Recent advances on conversion and co-production of acetone-butanol-ethanol into high value-added bioproducts

State-of-the-art advances in homogeneous molecular catalysis for the Guerbet upgrading of bio-ethanol to fuel-grade bio-butanol

The upgrading of ethanol to n-butanol marks a major breakthrough in the field of biofuel technology, offering the advantages of compatibility with existing infrastructure while simultaneously offering potential benefits in terms of transport efficiency and energy density. With its lower vapour pressure and reduced corrosiveness compared to ethanol, n-butanol is easier not only to manage but also to transport, eliminating the need for costly infrastructure changes. This leads to improved fuel efficiency and reduced fuel consumption. These features position n-butanol as a promising alternative to ethanol in the future of biodiesel. This review article delves into the cutting-edge advancements in upgrading ethanol to butanol, highlighting the critical importance of this transformation in enhancing the value and practical application of biofuels. While traditional methods for making butanol rely heavily on fossil fuels, those that employ ethanol as a starting material are dominated by heterogeneous catalysis, which is limited by the requirement of high temperatures and a lack of selectivity. Homogeneous catalysts have been pivotal in enhancing the efficiency and selectivity of this conversion, owing to their unique mode of operation at the molecular level. A comprehensive review of the various homogeneous catalytic processes employed in the transformation of feedstock-agnostic bio-ethanol to fuel-grade bio-n-butanol is provided here, with a major focus on the key advancements in catalyst design, reaction conditions and mechanisms that have significantly improved the efficiency and selectivity of these Guerbet reactions.

Biochar confers significant microbial resistance to ammonia toxicity in n-caproic acid production

Microbial chain elongation integrating innovative bioconversion technologies with organic waste utilization can transition current energy-intensive n-caproic acid production to sustainable circular bioeconomy systems. However, ammonia-rich waste streams, despite their suitability, pose inhibitory challenges to these bioconversion processes. Herein, biochar was employed as an additive to enhance the activity of chain elongating microbes under ammonia inhibition conditions, with an objective to detail underlying mechanisms of improvements. Biochar addition significantly improved chain elongation performance even under severe ammonia stress (exceeding 8 g N/L), increasing n-caproic acid yields by 40 % to 158 % and reducing lag times by 51 % to 90 %, compared with the best-performing group without biochar addition. The material contribution to n-caproic production reached up to 94.3 % (at 4 g N/L). These enhancements were mainly attributed to the new electron syntrophy induced by biochar, which improved electron transfer system activity and electrical conductivity of the fermentation system. This is further substantiated by increased relative abundances of the genus Sporanaerobacter, electroactive bacteria, and up-regulated direct electron transfer-related genes including conductive pili and c-type cytochrome. This study demonstrates that biochar can confer robust resilience to ammonia toxicity in functional microbes, paving a way for efficient and sustainable n-caproic acid production.

Construction of a Microbial Consortium for the De Novo Synthesis of Butyl Butyrate from Renewable Resources

Butyl butyrate has shown wide applications in food, cosmetic, and biofuel sectors. Currently, biosynthesis of butyl butyrate still requires exogenous addition of precursors and lipase, which increases the production cost and limits further large-scale development. In this study, a microbial consortium was first designed to realize direct butyl butyrate production from lignocellulose. The highest butyl butyrate concentration of 34.42 g/L was detected in the solvent phase from 60 g/L glucose using a microbial coculture system composed of Clostridium acetobutylicum NJ4 and Clostridium tyrobutyricum LD with the elimination of butyric acid supplementation. Meanwhile, 13.52 g/L butyl butyrate was synthesized from 60 g/L glucose using a microbial consortium composed of three strains including strain NJ4, strain LD, and Escherichia coli BL21- pET-29a(+)-LE without the addition of any exogenous precursors and lipase. In addition, 2.94 g/L butyl butyrate could be directly produced from 60 g/L microcrystalline cellulose when Trichoderma asperellum was added to the above-mentioned three-strain microbial consortium. This four-strain microbial consortium represents the first study regarding the direct butyl butyrate production from lignocellulose without the supplementation of exogenous precursors and lipase, which may be extended to the biosynthesis of other short-chain esters, such as ethyl acetate and butyl lactate.

