Aeration costs in stirred-tank and bubble column bioreactors

Improving product quality and productivity of an antibody-based biotherapeutic using inverted frustoconical shaking bioreactors

The Chinese hamster ovarian (CHO) cells serve as a common choice in biopharmaceutical production, traditionally cultivated in stirred tank bioreactors (STRs). Nevertheless, the pursuit of improved protein quality and production output for commercial purposes demand exploration into new bioreactor types. In this context, inverted frustoconical shaking bioreactors (IFSB) present unique physical properties distinct from STRs. This study aims to compare the production processes of an antibody-based biotherapeutic in both bioreactor types, to enhance production flexibility. The findings indicate that, when compared to STRs, IFSB demonstrates the capability to produce an antibody-based biotherapeutic with either comparable or enhanced bioprocess performance and product quality. IFSB reduces shear damage to cells, enhances viable cell density (VCD), and improves cell state at a 5-L scale. Consequently, this leads to increased protein expression (3.70 g/L vs 2.56 g/L) and improved protein quality, as evidenced by a reduction in acidic variants from 27.0% to 21.5%. Scaling up the culture utilizing the Froude constant and superficial gas velocity ensures stable operation, effective mixing, and gas transfer. The IFSB maintains a high VCD and cell viability at both 50-L and 500-L scales. Product expression levels range from 3.0 to 3.6 g/L, accompanied by an improved acidic variants attribute of 20.6%-22.7%. The IFSB exhibits superior productivity and product quality, underscoring its potential for incorporation into the manufacturing process for antibody-based biotherapeutics. These results establish the foundation for IFSB to become a viable option in producing antibody-based biotherapeutics for clinical and manufacturing applications.

Techno-Economic Analysis of Gas Fermentation for the Production of Single Cell Protein

Despite the large carbon footprint of livestock production, animal protein consumption has grown over the past several decades, necessitating new approaches to sustainable animal protein production. In this techno-economic analysis, single cell protein (SCP) produced via gas fermentation of carbon dioxide, oxygen, and hydrogen is studied as an animal feed source to replace fishmeal or soybean meal. Using wind-powered water electrolysis to produce hydrogen and oxygen with carbon dioxide captured from corn ethanol, the minimum selling price (MSP) of SCP is determined to be $2070 per metric ton. An emissions comparison between SCP, fishmeal, and soybean meal shows that SCP has a carbon intensity as low as 0.73 kg CO2-equiv/kg protein, while fishmeal and soybean meal have an average carbon intensity of 2.72 kg CO2-equiv/kg protein and 0.85 kg CO2-equiv/kg protein, respectively. Moreover, SCP production would occupy 0.4% of the land per ton of protein produced compared to soybean meal and would disturb less than 0.1% of the marine ecosystem currently disturbed by fishmeal harvesting practices. These results show promise for the future economic viability of SCP as a protein source in animal feed and indicate significant environmental benefits compared to other animal feed protein sources.

Microbial electrosynthesis of single cell protein and methane by coupling fast-growing Methanococcus maripaludis with microbial electrolysis cells

Single cell protein (SCP) is a promising alternative protein source, as its production bypasses the disadvantages of animal protein production in industrial agriculture. Coupling a fast-growing hydrogen consuming organism with microbial electrolysis cells (MECs) could be a viable method for SCP production. In this study, a fast-growing and protein-rich methanogen, Methanococcus maripaludis was selected as the primary SCP source. The inoculation of M. maripaludis in MECs triggered cell synthesis with methane production. The doubling time measured was 11.2 h and the specific growth rate was 0.062 1/h. The highest SCP production rate was 13.7 mg/L/h. In the dried biomass, the weight of protein was over 60 %. Amino acid profiling of the harvested biomass demonstrated high abundance of essential amino acids. The electron flux analysis indicated that 31.3 % electrons in the electrochemical systems were directed into SCP synthesis. These results illustrated the potential for SCP production by coupling a fast-growing methanogen with MECs.

Microbial gas fermentation technology for sustainable food protein production

The development of novel, sustainable, and robust food production technologies represents one of the major pillars to address the most significant challenges humanity is going to face on earth in the upcoming decades - climate change, population growth, and resource depletion. The implementation of microfoods, i.e., foods formulated with ingredients from microbial cultivation, into the food supply chain has a huge potential to contribute towards energy-efficient and nutritious food manufacturing and represents a means to sustainably feed a growing world population. This review recapitulates and assesses the current state in the establishment and usage of gas fermenting bacteria as an innovative feedstock for protein production. In particular, we focus on the most promising representatives of this taxon: the hydrogen-oxidizing bacteria (hydrogenotrophs) and the methane-oxidizing bacteria (methanotrophs). These unicellular microorganisms can aerobically metabolize gaseous hydrogen and methane, respectively, to provide the required energy for building up cell material. A protein yield over 70% in the dry matter cell mass can be reached with no need for arable land and organic substrates making it a promising alternative to plant- and animal-based protein sources. We illuminate the holistic approach to incorporate protein extracts obtained from the cultivation of gas fermenting bacteria into microfoods. Herein, the fundamental properties of the bacteria, cultivation methods, downstream processing, and potential food applications are discussed. Moreover, this review covers existing and future challenges as well as sustainability aspects associated with the production of microbial protein through gas fermentation.

