Continuous and biomass recycle fermentations of Clostridium acetobutylicum

The availability and demand of biosynthetic energy (ATP) is an important factor in the regulation of solvent production in steady state continuous cultures of Clostridium acetobutylicum. The effect of biomass recycle at a variety of dilution rates and recycle ratios under both glucose and non-glucose limited conditions on product yields and selectivities has been investigated. Under conditions of non-glucose limitation, when the ATP supply is not growth-limiting, a lower growth rate imposed by biomass recycle leads to a reduced demand for ATP and substantially higher acetone and butanol yields. When the culture is glucose limited, however, biomass recycle results in lower solvent yields and higher acid yields.List of Symbols A ₆₀₀ absorbance at 600 nm - ATP adenosine triphosphate - C _imol/dm³ concentration of componenti in the fermentor - C _i ⁰ mol/dm³ concentration of componenti in the feed - D h^–1 dilution rate - F dm³/h feed flow rate - FdH₂ ferredoxin, reduced form - NAD nicotinamide adenine dinucleotide, oxidized form - NADH nicotinamide adenine dinucleotide, reduced form - NfF mmol/g/h NADH produced from oxidation of FdH₂ per unit biomass per unit time - P dm³/h filtrate flow during biomass recycle operation - PCRP C-mole carbon per C-mole glucose utilized percent of (substrate) carbon recovered in products - R recycle ratio,P/F - SPR mmol/g/h specific production rate - X _imol product/100 mol glucose utilized product yield - Y _ATP g biomass/mol ATP biomass yield on ATP - Y _GLU g biomass/mol glucose biomass yield on glucose - Y _ig biomass/mol biomass yield on nutrienti - h^–1 specific growth rate     

Continuous and biomass recycle fermentations of Clostridium acetobutylicum

Using experimental data from continuous cultures of Clostridium acetobutylicum with and without biomass recycle, relationships between product formation, growth and energetic parameters were explored, developed and tested. For glucose-limited cultures the maintenance models for, the Y _ATP and biomass yield on glucose, and were found valid, as well as the following relationships between the butanol (Y _B/G) or butyrate (Y _BE/G) yields and the ATP ratio (R _ATP, an energetic parameter), Y _B/G =0.82-1.35 R _ATP, Y _BE/G =0.54 + 1.90 R _ATP. For non-glucose-limited cultures the following correlations were developed, Y _B/G =0.57-1.07 , Y _B/G =0.82-1.35 R _ATPATP and similar equations for the ethanol yield. All these expressions are valid with and without biomass recycle, and independently of glucose feed or residual concentrations, biomass and product concentrations. The practical significance of these expressions is also discussed.List of Symbols D h^–1 dilution rate - m _e mol g^–1 h^–1 maintenance energy coefficient - m _G mol g^–1 h^–1 maintenance energy coefficient - R biomass recycle ratio, (dimensionless) - R _ATP ATP ratio (eqs.(5), (10) and (11)), (dimensionless) - X kg/m³ biomass concentration - Y _ATP g biomass per mol ATP biomass yield on ATP - Y _ATP ^max g biomass per mol ATP maximum Y _ATP - Y _A/G mol acetate produced per mol glucose consumed molar yield of acetate - y _an/g mol acetone produced per mol glucose consumed molar yield of acetone - Y _B/G mol butanol produced per mol glucose consumed molar yield of butanol - y _be/g mol butyrate produced per mol glucose consumed molar yield of butyrate - Y _E/G mol ethanol produced per mol glucose consumed molar yield of ethanol - Y _X/G g biomass per mol glucose consumed biomass yield on glucose - Y _ATP ^max g biomass per mol maximum Y _X/G glucose consumed - h^–1 specific growth rate     

Competitive yeast fermentation with selective flocculation and recycle

Continuous fermentations were carried out involving competition between two strains of Saccharomyces cerevisiae. One of the strains has a lower specific growth rate and is very flocculent, whereas the fastergrowing strain is nonflocculent. The product stream from the chemostat was fed into an inclined settler where the flocculent strain was partially separated from the nonflocculent strain as a result of the higher sedimentation rate of the flocculent cells. The underflow from the inclined settler, which was concentrated and enriched with flocculent cells, was recycled to the chemostat. When no recycle was used, the fastergrowing, nonflocculent yeast rapidly overtook the culture. With selective recycle, however, the experiments demonstrated that the slower-growing flocculent yeast could be maintained as the dominant species. A theoretical development is also presented in order to describe the competition between two strains in the bioreactor-settler system. The concept of selective recycle via selective flocculation and sedimentation offers a possible means of maintaining unstable recombinant microorganisms in continuous fermentations.     

