Effects of moderately elevated pressure on gas fermentation processes

Pressure fermentation to boost CO2-based poly(3-hydroxybutyrate) production using Cupriavidus necator

CO2-based poly(3-hydroxybutyrate) (PHB) can be produced by the versatile bacterium Cupriavidus necator through chemolithoautotrophic fermentation, using a gas mixture consisting of CO2, H2, and O2. Despite offering a propitious route for carbon-neutral bioplastic manufacturing, its adoption is currently hampered by the wide explosive range of the required gas mixture, as well as the limited gas-to-liquid mass transfer rates. To address these challenges, pressure fermentation was applied as a robust and effective strategy, while ensuring safe operation by adhering to the limiting O2 concentration, utilizing state-of-the-art bioreactors. Consequently, exponential growth could be prolonged, boosting CO2-based PHB production from 10.8 g/L at 1.5 bar up to 29.6 g/L at 3 bar. The production gain closely aligns with the theoretical calculations, except for when the pressure was increased up to 4 bar. Overall, the demonstrated increase in PHB production underscores the potential of pressure fermentation to enhance aerobic gas fermentation.

Polyextremophile engineering: a review of organisms that push the limits of life

Nature exhibits an enormous diversity of organisms that thrive in extreme environments. From snow algae that reproduce at sub-zero temperatures to radiotrophic fungi that thrive in nuclear radiation at Chernobyl, extreme organisms raise many questions about the limits of life. Is there any environment where life could not "find a way"? Although many individual extremophilic organisms have been identified and studied, there remain outstanding questions about the limits of life and the extent to which extreme properties can be enhanced, combined or transferred to new organisms. In this review, we compile the current knowledge on the bioengineering of extremophile microbes. We summarize what is known about the basic mechanisms of extreme adaptations, compile synthetic biology's efforts to engineer extremophile organisms beyond what is found in nature, and highlight which adaptations can be combined. The basic science of extremophiles can be applied to engineered organisms tailored to specific biomanufacturing needs, such as growth in high temperatures or in the presence of unusual solvents.

Optimization of the Ex Situ Biomethanation of Hydrogen and Carbon Dioxide in a Novel Meandering Plug Flow Reactor: Start-Up Phase and Flexible Operation

With the increasing use of renewable energy resources for the power grid, the need for long-term storage technologies, such as power-to-gas systems, is growing. Biomethanation provides the opportunity to store energy in the form of the natural gas-equivalent biomethane. This study investigates a novel plug flow reactor that employs a helical static mixer for the biological methanation of hydrogen and carbon dioxide. In tests, the reactor achieved an average methane production rate of 2.5 LCH4LR∗d (methane production [LCH4] per liter of reactor volume [LR] per day [d]) with a maximum methane content of 94%. It demonstrated good flexibilization properties, as repeated 12 h downtimes did not negatively impact the process. The genera Methanothermobacter and Methanobacterium were predominant during the initial phase, along with volatile organic acid-producing, hydrogenotrophic, and proteolytic bacteria. The average ratio of volatile organic acid to total inorganic carbon increased to 0.52 ± 0.04, while the pH remained stable at an average of pH 8.1 ± 0.25 from day 32 to 98, spanning stable and flexible operation modes. This study contributes to the development of efficient flexible biological methanation systems for sustainable energy storage and management.

Recent advances in methanol production from methanotrophs

Methanol, the simplest aliphatic molecule of the alcohol family, finds diverse range of applications as an industrial solvent, a precursor for producing other chemicals (e.g., dimethyl ether, acetic acid and formaldehyde), and a potential fuel. There are conventional chemical routes for methanol production such as, steam reforming of natural gas to form syngas, followed by catalytic conversion into methanol; direct catalytic oxidation of methane, or hydrogenation of carbon dioxide. However, these chemical routes are limited by the requirement for expensive catalysts and extreme process conditions, and plausible environmental implications. Alternatively, methanotrophic microorganisms are being explored as biological alternative for methanol production, under milder process conditions, bypassing the requirement for chemical catalysts, and without imposing any adverse environmental impact. Methanotrophs possess inherent metabolic pathways for methanol production via biological methane oxidation or carbon dioxide reduction, thus offering a surplus advantage pertaining to the sequestration of two major greenhouse gases. This review sheds light on the recent advances in methanotrophic methanol production including metabolic pathways, feedstocks, metabolic engineering, and bioprocess engineering approaches. Furthermore, various reactor configurations are discussed in view of the challenges associated with solubility and mass transfer limitations in methanotrophic gas fermentation systems.