Improving microbial bioproduction under low-oxygen conditions

Microbial bioconversion provides access to a wide range of sustainably produced chemicals and commodities. However, industrial-scale bioproduction process operations are preferred to be anaerobic due to the cost associated with oxygen transfer. Anaerobic bioconversion generally offers limited substrate utilization profiles, lower product yields, and reduced final product diversity compared with aerobic processes. Bioproduction under conditions of reduced oxygen can overcome the limitations of fully aerobic and anaerobic bioprocesses, but many microbial hosts are not developed for low-oxygen bioproduction. Here, we describe advances in microbial strain engineering involving the use of redox cofactor engineering, genome-scale metabolic modeling, and functional genomics to enable improved bioproduction processes under low oxygen and provide a viable path for scaling these bioproduction systems to industrial scales.

Anode-assisted electro-fermentation with Bacillus subtilis under oxygen-limited conditions

BACKGROUND

Bacillus subtilis is generally regarded as a ubiquitous facultative anaerobe. Oxygen is the major electron acceptor of B. subtilis, and when oxygen is absent, B. subtilis can donate electrons to nitrate or perform fermentation. An anode electrode can also be used by microorganisms as the electron sink in systems called anodic electro-fermentation. The facultative anaerobic character of B. subtilis makes it an excellent candidate to explore with different electron acceptors, such as an anode. This study aimed to optimise industrial aerobic bioprocesses using alternative electron acceptors. In particular, different end product spectrum of B. subtilis with various electron acceptors, including anode from the electro-fermentation system, was investigated.

RESULTS

B. subtilis was grown using three electron acceptors, i.e. oxygen, nitrate and anode (poised at a potential of 0.7 V vs. standard hydrogen electrode). The results showed oxygen had a crucial role for cells to remain metabolically active. When nitrate or anode was applied as the sole electron acceptor anaerobically, immediate cell lysis and limited glucose consumption were observed. In anode-assisted electro-fermentation with a limited aeration rate, acetoin, as the main end product showed the highest yield of 0.78 ± 0.04 mol_product/mol_glucose, two-fold higher than without poised potential (0.39 ± 0.08 mol_product/mol_glucose).

CONCLUSIONS

Oxygen controls B. subtilis biomass growth, alternative electron acceptors utilisation and metabolites formation. Limited oxygen/air supply enabled the bacteria to donate excess electrons to nitrate or anode, leading to steered product spectrum. The anode-assisted electro-fermentation showed its potential to boost acetoin production for future industrial biotechnology applications.

Production of indigo by recombinant bacteria

Indigo is an economically important dye, especially for the textile industry and the dyeing of denim fabrics for jeans and garments. Around 80,000 tonnes of indigo are chemically produced each year with the use of non-renewable petrochemicals and the use and generation of toxic compounds. As many microorganisms and their enzymes are able to synthesise indigo after the expression of specific oxygenases and hydroxylases, microbial fermentation could offer a more sustainable and environmentally friendly manufacturing platform. Although multiple small-scale studies have been performed, several existing research gaps still hinder the effective translation of these biochemical approaches. No article has evaluated the feasibility and relevance of the current understanding and development of indigo biocatalysis for real-life industrial applications. There is no record of either established or practically tested large-scale bioprocess for the biosynthesis of indigo. To address this, upstream and downstream processing considerations were carried out for indigo biosynthesis. 5 classes of potential biocatalysts were identified, and 2 possible bioprocess flowsheets were designed that facilitate generating either a pre-reduced dye solution or a dry powder product. Furthermore, considering the publicly available data on the development of relevant technology and common bioprocess facilities, possible platform and process values were estimated, including titre, DSP yield, potential plant capacities, fermenter size and batch schedule. This allowed us to project the realistic annual output of a potential indigo biosynthesis platform as 540 tonnes. This was interpreted as an industrially relevant quantity, sufficient to provide an annual dye supply to a single industrial-size denim dyeing plant. The conducted sensitivity analysis showed that this anticipated output is most sensitive to changes in the reaction titer, which can bring a 27.8% increase or a 94.4% drop. Thus, although such a biological platform would require careful consideration, fine-tuning and optimization before real-life implementation, the recombinant indigo biosynthesis was found as already attractive for business exploitation for both, luxury segment customers and mass-producers of denim garments.

Graphical Abstract

Supplementary Information

The online version contains supplementary material available at 10.1186/s40643-023-00626-7.