A Computational Framework to Identify Metabolic Engineering Strategies for the Co-Production of Metabolites

Microbial production of chemicals is a more sustainable alternative to traditional chemical processes. However, the shift to bioprocess is usually accompanied by a drop in economic feasibility. Co-production of more than one chemical can improve the economy of bioprocesses, enhance carbon utilization and also ensure better exploitation of resources. While a number of tools exist for in silico metabolic engineering, there is a dearth of computational tools that can co-optimize the production of multiple metabolites. In this work, we propose co-FSEOF (co-production using Flux Scanning based on Enforced Objective Flux), an algorithm designed to identify intervention strategies to co-optimize the production of a set of metabolites. Co-FSEOF can be used to identify all pairs of products that can be co-optimized with ease using a single intervention. Beyond this, it can also identify higher-order intervention strategies for a given set of metabolites. We have employed this tool on the genome-scale metabolic models of Escherichia coli and Saccharomyces cerevisiae, and identified intervention targets that can co-optimize the production of pairs of metabolites under both aerobic and anaerobic conditions. Anaerobic conditions were found to support the co-production of a higher number of metabolites when compared to aerobic conditions in both organisms. The proposed computational framework will enhance the ease of study of metabolite co-production and thereby aid the design of better bioprocesses.

Microbial production of butyl butyrate: from single strain to cognate consortium

Butyl butyrate (BB) is an important chemical with versatile applications in beverage, food and cosmetics industries. Since chemical synthesis of BB may cause adverse impacts on the environment, biotechnology is an emerging alternative approach for microbial esters biosynthesis. BB can be synthesized by using a single Clostridium strain natively producing butanol or butyrate, with exogenously supplemented butyrate or butanol, in the presence of lipase. Recently, E. coli strains have been engineered to produce BB, but the titer and yield remained very low. This review highlighted a new trend of developing cognate microbial consortium for BB production and associated challenges, and end up with new prospects for further improvement for microbial BB biosynthesis.

Study on the selective hydrogenation of isophorone

3,3,5-Trimethylcyclohexanone (TMCH) is an important pharmaceutical intermediate and organic solvent, which has important industrial significance. The selective hydrogenation of isophorone was studied over noble metal (Pd/C, Pt/C, Ir/C, Ru/C, Pd/SiO₂, Pt/SiO₂, Ir/SiO₂, Ru/SiO₂), and non-noble metal (RANEY® Ni, RANEY® Co, RANEY® Cu, RANEY® Fe, Ni/SiO₂, Co/SiO₂, Cu/SiO₂, Fe/SiO₂) catalysts and using solvent-free and solvent based synthesis. The results show that the solvent has an important effect on the selectivity of TMCH. The selective hydrogenation of isophorone to TMCH can be influenced by the tetrahydrofuran solvent. The conversion of isophorone is 100%, and the yield of 3,3,5-trimethylcyclohexanone is 98.1% under RANEY® Ni and THF. The method was applied to the selective hydrogenation of isopropylidene acetone, benzylidene acetone and 6-methyl-5-ene-2-heptanone. The structures of the hydrogenation product target (4-methylpentan-2-one, 4-benzylbutan-2-one and 6-methyl-heptane-2-one) were characterized using ¹H-NMR and ¹³C-NMR. The yields of 4-methylpentan-2-one, 4-benzylbutan-2-one and 6-methyl-heptane-2-one were 97.2%, 98.5% and 98.2%, respectively. The production cost can be reduced by using RANEY® metal instead of noble metal palladium. This method has good application prospects.

The selective hydrogenation of isophorone to TMCH can be influenced by the tetrahydrofuran solvent. The conversion of isophorone is 100%, and the yield of 3,3,5-trimethylcyclohexanone is 98.1% under RANEY® Ni and THF.