Strategies to overcome mass transfer limitations of hydrogen during anaerobic gaseous fermentations: A comprehensive review

Fermentation of gaseous substrates such as carbon dioxide (CO₂) has emerged as a sustainable approach for transforming greenhouse gas emissions into renewable fuels and biochemicals. CO₂ fermentations are catalyzed by hydrogenotrophic methanogens and homoacetogens, these anaerobic microorganisms selectively reduce CO₂ using hydrogen (H₂) as electron donor. However, H₂ possesses low solubility in liquid media leading to slow mass transport, limiting the reaction rates of CO₂ reduction. Solving the problems of mass transport of H₂ could boost the advance of technologies for valorizing industrial CO₂-rich streams, like biogas or syngas. The application could further be extended to combustion flue gases or even atmospheric CO₂. In this work, an overview of strategies for overcoming H₂ mass transport limitations during methanogenic and acetogenic fermentation of H₂ and CO₂ is presented. The potential for using these strategies in future full-scale facilities and the knowledge gaps for these applications are discussed in detail.

Polyhydroxybutyrate Production from Methane and Carbon Dioxide by a Syntrophic Consortium of Methanotrophs with Oxygenic Photogranules without an External Oxygen Supply

Here, a syntrophic process was developed to produce polyhydroxy-β-butyrate (PHB) from a gas stream containing CH₄ and CO₂ without an external oxygen supply using a combination of methanotrophs with the community of oxygenic photogranules (OPGs). The co-culture features of Methylomonas sp. DH-1 and Methylosinus trichosporium OB3b were evaluated under carbon-rich and carbon-lean conditions. The critical role of O₂ in the syntrophy was confirmed through the sequencing of 16S rRNA gene fragments. Based on their carbon consumption rates and the adaptation to a poor environment, M. trichosporium OB3b with OPGs was selected for methane conversion and PHB production. Nitrogen limitation stimulated PHB accumulation in the methanotroph but hindered the growth of the syntrophic consortium. At 2.9 mM of the nitrogen source, 1.13 g/L of biomass and 83.0 mg/L of PHB could be obtained from simulated biogas. These results demonstrate that syntrophy has the potential to convert greenhouse gases into valuable products efficiently.

Process engineering strategy for improved methanol production in Methylosinus trichosporium through enhanced mass transfer and solubility of methane and carbon dioxide

Methanol was produced in a two-stage integrated process using Methylosinus trichosporium NCIMB 11131. The first stage involved sequestration of methane to produce methanotrophic biomass, which was utilized as biocatalyst in the second stage to convert CO₂ into methanol. A combinatorial process engineering approach of design of micro-sparger, engagement of draft tube, addition of mass transfer vector and elevation of reactor operating pressure was employed to enhance production of biomass and methanol. Maximum biomass titer of 7.68 g/L and productivity of 1.46 g/L d^-1 were achieved in an airlift reactor equipped with a micro-sparger of 5 µm pore size, in the presence of draft tube and 10 % v/v silicone oil, as mass transfer vector. Maximum methane fixation rate was estimated to be 0.80 g/L d^-1. Maximum methanol titer of 1.98 g/L was achieved under an elevated operating pressure of 4 bar in a high-pressure stirred tank reactor.

Turning C1-gases to isobutanol towards great environmental and economic sustainability via innovative biological routes: two birds with one stone

BACKGROUND

The dramatic increase in greenhouse gas (GHG) emissions, which causes serious global environmental issues and severe climate changes, has become a global problem of concern in recent decades. Currently, native and/or non-native C1-utilizing microbes have been modified to be able to effectively convert C1-gases (biogas, natural gas, and CO₂) into isobutanol via biological routes. Even though the current experimental results are satisfactory in lab-scale research, the techno-economic feasibility of C1 gas-derived isobutanol production at the industrial scale still needs to be analyzed and evaluated, which will be essential for the future industrialization of C1-gas bioconversion. Therefore, techno-economic analyses were conducted in this study with comparisons of capital cost (CAPEX), operating cost (OPEX), and minimum isobutanol selling price (MISP) derived from biogas (scenario #1), natural gas (scenario #2), and CO₂ (scenario #3) with systematic economic assessment.