Analyzing the Effect of Using Axial Impellers in Large-Scale Bioreactors

In high-performance industrial fermentation processes, stirring and aeration may account for significant production costs. Compared to the widely applied Rushton impellers, axial-pumping impellers are known to yield a lower power draw and at the same time improve mixing. However, their lower gas dispersion capability requires stronger agitation, compromising these benefits. Diverse advanced impeller forms have been developed to cope with this challenge. We apply alternating radial and axial impellers and demonstrate strong gas dispersion and energy-efficient mixing for the first time in a large-scale (160 m³ ) bioreactor, based on experimental and CFD simulation data. For equal operating conditions (stirrer speed, aeration rate), this setup yielded similar gas hold-ups and better mixing times (35 %) compared to a classical Rushton-only configuration. Hence, applying a radial impeller on an upper level for improving gas dispersion maintains the benefits of axial impellers in terms of reducing energy demand (up to 50 %). We conclude that this effect is significant only at large-scale, when bubbles substantially expand due to the release of the hydrostatic pressure and have time to coalesce. The work thus extends current knowledge on mixing and aeration of large-scale reactors using classical impeller types. This article is protected by copyright. All rights reserved.

Improving hydrogen production by pH adjustment in pressurized gas fermentation

Gas fermentation utilizes syngas converted from biomass or waste as feedstock. A bubble column reactor for pressurizing was designed to increase the mass transfer rate between gas and liquid, and reduce energy consumption by medium agitation. Thermococcus onnurineus, a hydrogenic CO-oxidizer, was cultured initially under ambient pressure with the initial inlet gas composition; 60% CO and 40% N₂. The maximum H₂ productivity was 363 mmol/l/h, without pH adjustment. When additional pressure was applied, the pH rapidly declined; this may be attributed to the increased CO₂ solubility under pressure. By controlling pH, H₂ productivity increased up to 450 mmol/l/h; which is comparable to the previously reported H₂ productivity in a continuous stirred tank reactor. The results may suggest energy saving potentials of bubble column reactors in gas fermentation. This finding may be applied to other gas fermentation processes, as syngas itself contains CO₂ and many microbial processes also release CO₂.

Ectoine Production from Biogas in Waste Treatment Facilities: A Techno-Economic and Sensitivity Analysis

The capacity of haloalkaliphilic methanotrophic bacteria to synthesize ectoine from CH₄-biogas represents an opportunity for waste treatment plants to improve their economic revenues and align their processes to the incoming circular economy directives. A techno-economic and sensitivity analysis for the bioconversion of biogas into 10 t ectoine·y^-1 was conducted in two stages: (I) bioconversion of CH₄ into ectoine in a bubble column bioreactor and (II) ectoine purification via ion exchange chromatography. The techno-economic analysis showed high investment (4.2 M€) and operational costs (1.4 M€·y^-1). However, the high margin between the ectoine market value (600-1000 €·kg^-1) and the estimated ectoine production costs (214 €·kg^-1) resulted in a high profitability for the process, with a net present value evaluated at 20 years (NPV₂₀) of 33.6 M€. The cost sensitivity analysis conducted revealed a great influence of equipment and consumable costs on the ectoine production costs. In contrast to alternative biogas valorization into heat and electricity or into low added-value bioproducts, biogas bioconversion into ectoine exhibited high robustness toward changes in energy, water, transportation, and labor costs. The worst- and best-case scenarios evaluated showed ectoine break-even prices ranging from 158 to 275 €·kg^-1, ∼3-6 times lower than the current industrial ectoine market value.

The history, state of the art and future prospects for oleaginous yeast research

Lipid-based biofuels, such as biodiesel and hydroprocessed esters, are a central part of the global initiative to reduce the environmental impact of the transport sector. The vast majority of production is currently from first-generation feedstocks, such as rapeseed oil, and waste cooking oils. However, the increased exploitation of soybean oil and palm oil has led to vast deforestation, smog emissions and heavily impacted on biodiversity in tropical regions. One promising alternative, potentially capable of meeting future demand sustainably, are oleaginous yeasts. Despite being known about for 143 years, there has been an increasing effort in the last decade to develop a viable industrial system, with currently around 100 research papers published annually. In the academic literature, approximately 160 native yeasts have been reported to produce over 20% of their dry weight in a glyceride-rich oil. The most intensively studied oleaginous yeast have been Cutaneotrichosporon oleaginosus (20% of publications), Rhodotorula toruloides (19%) and Yarrowia lipolytica (19%). Oleaginous yeasts have been primarily grown on single saccharides (60%), hydrolysates (26%) or glycerol (19%), and mainly on the mL scale (66%). Process development and genetic modification (7%) have been applied to alter yeast performance and the lipids, towards the production of biofuels (77%), food/supplements (24%), oleochemicals (19%) or animal feed (3%). Despite over a century of research and the recent application of advanced genetic engineering techniques, the industrial production of an economically viable commodity oil substitute remains elusive. This is mainly due to the estimated high production cost, however, over the course of the twenty-first century where climate change will drastically change global food supply networks and direct governmental action will likely be levied at more destructive crops, yeast lipids offer a flexible platform for localised, sustainable lipid production. Based on data from the large majority of oleaginous yeast academic publications, this review is a guide through the history of oleaginous yeast research, an assessment of the best growth and lipid production achieved to date, the various strategies employed towards industrial production and importantly, a critical discussion about what needs to be built on this huge body of work to make producing a yeast-derived, more sustainable, glyceride oil a commercial reality.