Rapid ethanol fermentations using vacuum and cell recycle

Cell recycle and vacuum fermentation systems were developed for continuous ethanol production. Cell recycle was employed in both atmospheric pressure and vacuum fermentations to achieve high cell densities and rapid ethanol fermentation rates. Studies were conducted with Saccharomyces cerevisiae (ATCC No. 4126) at a fermentation temperature of 35°C. Employing a 10% glucose feed, a cell density of 50 g dry wt/liter was obtained in atmospheric-cell recycle fermentations which produced a fermentor ethanol productivity of 29.0 g/liter-hr. The vacuum fermentor eliminated ethanol inhibition by boiling away ethanol from the fermenting beer as it was formed. This permitted the rapid and complete fermentation of concentrated sugar solutions. At a total pressure of 50 mmHg and using a 33.4% glucose feed, ethanol productivities of 82 and 40 g/liter-hr were achieved with the vacuum system with and without cell recycle, respectively. Fermentor ethanol productivities were thus increased as much as twelvefold over conventional continuous fermentations. In order to maintain a viable yeast culture in the vacuum fermentor, a bleed of fermented broth had to be continuously withdrawn to remove nonvolatile compounds. It was also necessary to sparge the vacuum fermentor with pure oxygen to satisfy the trace oxygen requirement of the fermenting yeast.     

Analysis of two-stage recombinant bacterial fermentations using a structured kinetic model

A structured kinetic model has been employed to analyze the performance of a two-stage continuous fermentation of a recombinant Escherichia coli. Separating the cell growth phase from the gene expression phase in two fermentors minimizes the growth rate difference between the recombinant cells and the plasmid-free cells in the first fermentor, thereby increasing the plasmid stability. The plasmid-harboring cells from the first fermentor are continuously fed into the second fermentor, in which the foreign protein synthesis is turned on by the addition of the inducer. Consequently, the recombinant cells experience an immediate reduction in growth rates as soon as they enter the second stage and then recover to synthesize the foreign protein. To analyze the fermentation performance contributed by these cells with different intracellular foreign protein levels and growth rates, a novel method for determining the residence time distribution of the growing cells in the second stage has been formulated. Combined with this method, the structured kinetic model for recombinant bacterial cells is used to predict the plasmid stability and foreign productivity at various operation conditions, such as induction strength and dilution rates. This model can provide us with thorough understanding of the characteristics of the two-stage fermentations, and is useful for the development of large scale continuous cultures of recombinant bacteria.     

13C NMR studies of bacterial fermentations.

We describe the experimental methods used and the constraints that apply in studies of anaerobic cell metabolism by 13C NMR. We review some of the results of our recent work in this area. Clostridium neopropionicum was shown to ferment ethanol into propionate by the acrylate, non-randomizing pathway. The same metabolic route accounts for 50% of the propionate formed in the complex ecosystem that inhabits the pig's large intestine. The rest is formed via the randomizing succinate pathway. Reductive, hydrogenotrophic acetogenesis was studied in several ecosystems. Although it is usually overshadowed by methanogenesis in the competition for hydrogen, it may become an efficient electron sink when methane biosynthesis is blocked by a specific inhibitor.     

Plasmid maintenance and protein overproduction in selective recycle bioreactors

A new plasmid construct has been used in conjunction with selective recycle to successfully maintain otherwise unstable plasmid-bearing E. coli cells in a continuous bioreactor and to produce significant amounts of the plasmid-encoded protein beta-lactamase. The plasmid is constructed so that pilin expression, which leads to bacterial flocculation, is under control of the tac operon. The plasmid-bearing cells are induced to flocculate in the separator, whereas cell growth and product synthesis occur in the main fermentation vessel without the inhibiting effects of pilin production. Selective recycle allows for the maintenance of the plasmid-bearing cells by separating flocculent, plasmid-bearing cells from nonflocculent, segregant cells in an inclined settler, and recycling only the plasmid-bearing cells to the reactor. As a result, product expression levels are maintained that are more than ten times the level achieved without selective recycle. All experimental data agree well with theoretical predictions.     

Extended recombinant bacterial ghost system.

