, consisting of a growth stage; an N-, P-, and NP-depleted phototrophic stage; and a subsequent mixotrophic deficiency stage, initiated by sodium acetate supplementation. The extracted cyanobacterial PHB was confirmed by FTIR- and GC-MS analyses. Furthermore, the fluorescent dyes LipidGreen2 and Nile red were used for fluorescence-based monitoring and the visualization of PHB. LipidGreen2 was well suited for PHB quantification, while the application of Nile red was limited by fluorescence emission crosstalk with phycocyanin. The highest PHB yields were detected in NP- (325 mg g⁻¹) and N-deficiency (213 mg g⁻¹). The glycogen pool was reduced in all cultures during mixotrophy, while lipid composition was not affected. The highest glycogen yield was formed under N-deficiency (217 mg g⁻¹). Due to the high carbon storage capacity and PHB formation, Leptolyngbya sp. NIVA-CYA 255 is a promising candidate for PHB production. Further work will focus on upscaling to a technical scale and monitoring the formation by LipidGreen2-based fluorometry.

Current application of algae derivatives for bioplastic production: A review

Improper use of conventional plastics poses challenges for sustainable energy and environmental protection. Algal derivatives have been considered as a potential renewable biomass source for bioplastic production. Algae derivatives include a multitude of valuable substances, especially starch from microalgae, short-chain length polyhydroxyalkanoates (PHAs) from cyanobacteria, polysaccharides from marine and freshwater macroalgae. The algae derivatives have the potential to be used as key ingredients for bioplastic production, such as starch and PHAs or only as an additive such as sulfated polysaccharides. The presence of distinctive functional groups in algae, such as carboxyl, hydroxyl, and sulfate, can be manipulated or tailored to provide desirable bioplastic quality, especially for food, pharmaceutical, and medical packaging. Standardizing strains, growing conditions, harvesting and extracting algae in an environmentally friendly manner would be a promising strategy for pollution control and bioplastic production.

Techno-economic assessment of a sustainable and cost-effective bioprocess for large scale production of polyhydroxybutyrate

The rapid depletion of crude-oil resource which sustains a conventional petroleum refinery together with its environmental impact has led to the search for more sustainable alternatives. In this context, biorefinery serves to fulfil the aim by utilizing waste resources. Hence, this study focused on techno-economic assessment of PHB production at large scale from waste carob pods in a closed-loop biorefinery setup. Firstly, the use of pure sugars in SC1 was shifted to use of carob pods as feedstock in SC2, upgradation of stirred tank bioreactor with novel annular gap bioreactor in SC3 and replacing the conventional centrifugation process with the upcoming ceramic membrane separation process in SC4. An Aspen plus™ flowsheet was developed by including the aforementioned novel strategies for PHB production. The effectiveness of PHB production under various scenarios was evaluated based on its pay-out period and turnover accumulated at the end of 7th year of a PHB plant operation. Instead of pure sugars as the feedstock (SC1), carob pod extract (SC2) reduced the pay-out period from 12.6 to 6.8 years. Likewise, switching onto ABR from the conventional STBR further decreased the pay-out period to 4.8 years. Finally, the use of ceramic membranes (SC4) instead of centrifugation resulted in a similar pay-out period of 4.8 years with increased turnover of about 1.4 billion USD. Thus, the use of carob pods along with an improved PHB titre in ABR and incorporation of affordable ceramic membrane technology for PHB rich biomass separation resulted in a highly cost-effective PHB production strategy.

Poly-β-Hydroxybutyrate Production by Rhodopseudomonas sp. Grown in Semi-Continuous Mode in a 4 L Photobioreactor

The synthesis of polyhydroxybutyrate (PHB) by photosynthetic non-sulfur bacteria is a potential approach for producing biodegradable plastics. In this work, acetate was used as a single carbon source to study the effect on PHB formation in Rhodopseudomonas sp. cultured in a cylindrical four-liter photobioreactor under semi-continuous mode. The cultivation process is divided into a symmetrical growth phase and a PHB accumulation phase separated temporally. The symmetrical growth phase (nutrient sufficient conditions) was followed by a sulfur-limited phase to promote PHB accumulation. The main novelty is the progressive lowering of the sulfur concentration into Rhodopseudomonas culture, which was obtained by two concomitant conditions: (1) sulfur consumption during the bacterial growth and (2) semi-continuous growth strategy. This caused a progressive lowering of the sulfur concentration into Rhodopseudomonas culturedue to the sulfur-free medium used to replace 2 L of culture (50% of the total) that was withdrawn from the photobioreactor at each dilution. The PHB content ranged from 9.26% to 15.24% of cell dry weight. At the steady state phase, the average cumulative PHB was >210 mg/L. Sulfur deficiency proved to be one of the most suitable conditions to obtain high cumulative PHB in Rhodopseudomonas culture.