Biodesulfurization of Dibenzothiophene and Its Alkylated Derivatives in a Two-Phase Bubble Column Bioreactor by Resting Cells of Rhodococcus erythropolis IGTS8

Biodesulfurization (BDS) is considered a complementary technology to the traditional hydrodesulfurization treatment for the removal of recalcitrant sulfur compounds from petroleum products. BDS was investigated in a bubble column bioreactor using two-phase media. The effects of various process parameters, such as biocatalyst age and concentration, organic fraction percentage (OFP), and type of sulfur compound—namely, dibenzothiophene (DBT), 4-methyldibenzothiophene (4-MDBT), 4,6-dimethyldibenzothiophene (4,6-DMDBT), and 4,6-diethyldibenzothiophene (4,6-DEDBT)—were evaluated, using resting cells of Rhodococcus erythropolis IGTS8. Cells derived from the beginning of the exponential growth phase of the bacterium exhibited the highest biodesulfurization efficiency and rate. The biocatalyst performed better in an OFP of 50% v/v. The extent of DBT desulfurization was dependent on cell concentration, with the desulfurization rate reaching its maximum at intermediate cell concentrations. A new semi-empirical model for the biphasic BDS was developed, based on the overall Michaelis-Menten kinetics and taking into consideration the deactivation of the biocatalyst over time, as well as the underlying mass transfer phenomena. The model fitted experimental data on DBT consumption and 2-hydroxibyphenyl (2-HBP) accumulation in the organic phase for various initial DBT concentrations and different organosulfur compounds. For constant OFP and biocatalyst concentration, the most important parameter that affects BDS efficiency seems to be biocatalyst deactivation, while the phenomenon is controlled by the affinities of biodesulfurizing enzymes for the different organosulfur compounds. Thus, desulfurization efficiency decreased with increasing initial DBT concentration, and in inverse proportion to increases in the carbon number of alkyl substituent groups.

Salt-stress adaptation of yeast as a simple method to improve high-gravity fermentation in an industrial medium

While Saccharomyces cerevisiae is a popular organism to produce ethanol, its fermentation performance is affected at high sugar concentrations due to osmotic stress. We hypothesized that adaptation under ionic stress conditions will improve the fermentation performance at high sugar concentrations due to cross-stress adaptation. We, therefore, adapted a high-performance yeast strain, S. cerevisiae CEN.PK 122, to increasing salt concentrations in an industrial medium. Control cells were adapted in the medium without added salt. The cells adapted to 3.5% (w/v) salt concentration demonstrated a superior performance when fermenting 10-30% (w/v) glucose. When fermenting 30% (w/v) glucose, the ethanol yields of the adapted cells (0.49 ± 0.01 g g^-1) were about 30% higher than the control cells (0.37 ± 0.01 g g^-1) and are comparable with the best reported to date for any medium employed. Similar improvements were also observed when fermenting 10% (w/v) sucrose. However, little improvement in fermentation was observed at the higher temperature tested (40 °C), even though the growth of the adapted cells was greater when tested in YPD medium. The improvements in fermentation at 30 °C were primarily related to the faster growth of the adapted cells and not to an increase in specific intake rates. Additionally, a significantly reduced lag phase was also observed when fermenting 30% (w/v) glucose. Thus, our work shows the application of a simple strategy to significantly improve high-gravity fermentation (HGF) performance through adaptation. KEY POINTS: • Cell adapted on 3.5% NaCl made 28% more ethanol when fermenting 30% glucose. • The adapted cells had reduced lag phase, grew faster, and produced less glycerol. • The improvements were not related to increased specific rates of production.