Controlled expression of cloned PhiX174 gene E in Gram-negative bacteria results in lysis of the bacteria by formation of an E-specific transmembrane tunnel structure built through the cell envelope complex. Bacterial ghosts from a variety of bacteria are used as non-living candidate vaccines. In the recombinant ghost system, foreign proteins are attached on the inside of the inner membrane as fusions with specific anchor sequences. Ghosts have a sealed periplasmic space and the export of proteins into this space vastly extends the capacity of ghosts or recombinant ghosts to function as carriers of foreign antigens. In addition, S-layer proteins forming shell-like self assembly structures can be expressed in candidate vaccine strains prior to E-mediated lysis. Such recombinant S-layer proteins carrying foreign epitopes further extend the possibilities of ghosts as carriers of foreign epitopes. As ghosts have inherent adjuvant properties, they can be used as adjuvants in combination with subunit vaccines. Subunits or other ligands can also be coupled to matrixes like dextran which are used to fill the internal lumen of ghosts. Oral, aerogenic or parenteral immunization of experimental animals with recombinant ghosts induced specific humoral and cellular immune responses against bacterial and target components including protective mucosal immunity. The most relevant advantage of recombinant bacterial ghosts as immunogens is that no inactivation procedures that denature relevant immunogenic determinants are employed in this production. This fact explains the superior quality of ghosts when compared to other inactivated vaccines. The endotoxic component of the outer membrane does not limit the use of ghosts as vaccine candidates but triggers the release of several potent immunoregulatory cytokines. As carriers, there is no limitation in the size of foreign antigens that can be inserted in the membrane and the capacity of all spaces including the membranes, peri-plasma and internal lumen of the ghosts can be fully utilized. This extended recombinant ghost system represents a new strategy for adjuvant free combination vaccines.     

The selective value of bacterial shape.

Why do bacteria have shape? Is morphology valuable or just a trivial secondary characteristic? Why should bacteria have one shape instead of another? Three broad considerations suggest that bacterial shapes are not accidental but are biologically important: cells adopt uniform morphologies from among a wide variety of possibilities, some cells modify their shape as conditions demand, and morphology can be tracked through evolutionary lineages. All of these imply that shape is a selectable feature that aids survival. The aim of this review is to spell out the physical, environmental, and biological forces that favor different bacterial morphologies and which, therefore, contribute to natural selection. Specifically, cell shape is driven by eight general considerations: nutrient access, cell division and segregation, attachment to surfaces, passive dispersal, active motility, polar differentiation, the need to escape predators, and the advantages of cellular differentiation. Bacteria respond to these forces by performing a type of calculus, integrating over a number of environmental and behavioral factors to produce a size and shape that are optimal for the circumstances in which they live. Just as we are beginning to answer how bacteria create their shapes, it seems reasonable and essential that we expand our efforts to understand why they do so.     

Study of gaseous substrate fermentations: carbon monoxide conversion to acetate. 2. Continuous culture

The fermentation of gaseous substrates such as CO, H(2), and CO(2) may be performed in a continuous stirred tank reactor, as well as the traditional batch reactor. In this article, the conversion of carbon monoxide by Peptostreptococcus productus is demonstrated in a stirred tank reactor under both mass transfer-controlled and nonmass transfer-controlled conditions. Utilizing a non-steady-state procedure, intrinsic rates are evaluated under non-mass transfer-controlled conditions in a time period of only 5-6 hours. A steady-state procedure was used to evaluate CSTR performance under mass transfer-controlled conditions. The mass transfer coefficient was calculated, followed by the development of a model to predict CSTR behavior for this gas phase substrate.     

Efficient bacterial expression of fusion proteins and their selective processing by a recombinant Kex-1 protease

A secreted, soluble variant of the Kex-1 endopeptidase from Kluyveromyces lactis has been produced and studied as a novel cleavage enzyme exhibiting high specificity for the Lys-Arg peptide. This highly selective, efficient enzyme is particularly adapted for use in manufacturing when a recombinant therapeutic protein, possessing its native N-terminus, has to be released in vitro from a bacterially-expressed fusion protein. In this paper, we describe the preparation of a Kex-1 variant using Saccharomyces cerevisiae and its application in the production of important therapeutic recombinant proteins such as human growth hormone, granulocyte colony-stimulating factor and interferon-α-2b.     