Maximizing PHB content in Synechocystis sp. PCC 6803: a new metabolic engineering strategy based on the regulator PirC

BACKGROUND

PHB (poly-hydroxy-butyrate) represents a promising bioplastic alternative with good biodegradation properties. Furthermore, PHB can be produced in a completely carbon-neutral fashion in the natural producer cyanobacterium Synechocystis sp. PCC 6803. This strain has been used as model system in past attempts to boost the intracellular production of PHB above ~ 15% per cell-dry-weight (CDW).

RESULTS

We have created a new strain that lacks the regulatory protein PirC (product of sll0944), which exhibits a higher activity of the phosphoglycerate mutase resulting in increased PHB pools under nutrient limiting conditions. To further improve the intracellular PHB content, two genes involved in PHB metabolism, phaA and phaB, from the known producer strain Cupriavidus necator, were introduced under the control of the strong promotor PpsbA2. The resulting strain, termed PPT1 (ΔpirC-REphaAB), produced high amounts of PHB under continuous light as well under a day-night regime. When grown in nitrogen and phosphorus depleted medium, the cells produced up to 63% per CDW. Upon the addition of acetate, the content was further increased to 81% per CDW. The produced polymer consists of pure PHB, which is highly isotactic.

CONCLUSION

The amounts of PHB achieved with PPT1 are the highest ever reported in any known cyanobacterium and demonstrate the potential of cyanobacteria for a sustainable, industrial production of PHB.

Novel unexpected functions of PHA granules

Polyhydroxyalkanoates (PHA), polyesters accumulated by numerous prokaryotes in the form of intracellular granules, have been for decades considered being predominantly storage molecules. However, numerous recent discoveries revealed and emphasized their complex biological role for microbial cells. Most of all, it was repeatedly reported and confirmed that the presence of PHA granules in prokaryotic cells enhances stress resistance and robustness of microbes against various environmental stress factors such as high or low temperature, freezing, oxidative, and osmotic pressure. It seems that protective mechanisms of PHA granules are associated with their extraordinary architecture and biophysical properties as well as with the complex and deeply interconnected nature of PHA metabolism. Therefore, this review aims at describing novel and unexpected properties of PHA granules with respect to their contribution to stress tolerance of various prokaryotes including common mesophilic heterotrophic bacteria, but also extremophiles or photo-autotrophic cyanobacteria. KEY POINTS: • PHA granules present in bacterial cells reveal unique properties and functions. • PHA enhances stress robustness of bacterial cells.

On the Role and Production of Polyhydroxybutyrate (PHB) in the Cyanobacterium Synechocystis sp. PCC 6803

The cyanobacterium Synechocystis sp. PCC 6803 is known for producing polyhydroxybutyrate (PHB) under unbalanced nutrient conditions. Although many cyanobacteria produce PHB, its physiological relevance remains unknown, since previous studies concluded that PHB is redundant. In this work, we try to better understand the physiological conditions that are important for PHB synthesis. The accumulation of intracellular PHB was higher when the cyanobacterial cells were grown under an alternating day–night rhythm as compared to continuous light. In contrast to previous reports, a reduction of PHB was observed when the cells were grown under conditions of limited gas exchange. Since previous data showed that PHB is not required for the resuscitation from nitrogen starvation, a series of different abiotic stresses were applied to test if PHB is beneficial for its fitness. However, under none of the tested conditions did cells containing PHB show a fitness advantage compared to a PHB-free-mutant (ΔphaEC). Additionally, the distribution of PHB in single cells of a population Synechocystis cells was analyzed via fluorescence-activated cell sorting (FACS). The results showed a considerable degree of phenotypic heterogeneity at the single cell level concerning the content of PHB, which was consistent over several generations. These results improve our understanding about how and why Synechocystis synthesizes PHB and gives suggestions how to further increase its production for a biotechnological process.