Using Co-Culture to Functionalize Clostridium Fermentation

Clostridium fermentations have been developed for producing butanol and other value-added chemicals, but their development is constrained by some limitations, such as relatively high substrate cost and the need to maintain an anaerobic condition. Recently, co-culture is emerging as a popular way to address these limitations by introducing a partner strain with Clostridium. Generally speaking, the co-culture strategy enables the use of a cheaper substrate, maintains the growth of Clostridium without any anaerobic treatment, improves product yields, and/or widens the product spectrum. Herein, we review recent developments of co-culture strategies involving Clostridium species according to their partner stains' functions with representative examples. We also discuss research challenges that need to be addressed for the future development of Clostridium co-cultures.

Production of isopropyl and butyl esters by Clostridium mono-culture and co-culture

Production of esters from the acetone-butanol-ethanol (ABE) fermentation by Clostridium often focuses on butyl butyrate, leaving acetone as an undesired product. Addition of butyrate is also often needed because ABE fermentation does not produce enough butyrate. Here we addressed the problems using Clostridium beijerinckii BGS1 that preferred to produce isopropanol instead of acetone, and co-culturing it with Clostridium tyrobutyricum ATCC 25,755 that produced butyrate. Unlike acetone, isopropanol could be converted into ester using lipase and acids . C. tyrobutyricum ATCC 25,755 produced acids at pH 6, while C. beijerinckii BGS1 produced mainly solvents at the same pH. When the two strains were co-cultured, more butyrate was produced, leading to a higher titer of esters than the mono-culture of C. beijerinckii BGS1. As the first study reporting the production of isopropyl butyrate from the Clostridium fermentation, this study highlighted the potential use of lipase and co-culture strategy in ester production.

Pathway dissection, regulation, engineering and application: lessons learned from biobutanol production by solventogenic clostridia

The global energy crisis and limited supply of petroleum fuels have rekindled the interest in utilizing a sustainable biomass to produce biofuel. Butanol, an advanced biofuel, is a superior renewable resource as it has a high energy content and is less hygroscopic than other candidates. At present, the biobutanol route, employing acetone-butanol-ethanol (ABE) fermentation in Clostridium species, is not economically competitive due to the high cost of feedstocks, low butanol titer, and product inhibition. Based on an analysis of the physiological characteristics of solventogenic clostridia, current advances that enhance ABE fermentation from strain improvement to product separation were systematically reviewed, focusing on: (1) elucidating the metabolic pathway and regulation mechanism of butanol synthesis; (2) enhancing cellular performance and robustness through metabolic engineering, and (3) optimizing the process of ABE fermentation. Finally, perspectives on engineering and exploiting clostridia as cell factories to efficiently produce various chemicals and materials are also discussed.

Biofuel production from straw hydrolysates: current achievements and perspectives

Straw is an agricultural residue of the production of e.g. cereals, rapeseed or sunflowers. It includes dried stalks, leaves, and empty ears and corncobs, which are separated from the grains during harvest. Straw is a promising lignocellulosic feedstock with a beneficial greenhouse gas balance for the production of biofuels and chemicals. Like all lignocellulosic materials, straw is recalcitrant and requires thermochemical and enzymatic pretreatment to enable access to the three major biopolymers of straw-the polysaccharides cellulose and hemicellulose and the polyaromatic compound lignin. Straw is used for commercial ethanol and biogas production. Considerable research has also been conducted to produce biobutanol, biodiesel and biochemicals from this raw material, but more research is required to establish them on a commercial scale. The major hindrance for launching industrial biofuel and chemicals' production from straw is the high cost necessitated by pretreatment of the material. Improvements of microbial strains, production and extraction technologies, as well as co-production of high-value compounds represent ways of establishing straw as feedstock for the production of biofuels, chemicals and food.

Co-production of solvents and organic acids in butanol fermentation by Clostridium acetobutylicum in the presence of lignin-derived phenolics