RESULTS

By calculating capital investments and necessary expenses, the highest CAPEX ($317 MM) and OPEX ($67 MM) were projected in scenario #1 and scenario #2, respectively. Because of the lower CAPEX and OPEX from scenario #3, the results revealed that bioconversion of CO₂ into isobutanol temporally exhibited the best economic performance with an MISP of $1.38/kg isobutanol. Furthermore, a single sensitivity analysis with nine different parameters was carried out for the production of CO₂-derived isobutanol. The annual plant capacity, gas utilization rate, and substrate cost are the three most important economic-driving forces on the MISP of CO₂-derived isobutanol. Finally, a multiple-point sensitivity analysis considering all five parameters simultaneously was performed using ideal targets, which presented the lowest MISP of $0.99/kg in a long-term case study.

CONCLUSIONS

This study provides a comprehensive assessment of the bioconversion of C1-gases into isobutanol in terms of the bioprocess design, mass/energy calculation, capital investment, operating expense, sensitivity analysis, and minimum selling price. Compared with isobutanol derived from biogas and natural gas, the CO₂-based isobutanol showed better economic feasibility. A market competitive isobutanol derived from CO₂ is predicable with lower CO₂ cost, better isobutanol titer, and higher annual capacity. This study will help researchers and decision-makers explore innovative and effective approaches to neutralizing GHGs and focus on key economic-driving forces to improve techno-economic performance.

Biological selenate and selenite reduction by waste activated sludge using hydrogen as electron donor

Biological reduction of selenium oxyanions is widely used for selenium removal from wastewater. The process is, however, limited by the availability of a suitable, efficient and low cost electron donor. In this study, selenite and selenate reduction by waste activated sludge using hydrogen as the electron donor was investigated. Both selenite and selenate (80 mg/L) were completely removed using H₂ within 8 days of incubation. In the presence of sulfate in the medium, the Se removal efficiency decreased to 77.8-95.4% (for selenite) and 88.2-99.4% (for selenate) at different temperatures and initial sulfate concentrations. Thermophilic conditions (50 °C) were better suited for both selenite and selenate reduction using H₂ as electron donor with a 0.8-13.5% increase in overall Se removal. Similarly, sulfate reduction also increased from 69.1- 88% at 30 °C to 72-94.6% at 50 °C. Most of the H₂ utilized was diverted towards Se and sulfate reduction with minimal production of byproducts such as methane (<0.32 mM) or volatile fatty acids (<0.92 mg/L). The elemental Se produced from selenite and selenate reduction ranged between 33.9 and 52.1 mg/L. The elemental selenium nanoparticles produced as a result of selenite and selenate reduction were characterized using transmission electron microscopy (TEM), energy-dispersive X-ray spectroscopy (EDX) and dynamic light scattering (DLS) spectroscopy. Furthermore, characterization of the biomass using Fourier-transform infrared spectroscopy (FTIR) and excitation emission matrix (EEM) spectra of the extracellular polymeric substances (EPS) produced by the waste activated sludge were performed to elucidate the mechanism of selenium oxyanion reduction to elemental selenium nanoparticles.

Syngas fermentation and microbial electrosynthesis integration as a single process unit

Industrially relevant syngas (15 % CO, 15% H₂, 20% N₂ in 50% CO₂) fermentation and microbial electrosynthesis were integrated as a single process unit in open and closed-circuit modes. This study examined the impact of electrochemical reducing power from -50 to -400 mV on the acetic acid synthesis and CO inhibition on fermentation. -150 mV vs. Ag/AgCl (3.0 NaCl) was identified as the lowest benchmark potential for improved acetic acid synthesis rate (0.263 mmol L^-1h^-1), which is 15-fold higher than the open circuit mode's rate. No significant inhibition by CO in the fermentation was observed, while 60% of the gas was consumed. Anodic potential above 2.0 V substantially lowered the product formation. Superseding the fermentation medium with fresh inoculum through a fed-batch operation helped lower the anodic potential.