Reconciling the Sustainable Manufacturing of Commodity Chemicals with Feasible Technoeconomic Outcomes : Assessing the investment case for heat integrated aerobic gas fermentation

The manufacturing industry must diverge from a ‘take, make and waste’ linear production paradigm towards more circular economies. Truly sustainable, circular economies are intrinsically tied to renewable resource flows, where vast quantities need to be available at a central point of consumption. Abundant, renewable carbon feedstocks are often structurally complex and recalcitrant, requiring costly pretreatment to harness their potential fully. As such, the heat integration of supercritical water gasification (SCWG) and aerobic gas fermentation unlocks the promise of renewable feedstocks such as lignin. This study models the technoeconomics and life cycle assessment (LCA) for the sustainable production of the commodity chemicals, isopropanol and acetone, from gasified Kraft black liquor. The investment case is underpinned by rigorous process modelling informed by published continuous gas fermentation experimental data. Time series analyses support the price forecasts for the solvent products. Furthermore, a Monte Carlo simulation frames an uncertain boundary for the technoeconomic model. The technoeconomic assessment (TEA) demonstrates that production of commodity chemicals priced at ~US$1000 per tonne is within reach of aerobic gas fermentation. In addition, owing to the sequestration of biogenic carbon into the solvent products, negative greenhouse gas (GHG) emissions are achieved within a cradle-to-gate LCA framework. As such, the heat integrated aerobic gas fermentation platform has promise as a best-in-class technology for the production of a broad spectrum of renewable commodity chemicals.

Effectiveness of various bioreactors for thraustochytrid culture and production (Aurantiochytruim limacinum BUCHAXM 122)

This study aimed to develop bioreactors for cultivation of thraustochytrid, Aurantiochytrium limacinum BUCHAXM 122, that are low in cost and simple to operate. Obtaining maximum biomass and fatty acid production was a prerequisite. Three bioreactor designs were used: stirred tank bioreactor (STB), bubble bioreactor (BB) and internal loop airlift bioreactor (ILAB). The bioreactors were evaluated for their influence on oxygen mass transfer coefficient (k_La), using various spargers, mixing speed, and aeration rates. Biomass and DHA production from STB, BB, ILAB were then compared with an incubator shaker, using batch culture experiments. Results showed that a bundle of eight super-fine pore air stones was the best type of aeration sparger for all three bioreactors. Optimal culture conditions in STB were 600 rpm agitation speed and 2 vvm aeration rate, while 2 vvm and 1.5 vvm aeration provided highest biomass productivity in BB and ILAB, respectively. Antifoam agent was needed for all reactor types in order to reduce excessive foaming. Results indicated that with optimized conditions, these bioreactors are capable of thraustochytrid cultivation with a similar efficiency as cultivation using a rotary shaker. STB had the highest k_La and provided the highest biomass of 43.05 ± 0.35 g/L at 48 h. BB was simple in design, had low operating costs and was easy to build, but yielded the lowest biomass (27.50 ± 1.56 g/L). ILAB, on the other hand, had lower k_La than STB, but provided highest fatty acid productivity, of 35.36 ± 2.51% TFA.

Very high gravity ethanol fermentation from sweet sorghum stem juice using a stirred tank bioreactor coupled with a column bioreactor

A stirred tank bioreactor (STR) coupled with two column bioreactors (CRs) was used for ethanol production from sweet sorghum stem juice by Saccharomyces cerevisiae SSJ01KKU in a very high gravity fermentation. The effects of the medium circulation rate between the STR and CRs (2.6 and 5.2 mL/min, corresponding to 25 and 50 % of the S. cerevisiae specific growth rate), the starting time of medium circulation (0 and 4 h) and cell inoculation were investigated. The results showed that a medium circulation rate of 5.2 mL/min, starting the medium circulation at the beginning of fermentation (0 h) with cell inoculation into the STR only were appropriate conditions for ethanol production. This yielded an average ethanol concentration (P_E) of 120.96 g/L and ethanol productivity (Q_P) of 2.52 g/L⋅h. When a repeated-batch (RB) ethanol fermentation in the STR coupled with CR was carried out using a drain and fill technique at different volumes (75 and 90 %, referenced as RB1 and RB2, respectively), it was found that at least eight successive cycles could be operated under both RB1 and RB2. The average P_E and Q_P for RB1 and RB2 were not significantly different. However, the average total ethanol production rate in RB2 (3.25 g/h) over the eight cycles was significantly higher than that of RB1 (2.60 g/h).

Anodic electro-fermentation: Empowering anaerobic production processes via anodic respiration

In nature as well as in industrial microbiology, all microorganisms need to achieve redox balance. Their redox state and energy conservation highly depend on the availability of a terminal electron acceptor, for example oxygen in aerobic production processes. Under anaerobic conditions in the absence of an electron acceptor, redox balance is achieved via the production of reduced carbon-compounds (fermentation). An alternative strategy to artificially stabilize microbial redox and energy state is the use of anodic electro-fermentation (AEF). This emerging biotechnology empowers respiration under anaerobic conditions using the anode of a bioelectrochemical system as an undepletable terminal electron acceptor. Electrochemical control of redox metabolism and energy conservation via AEF can steer the carbon metabolism towards a product of interest and avoid the need for continuous and cost-inefficient supply of oxygen as well as the production of mixed reduced by-products, as is the case in aerobic production and fermentation processes, respectively. The great challenge for AEF is to establish efficient extracellular electron transfer (EET) from the microbe to the anode and link it to central carbon metabolism to enhance the synthesis of a target product. This article reviews the advantages and challenges of AEF, EET mechanisms, microbial energy gain, and discusses the rational choice of substrate-product couple as well as the choice of microbial catalyst. Besides, it discusses the potential of the industrial model-organism Bacillus subtilis as a promising candidate for AEF, which has not been yet considered for such an application. This prospective review contributes to a better understanding of how industrial microbiology can benefit from AEF and analyses key-factors required to successfully implement AEF processes. Overall, this work aims to advance the young research field especially by critically revisiting the fundamental aspects of AEF.