Co-production of solvents (butanol, acetone, and ethanol) and organic acids (butyrate and acetate) by Clostridium acetobutylicum using lignocellulosic biomass as a substrate could further enlarge the application scope of butanol fermentation. This is mainly because solvents and organic acids could be used for production of fine chemicals such as butyl butyrate, butyl oleate, etc. However, many phenolic fermentation inhibitors are formed during the pretreatment process because of lignin degradation. The present study investigated the effects of five typical lignin-derived phenolics on the biosynthesis of solvents and organic acids in C. acetobutylicum ATCC 824. Results obtained in 100 mL anaerobic bottles indicated that butanol concentration was enhanced from 10.29 g L⁻¹ to 11.36 g L⁻¹ by the addition of 0.1 g L⁻¹ vanillin. Subsequently, a pH-control strategy was proposed in a 5 L anaerobic fermenter to alleviate the “acid crash” phenomenon and improve butanol fermentation performance, simultaneously. Notably, organic acid concentration was enhanced from 6.38 g L⁻¹ (control) to a high level of 9.21–12.57 g L⁻¹ with vanillin or/and vanillic acid addition (0.2 g L⁻¹) under the pH-control strategy. Furthermore, the butyrate/butanol ratio reached the highest level of 0.80 g g⁻¹ with vanillin/vanillic acid co-addition, and solvent concentration reached 13.85 g L⁻¹, a comparable level to the control (13.69 g L⁻¹). The effectiveness and robustness of the strategy for solvent and organic acid co-production was also verified under five typical phenolic environments. In conclusion, these results suggest that the proposed process strategy would potentially promote butanol fermentative products from renewable biomass.

Lignin-derived phenolics enhance solvent and organic acid biosynthesis in butanol fermentation by Clostridium acetobutylicum ATCC 824.

Dual function of ammonium acetate in acetone-butanol-ethanol fermentation by Clostridium acetobutylicum

In this study, a compound nitrogen source, integrating the advantages of ammonium acetate and soybean meal, was proposed to further improve acetone-butanol-ethanol fermentation. Unfortunately, this compound nitrogen source was found to effectively inhibit cellular performance, as the introduction of NH₄⁺ significantly decreased the yield of butanol and total solvents by 34.78% and 35.14%, to only 6.62 g/L and 10.76 g/L, respectively. Meanwhile, the regulatory mechanism was further elucidated at different levels. As a result, the NH₄⁺ could down-regulate the transcriptional levels of key genes involved in butanol synthesis, and the activity of acetoacetyl-CoA/acyl-CoA transferase, and then decrease the accumulation of key intermediates. Therefore, ammonium acetate has a dual function in ABE fermentation, as it effectively improves ABE fermentation when it is the sole nitrogen source but significantly decreases fermentation performance in the presence of soybean meal, broadening the understanding of nitrogen regulation mechanism of C. acetobutylicum.

Consolidated processing of biobutanol production from food wastes by solventogenic Clostridium sp. strain HN4

In this study, biobutanol production from glucose, starch and food waste by newly identified Clostridium sp. strain HN4 was comprehensively investigated, which is capable of secreting amylase indigenously for the following acetone-butanol-ethanol fermentation. With pH adjustment, strain HN4 could produce 5.23 g/L of butanol from 60 g/L of starch with secretion of 1.95 U/mL amylase through consolidated bioprocessing. Further supplementation of 3 g/L of CaCO₃ and 0.5% non-ionic surfactant of Tween 80 could stimulate both amylase activities and the final butanol titer, leading to 17.64 g/L of butanol with yield of 0.15 g/g. Fed batch fermentation integrated with in situ removal could further improve the butanol titer to 35.63 g/L with yield of , representing the highest butanol production and yield from food waste. These unique features of Clostridium sp. strain HN4 could open the door to the possibility of cost-effective biobutanol production from food waste on a large scale.

The Draft Genome Sequence of a Novel High-Efficient Butanol-Producing Bacterium Clostridium Diolis Strain WST

A wild-type solventogenic strain Clostridium diolis WST, isolated from mangrove sediments, was characterized to produce high amount of butanol and acetone with negligible level of ethanol and acids from glucose via a unique acetone-butanol (AB) fermentation pathway. Through the genomic sequencing, the assembled draft genome of strain WST is calculated to be 5.85 Mb with a GC content of 29.69% and contains 5263 genes that contribute to the annotation of 5049 protein-coding sequences. Within these annotated genes, the butanol dehydrogenase gene (bdh) was determined to be in a higher amount from strain WST compared to other Clostridial strains, which is positively related to its high-efficient production of butanol. Therefore, we present a draft genome sequence analysis of strain WST in this article that should facilitate to further understand the solventogenic mechanism of this special microorganism.