Design and evaluation of gas fermentation systems for CO2 reduction to C2 and C4 fatty acids: Non-genetic metabolic regulation with pressure, pH and reaction time

Addressing the carbon emissions through microbial mediated fermentation is an emerging interest. Custom designed and fabricated gas fermentation (GF) systems were evaluated to optimize the headspace pressure, pH (6.5, 7.5, and 8.5), fermentation time, and substrate concentration by employing enriched homoacetogenic chemolithoautotrophs in non-genetic approach. Headspace pressure showed marked influence on the metabolic conversion of inorganic carbon to acetic and butyric acids with 26% higher productivity than the control (atmospheric pressure). Maximum volatile fatty acid (VFA) yield of 3.7 g/L was observed at alkaline pH (8.5) under 2 bar pressure at carbon load of 10 g/L, 96 h). Acetic (3.0 g/L) and butyric (0.7 g/L) acids were the major products upon conversion of 85% of the inorganic substrate. A better in-situ buffering (β = 0.048) at pH 8.5 along with higher reductive current (RCC: -4.4 mA) depicted better performance of GF towards CO₂ reduction.

Microbial Utilization of Next-Generation Feedstocks for the Biomanufacturing of Value-Added Chemicals and Food Ingredients

Global shift to sustainability has driven the exploration of alternative feedstocks beyond sugars for biomanufacturing. Recently, C1 (CO₂, CO, methane, formate and methanol) and C2 (acetate and ethanol) substrates are drawing great attention due to their natural abundance and low production cost. The advances in metabolic engineering, synthetic biology and industrial process design have greatly enhanced the efficiency that microbes use these next-generation feedstocks. The metabolic pathways to use C1 and C2 feedstocks have been introduced or enhanced into industrial workhorses, such as Escherichia coli and yeasts, by genetic rewiring and laboratory evolution strategies. Furthermore, microbes are engineered to convert these low-cost feedstocks to various high-value products, ranging from food ingredients to chemicals. This review highlights the recent development in metabolic engineering, the challenges in strain engineering and bioprocess design, and the perspectives of microbial utilization of C1 and C2 feedstocks for the biomanufacturing of value-added products.

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.

Reactor Designs and Configurations for Biological and Bioelectrochemical C1 Gas Conversion: A Review

Microbial C1 gas conversion technologies have developed into a potentially promising technology for converting waste gases (CO₂, CO) into chemicals, fuels, and other materials. However, the mass transfer constraint of these poorly soluble substrates to microorganisms is an important challenge to maximize the efficiencies of the processes. These technologies have attracted significant scientific interest in recent years, and many reactor designs have been explored. Syngas fermentation and hydrogenotrophic methanation use molecular hydrogen as an electron donor. Furthermore, the sequestration of CO₂ and the generation of valuable chemicals through the application of a biocathode in bioelectrochemical cells have been evaluated for their great potential to contribute to sustainability. Through a process termed microbial chain elongation, the product portfolio from C1 gas conversion may be expanded further by carefully driving microorganisms to perform acetogenesis, solventogenesis, and reverse β-oxidation. The purpose of this review is to provide an overview of the various kinds of bioreactors that are employed in these microbial C1 conversion processes.

A quantitative metabolic analysis reveals Acetobacterium woodii as a flexible and robust host for formate-based bioproduction

Cheap and renewable feedstocks such as the one-carbon substrate formate are emerging for sustainable production in a growing chemical industry. We investigated the acetogen Acetobacterium woodii as a potential host for bioproduction from formate alone and together with autotrophic and heterotrophic co-substrates by quantitatively analyzing physiology, transcriptome, and proteome in chemostat cultivations in combination with computational analyses. Continuous cultivations with a specific growth rate of 0.05 h^-1 on formate showed high specific substrate uptake rates (47 mmol g^-1 h^-1). Co-utilization of formate with H₂, CO, CO₂ or fructose was achieved without catabolite repression and with acetate as the sole metabolic product. A transcriptomic comparison of all growth conditions revealed a distinct adaptation of A. woodii to growth on formate as 570 genes were changed in their transcript level. Transcriptome and proteome showed higher expression of the Wood-Ljungdahl pathway during growth on formate and gaseous substrates, underlining its function during utilization of one-carbon substrates. Flux balance analysis showed varying flux levels for the WLP (0.7-16.4 mmol g^-1 h^-1) and major differences in redox and energy metabolism. Growth on formate, H₂/CO₂, and formate + H₂/CO₂ resulted in low energy availability (0.20-0.22 ATP/acetate) which was increased during co-utilization with CO or fructose (0.31 ATP/acetate for formate + H₂/CO/CO₂, 0.75 ATP/acetate for formate + fructose). Unitrophic and mixotrophic conversion of all substrates was further characterized by high energetic efficiencies. In silico analysis of bioproduction of ethanol and lactate from formate and autotrophic and heterotrophic co-substrates showed promising energetic efficiencies (70-92%). Collectively, our findings reveal A. woodii as a promising host for flexible and simultaneous bioconversion of multiple substrates, underline the potential of substrate co-utilization to improve the energy availability of acetogens and encourage metabolic engineering of acetogenic bacteria for the efficient synthesis of bulk chemicals and fuels from sustainable one carbon substrates.