Using techno-economic modelling to determine the minimum cost possible for a microbial palm oil substitute

BACKGROUND

Heterotrophic single-cell oils (SCOs) are one potential replacement to lipid-derived biofuels sourced from first-generation crops such as palm oil. However, despite a large experimental research effort in this area, there are only a handful of techno-economic modelling publications. As such, there is little understanding of whether SCOs are, or could ever be, a potential competitive replacement. To help address this question, we designed a detailed model that coupled a hypothetical heterotroph (using the very best possible biological lipid production) with the largest and most efficient chemical plant design possible.

RESULTS

Our base case gave a lipid selling price of $1.81/kg for ~ 8,000 tonnes/year production, that could be reduced to $1.20/kg on increasing production to ~ 48,000 tonnes of lipid a year. A range of scenarios to further reduce this cost were then assessed, including using a thermotolerant strain (reducing the cost from $1.20 to $1.15/kg), zero-cost electricity ($ 1.12/kg), using non-sterile conditions ($1.19/kg), wet extraction of lipids ($1.16/kg), continuous production of extracellular lipid ($0.99/kg) and selling the whole yeast cell, including recovering value for the protein and carbohydrate ($0.81/kg). If co-products were produced alongside the lipid then the price could be effectively reduced to $0, depending on the amount of carbon funnelled away from lipid production, as long as the co-product could be sold in excess of $1/kg.

CONCLUSIONS

The model presented here represents an ideal case that which while not achievable in reality, importantly would not be able to be improved on, irrespective of the scientific advances in this area. From the scenarios explored, it is possible to produce lower cost SCOs, but research must start to be applied in three key areas, firstly designing products where the whole cell is used. Secondly, further work on the product systems that produce lipids extracellularly in a continuous processing methodology or finally that create an effective biorefinery designed to produce a low molecular weight, bulk chemical, alongside the lipid. All other research areas will only ever give incremental gains rather than leading towards an economically competitive, sustainable, microbial oil.

Engineering Escherichia coli for the utilization of ethylene glycol

Background

A considerable challenge in the development of bioprocesses for producing chemicals and fuels has been the high cost of feedstocks relative to oil prices, making it difficult for these processes to compete with their conventional petrochemical counterparts. Hence, in the absence of high oil prices in the near future, there has been a shift in the industry to produce higher value compounds such as fragrances for cosmetics. Yet, there is still a need to address climate change and develop biotechnological approaches for producing large market, lower value chemicals and fuels.

Results

In this work, we study ethylene glycol (EG), a novel feedstock that we believe has promise to address this challenge. We engineer Escherichia coli (E. coli) to consume EG and examine glycolate production as a case study for chemical production. Using a combination of modeling and experimental studies, we identify oxygen concentration as an important metabolic valve in the assimilation and use of EG as a substrate. Two oxygen-based strategies are thus developed and tested in fed-batch bioreactors. Ultimately, the best glycolate production strategy employed a target respiratory quotient leading to the highest observed fermentation performance. With this strategy, a glycolate titer of 10.4 g/L was reached after 112 h of production time in a fed-batch bioreactor. Correspondingly, a yield of 0.8 g/g from EG and productivity of 0.1 g/L h were measured during the production stage. Our modeling and experimental results clearly suggest that oxygen concentration is an important factor in the assimilation and use of EG as a substrate. Finally, our use of metabolic modeling also sheds light on the intracellular distribution through central metabolism, implicating flux to 2-phosphoglycerate as the primary route for EG assimilation.

Conclusion

Overall, our work suggests that EG could provide a renewable starting material for commercial biosynthesis of fuels and chemicals that may achieve economic parity with petrochemical feedstocks while sequestering carbon dioxide.

Technoeconomic analysis for biofuels and bioproducts

Technoeconomic analysis (TEA) is an approach for conducting process design and simulation, informed by empirical data, to estimate capital costs, operating costs, mass balances, and energy balances for a commercial scale biorefinery. TEA serves as a useful method to screen potential research priorities, identify cost bottlenecks at the earliest stages of research, and provide the mass and energy data needed to conduct life-cycle environmental assessments. Recent studies have produced new tools and methods to enable faster iteration on potential designs, more robust uncertainty analysis, and greater accessibility through the use of open-source platforms. There is also a trend toward more expansive system boundaries to incorporate the impact of policy incentives, use-phase performance differences, and potential impacts on global market supply.