Influence of plasmid origin and promoter strength in fermentations of recombinant yeast

The effects of plasmid promoter strength and origin of replication on cloned gene expression in recombinant Saccharomyces cerevisiae have been studied in batch and continuous culture. The plasmids employed contain the Escherichia coli lacZ gene under the control of yeast promoters regulated by the galactose regulatory circuit. The synthesis of beta-galactosidase was therefore induced by the addition of galactose. The initial induction transients in batch culture were compared for strains containing plasmids with 2mu and ARS1 origins. As expected, cloned gene product synthesis was much lower with the ARS1 plasmid: average beta-galactosidase specific activity was an order of magnitude below that with the 2mu-based plasmid. This was primarily due to the low plasmid stability of 7.5% when the plasmid origin of replication was the ARS1 element. The influence of plasmid promoter strength was studied using the yeast GAL1, GAL10, and hybrid GAL10-CYC1 promoters. The rate of increase in beta-galactosidase specific activity after induction in batch culture was 3-5 times higher with the GAL1 promoter. Growth rate under induced conditions, however, was 15% lower than in the absence of lacZ expression for this promoter system. The influence of plasmid promoter strength on induction behavior and cloned gene expression was also studied in continuous fermentations. Higher beta-galactosidase production and lower biomass concentration and plasmid stability were observed for the strain bearing the plasmid with the stronger GAL1 promoter. Despite the decrease in biomass concentration and plasmid stability, overall productivity in continuous culture using the GAL1 promoter was three times that obtained with the GAL10-CYC1 promoter.     

Conventional and nonconventional strategies for controlling bacterial contamination in fuel ethanol fermentations

Ethanol bio-production in Brazil has some unique characteristics that inevitably lead to bacterial contamination, which results in the production of organic acids and biofilms and flocculation that impair the fermentation yield by affecting yeast viability and diverting sugars to metabolites other than ethanol. The ethanol-producing units commonly give an acid treatment to the cells after each fermentative cycle to decrease the bacterial number, which is not always effective. An alternative strategy must be employed to avoid bacterial multiplication but must be compatible with economic, health and environmental aspects. This review analyzes the issue of bacterial contamination in sugarcane-based fuel ethanol fermentation, and the potential strategies that may be utilized to control bacterial growth besides acid treatment and antibiotics. We have emphasized the efficiency and suitability of chemical products other than acids and those derived from natural sources in industrial conditions. In addition, we have also presented bacteriocins, bacteriophages, and beneficial bacteria as non-conventional antimicrobial agents to mitigate bacterial contamination in the bioethanol industry.     

rIL-2工程菌诱导阶段细胞再循环培养的研究

为了减少rIL-2工程菌高密度培养时乙酸的积累,在诱导阶段对该工程菌进行细胞再循环培养的研究,比较了细胞再循环补料液、pH、细胞循环培养时间段对工程菌的生长及rIL-2表达的影响。结果表明在菌密度D_(600)为50时,细胞再循环补料液中酵母抽提物与胰蛋白胨浓度为发酵培养基的5倍就能满足rIL-2表达的需求,同时选择诱导后4～6h之间的细胞再循环培养能有效地防止乙酸的过高积累并减少营养物质的损失,有利于rIL-2的表达。根据以上研究结果得到了rIL-2工程菌诱导阶段细胞再循环培养方法,使得在诱导前菌密度D_(600)为50左右时rIL-2的表达水平约为40％。     

Improvement of tempe fermentations by application of mixed cultures consisting of Rhizopus sp. and bacterial strains

Tempe fermentations using mixed cultures of Rhizopus oligosporus MS5, R. oryzae EN, Citrobacter freundii, and Brevibacterium epidermidis were investigated. Consumption of 150 g tempe, produced with a pure fungal mixed culture out of strains MS5 and EN, is sufficient to cover the daily requirements of niacin, vitamin K, ergosterol, and tocopherol as well as half of the daily requirement of pyridoxine, riboflavin, and biotin. Moreover, one-fourth of the recommended amount of folate is supplied. Supplementation of the fungal inoculum with C. freundii results in tempe enriched with vitamin B₁₂. Menachinone was produced as a typical bacterial vitamin K derivative. Metabolic activity of C.␣freundii led to an additional decrease of the α-galactosides stachyose and raffinose compared to pure fungal fermentations. No bacterial formation of factor 2 could be observed. Received: 31 July 1996 / Received revision: 4 October 1996 / Accepted: 14 October 1996     

On-line process monitoring and chemometric modeling with 2D fluorescence spectra obtained in recombinant E. coli fermentations

2D spectrofluorometry produces a large volume of spectral data during fermentation processes with recombinant E. coli, which can be analyzed using chemometric methods such as principal component analysis (PCA), principal component regression (PCR) and partial least square regression (PLS). An analysis of the spectral data by PCA results in scores and loadings that are not only visualized in the score-loading plots but are also used to monitor the fermentation processes on-line. The score plots provided useful qualitative information on four fermentation processes for the production of extracellular 5-aminolevulinic acid (ALA). Two chemometric models (PCR and PLS) were used to examine the correlation between the 2D fluorescence spectra and a few parameters of the fermentation processes. The results showed that PLS had slightly better calibration and prediction performance than PCR.