Stepping on the Gas to a Circular Economy: Accelerating Development of Carbon-Negative Chemical Production from Gas Fermentation

Owing to rising levels of greenhouse gases in our atmosphere and oceans, climate change poses significant environmental, economic, and social challenges globally. Technologies that enable carbon capture and conversion of greenhouse gases into useful products will help mitigate climate change by enabling a new circular carbon economy. Gas fermentation usingcarbon-fixing microorganisms offers an economically viable and scalable solution with unique feedstock and product flexibility that has been commercialized recently. We review the state of the art of gas fermentation and discuss opportunities to accelerate future development and rollout. We discuss the current commercial process for conversion of waste gases to ethanol, including the underlying biology, challenges in process scale-up, and progress on genetic tool development and metabolic engineering to expand the product spectrum. We emphasize key enabling technologies to accelerate strain development for acetogens and other nonmodel organisms.

Online monitoring of gas transfer rates during CO and CO/H2 gas fermentation in quasi-continuously ventilated shake flasks

Syngas fermentation is a potential player for future emission reduction. The first demonstration and commercial plants have been successfully established. However, due to its novelty, development of syngas fermentation processes is still in its infancy, and the need to systematically unravel and understand further phenomena, such as substrate toxicity as well as gas transfer and uptake rates, still persists. This study describes a new online monitoring device based on the respiration activity monitoring system for cultivation of syngas fermenting microorganisms with gaseous substrates. The new device is designed to online monitor the carbon dioxide transfer rate (CO₂ TR) and the gross gas transfer rate during cultivation. Online measured data are used for the calculation of the carbon monoxide transfer rate (COTR) and hydrogen transfer rate (H₂ TR). In cultivation on pure CO and CO + H₂ , CO was continuously limiting, whereas hydrogen, when present, was sufficiently available. The maximum COTR measured was approximately 5 mmol/L/h for pure CO cultivation, and approximately 6 mmol/L/h for cultivation with additional H₂ in the gas supply. Additionally, calculation of the ratio of evolved carbon dioxide to consumed monoxide, similar to the respiratory quotient for aerobic fermentation, allows the prediction of whether acetate or ethanol is predominantly produced. Clostridium ljungdahlii, a model acetogen for syngas fermentation, was cultivated using only CO, and CO in combination with H₂ . Online monitoring of the mentioned parameters revealed a metabolic shift in fermentation with sole CO, depending on COTR. The device presented herein allows fast process development, because crucial parameters for scale-up can be measured online in small-scale gas fermentation.

Towards continuous industrial bioprocessing with solventogenic and acetogenic clostridia: challenges, progress and perspectives

The sustainable production of solvents from above ground carbon is highly desired. Several clostridia naturally produce solvents and use a variety of renewable and waste-derived substrates such as lignocellulosic biomass and gas mixtures containing H2/CO2 or CO. To enable economically viable production of solvents and biofuels such as ethanol and butanol, the high productivity of continuous bioprocesses is needed. While the first industrial-scale gas fermentation facility operates continuously, the acetone-butanol-ethanol (ABE) fermentation is traditionally operated in batch mode. This review highlights the benefits of continuous bioprocessing for solvent production and underlines the progress made towards its establishment. Based on metabolic capabilities of solvent producing clostridia, we discuss recent advances in systems-level understanding and genome engineering. On the process side, we focus on innovative fermentation methods and integrated product recovery to overcome the limitations of the classical one-stage chemostat and give an overview of the current industrial bioproduction of solvents.