Preliminary Techno-Economic Assessment of Animal Cell-Based Meat

Interest in animal cell-based meat (ACBM) or laboratory-grown meat has been increasing; however, the economic viability of these potential products has not been thoroughly vetted. Recent studies suggest monoclonal antibody production technology can be adapted for the industrialization of ACBM production. This study provides a scenario-based assessment of the projected cost per kilogram of ACBM produced in the United States based on cellular metabolic requirements and process/chemical engineering conventions. A sensitivity analysis of the model identified the nine most influential cost factors for ACBM production out of 67 initial parameters. The results indicate that technological performance will need to approach technical limits for ACBM to achieve profitably as a commodity. However, the model also suggests that low-volume high-value specialty products could be viable based on current technology.

Understanding gradients in industrial bioreactors

Gradients in industrial bioreactors have attracted substantial research attention since exposure to fluctuating environmental conditions has been shown to lead to changes in the metabolome, transcriptome as well as population heterogeneity in industrially relevant microorganisms. Such changes have also been found to impact key process parameters like the yield on substrate and the productivity. Hence, understanding gradients is important from both the academic and industrial perspectives. In this review the causes of gradients are outlined, along with their impact on microbial physiology. Quantifying the impact of gradients requires a detailed understanding of both fluid flow inside industrial equipment and microbial physiology. This review critically examines approaches used to investigate gradients including large-scale experimental work, computational methods and scale-down approaches. Avenues for future work have been highlighted, particularly the need for further coordinated development of both in silico and experimental tools which can be used to further the current understanding of gradients in industrial equipment.

Production of 2-keto-gluconic acid from glucose by immobilized Pseudomonas plecoglossicida resting cells

2-Keto-d-gluconic acid (2KGA) is an important organic acid derived from d-glucose and is used to produce the food antioxidant erythorbic acid. To improve the 2KGA production performance and cell reusability, various carriers such as calcium alginate, k-carrageenan, chitosan, and poly(vinyl alcohol)-alginate were evaluated to immobilize Pseudomonas plecoglossicida JUIM01 resting cells. Calcium alginate was shown to be a suitable carrier since the immobilized cells had the highest number of reuse times and produced the highest 2KGA concentration of 171.77 g/L, with a productivity of 3.58 g/L·h and conversion ratio of 98.38%. The cell concentration, cultivation temperature, aeration rate and initial glucose concentration were further optimized in a 5-L airlift bioreactor to obtain the best 2KGA production performance by calcium alginate-immobilized P. plecoglossicida cells. Under the optimal conditions including a cell concentration of 4.0 g/L, glucose concentration of 126.0 g/L, temperature of 34 °C and aeration rate of 2.8 L/min, 134.45 g/L 2KGA was produced by alginate-immobilized P. plecoglossicida cells within 30 h, with a total productivity of 4.48 g/L·h and yield of 1.07 g/g (conversion ratio of over 99.0%). The immobilized cells maintained a stable conversion capacity after nine reuses and 25 days of storage at 4 °C, which indicated that calcium alginate immobilization of P. plecoglossicida cells had industrial practicability for 2KGA production.

Insights from Mathematical Modelling into Process Control of Oxygen Transfer in Batch Stirred Tank Bioreactors for Reducing Energy Requirement

Significant energy savings can be made in aerobic stirred tank batch bioreactors by the manipulation of agitator power (Pag) and air flowrate per unit working volume (vvm). Control is often implemented to maintain the oxygen concentration in the bioreaction liquid (COL) at a constant value. This work used model simulations to show that controlling the Pag and vvm continuously over time, such that it is operated at or near the impeller flooding constraint results in the minimum energy requirement for oxygen transfer (strategy Cmin); however, this might prove impractical to control and operate in practice. As an alternative, the work shows that dividing the bioreaction time into a small number of constant Pag time segments (5–10), where a PID controller is used to control vvm to maintain COL constant in each segment, can achieve much of the energy saving that is associated with Cmin. During each time segment, vvm is increased and a sudden decrease in COL is used to detect the onset of flooding, after which there is a step increase in Pag. This sequence of Pag step increases continues until the bioreaction is completed. This practical control approach was shown to save most of the energy that is associated with Cmin.

Bubbly flow in degassing cyclones and potential applications

A degassing cyclone is a separator that is widely used for the removal of bubbles and dissolved gas from liquids. Gas bubbles move toward the swirling center region in a degassing cyclone due to centrifugal force. The dissolved gas is desorbed due to a decrease in the saturated solubility resulting from the pressure gradient in the degassing cyclone. Additional carrier gas bubbles with lower partial pressure lead to mass transfer at the turbulent bubble interface. The final state of the dissolved gas and carrier gas bubble in degassing cyclones is an important issue that can be used to develop a theoretical foundation for green separation engineering. The feasible development of this technology and potential applications are discussed in this work.

Modeling ethanol production through gas fermentation: a biothermodynamics and mass transfer-based hybrid model for microbial growth in a large-scale bubble column bioreactor

BACKGROUND

Ethanol production through fermentation of gas mixtures containing CO, CO₂ and H₂ has just started operating at commercial scale. However, quantitative schemes for understanding and predicting productivities, yields, mass transfer rates, gas flow profiles and detailed energy requirements have been lacking in literature; such are invaluable tools for process improvements and better systems design. The present study describes the construction of a hybrid model for simulating ethanol production inside a 700 m³ bubble column bioreactor fed with gas of two possible compositions, i.e., pure CO and a 3:1 mixture of H₂ and CO₂.

RESULTS

Estimations made using the thermodynamics-based black-box model of microbial reactions on substrate threshold concentrations, biomass yields, as well as CO and H₂ maximum specific uptake rates agreed reasonably well with data and observations reported in literature. According to the bioreactor simulation, there is a strong dependency of process performance on mass transfer rates. When mass transfer coefficients were estimated using a model developed from oxygen transfer to water, ethanol productivity reached 5.1 g L^-1 h^-1; when the H₂/CO₂ mixture is fed to the bioreactor, productivity of CO fermentation was 19% lower. Gas utilization reached 23 and 17% for H₂/CO₂ and CO fermentations, respectively. If mass transfer coefficients were 100% higher than those estimated, ethanol productivity and gas utilization may reach 9.4 g L^-1 h^-1 and 38% when feeding the H₂/CO₂ mixture at the same process conditions. The largest energetic requirements for a complete manufacturing plant were identified for gas compression and ethanol distillation, being higher for CO fermentation due to the production of CO₂.

CONCLUSIONS

The thermodynamics-based black-box model of microbial reactions may be used to quantitatively assess and consolidate the diversity of reported data on CO, CO₂ and H₂ threshold concentrations, biomass yields, maximum substrate uptake rates, and half-saturation constants for CO and H₂ for syngas fermentations by acetogenic bacteria. The maximization of ethanol productivity in the bioreactor may come with a cost: low gas utilization. Exploiting the model flexibility, multi-objective optimizations of bioreactor performance might reveal how process conditions and configurations could be adjusted to guide further process development.

Assessment of upstream bioprocessing

Depending on the purpose and use, bioprocesses are carried out in order to reduce, maintain or increase the molar O/C ratio of biomass as the initial substrate. Cascade use considers the holistic and efficient use of biomass. In the current debate of biomass use, however, one may admit that an efficient use of biomass can further be based on the maintenance of initially present molar O/C ratio and functionality. In this regard, what compound should be formed that possesses highest functionality and similar molar O/C ratio as the substrate? How much energy should be spent on bioprocesses for the conversion of biomass under aerobic or anaerobic conditions? This study discusses and contributes to the efficiency assessment of aerobic and anaerobic bioprocesses based on chemical functionality and molar O/C ratio and their scale-depended energy need for creating appropriate environmental conditions for biological agents.

Oxidoreductases and Reactive Oxygen Species in Conversion of Lignocellulosic Biomass

Biomass constitutes an appealing alternative to fossil resources for the production of materials and energy. The abundance and attractiveness of vegetal biomass come along with challenges pertaining to the intricacy of its structure, evolved during billions of years to face and resist abiotic and biotic attacks. To achieve the daunting goal of plant cell wall decomposition, microorganisms have developed many (enzymatic) strategies, from which we seek inspiration to develop biotechnological processes. A major breakthrough in the field has been the discovery of enzymes today known as lytic polysaccharide monooxygenases (LPMOs), which, by catalyzing the oxidative cleavage of recalcitrant polysaccharides, allow canonical hydrolytic enzymes to depolymerize the biomass more efficiently. Very recently, it has been shown that LPMOs are not classical monooxygenases in that they can also use hydrogen peroxide (H2O2) as an oxidant. This discovery calls for a revision of our understanding of how lignocellulolytic enzymes are connected since H2O2 is produced and used by several of them. The first part of this review is dedicated to the LPMO paradigm, describing knowns, unknowns, and uncertainties. We then present different lignocellulolytic redox systems, enzymatic or not, that depend on fluxes of reactive oxygen species (ROS). Based on an assessment of these putatively interconnected systems, we suggest that fine-tuning of H2O2 levels and proximity between sites of H2O2 production and consumption are important for fungal biomass conversion. In the last part of this review, we discuss how our evolving understanding of redox processes involved in biomass depolymerization may translate into industrial applications.