Efficient phase separation and product recovery in organic‐aqueous bioprocessing using supercritical carbon dioxide

Biphasic hydrocarbon functionalizations catalyzed by recombinant microorganisms have been shown to be one of the most promising approaches for replacing common chemical synthesis routes on an industrial scale. However, the formation of stable emulsions complicates downstream processing, especially phase separation. This fact has turned out to be a major hurdle for industrial implementation. To overcome this limitation, we used supercritical carbon dioxide (scCO₂) for both phase separation and product purification. The stable emulsion, originating from a stereospecific epoxidation of styrene to (S)‐styrene oxide, a reaction catalyzed by recombinant Escherichia coli, could be destabilized efficiently and irreversibly, enabling complete phase separation within minutes. By further use of scCO₂ as extraction agent, the product (S)‐styrene oxide could be obtained with a purity of 81% (w/w) in one single extraction step. By combining phase separation and product purification using scCO₂, the number of necessary workup steps can be reduced to one. This efficient and easy to use technique is generally applicable for the workup of biphasic biocatalytic hydrocarbon functionalizations and enables a cost effective downstream processing even on a large scale. Biotechnol. Bioeng. 2010;107:642–651. © 2010 Wiley Periodicals, Inc.     

Microalgae mediated photoproduction of beta-carotene in aqueous-organic two phase systems

Improving productivity is a usual requirement for most biotechnological processes, and the utilisation of two-phase aqueous organic systems has proved to be an effective way to improve the productivity of poorly water-soluble or toxic compounds. The high hydrophobicity of beta-carotene, which is highly demanded by the pharma and agrofood industry, makes it a good candidate for aqueous/organic biphasic photoproduction. In the present work we have investigated the viability of a two-phase system for the production of beta-carotene by the marine microalgae Dunaliella salina using decane as organic phase. Decane, with a logP(octanol) value of 5.6, showed no toxicity to Dunaliella cells for more than 72 h, and its ability for beta-carotene extraction is acceptable. Transferring Dunaliella cells from standard to carotenogenic conditions caused inhibition of chlorophyll production and induced a strong synthesis of beta-carotene. The two-phase aqueous/decane system was stable and beta-carotene content of the cells was increasing during 4-days. About 8% of the total carotenoids produced were excreted and extracted into the decane phase.     

Production and characterization of liquid-core capsules made from cross-linked acrylamide copolymers for biotechnological applications

A novel chemistry has been developed for the production of capsules composed of a hydrophobic liquid core surrounded by a cross-linked polyacrylamide/alginate membrane. These liquid-core capsules may be used in capsular perstraction for the removal of inhibitory products from bioprocesses and bioconversions. They have the advantage of having a high surface area to promote rapid mass transfer, while separation of the organic core phase from the aqueous environment by the capsule membrane prevents the formation of stable emulsions and potential problems associated with toxicity of the organic phase for microbial cells or enzymes. Monodisperse spherical liquid-core capsules of between 800 microm and 1.6 mm diameter, with high mechanical resistance, have been prepared by co-extrusion, using the jet break-up technique. Capsules produced from a solution of MBA/total monomer (5%) were found to be more elastic and have a higher burst force when exposed to chelating agents such as phosphate or citrate. The mechanical resistance was unaffected by buffer solutions in the pH range 4-9 and after sterilization at 121 degrees C for 20 min. Capsules having membranes composed of a copolymer of acrylamide and N-hydroxymethylacrylamide exhibited even higher mechanical stability toward chelating agents.     

Chiral separation of tryptophan enantiomers by liquid chromatography with BSA-silica stationary phase

The separation of tryptophan enantiomers was carried out with medium-pressure liquid chromatography using BSA (bovine serum albumin)-bonded silica as a chiral stationary phase. The influence of various experimental factors such as pH and ionic strength of mobile phase, separation temperature, and the presence of organic additives on the resolution was studied. In order to expand this system to preparative scale, the loadability of sample and the stability of stationary phase for repeated use were also examined. The separation of tryptophan enantiomers was successful with this system. The data indicated that a higher separation factor (α) was obtained at a higher pH and lower temperature and ionic strength in mobile phase. Addition of organic additives (acetonitrile and 2-propanol) in mobile phase contributed to reduce the retention time of L-tryptophan. About 30% of the separation factor was reduced after 80 days of repeated use.     

Microorganism viability influences internal phase droplet size changes during storage in water-in-oil emulsions

Water-in-oil emulsions provide an alternative for long-term stabilization of microorganisms. Maintaining physical stability of the emulsion and cell viability is critical for large-scale application. Water-in-oil (W/O) emulsions were prepared with the biolarvacide Lagenidium giganteum and the green alga Chlorella vulgaris. Physical stability was measured via light scattering measurements of the internal phase droplets and cell viability was measured by plating and enumerating colony forming units. Emulsions were demonstrated to stabilize L. giganteum and C. vulgaris for more than 4 months without refrigeration. Introducing nutrients into the internal phase of W/O emulsions without cells had no significant effect on changes in aqueous phase droplet size dynamics. Internal phase droplet size changes that occurred over time were greater in the presence of cells. Increases in droplet size were correlated with cell death indicating measurement of internal phase droplet size changes may be an approach for monitoring declines in cell viability during storage.     

Effect of the interfacial surfactant layer on oxygen transfer through the oil/water phase boundary in perfluorocarbon emulsions

The effect of interfacial surfactant molecules on oxygen transfer through oil/water phase boundary has been studied in FlurO(2) (TM) emulsions, i.e., perfluorocarbon (PFC) emulsions developed as oxygen carriers in cell culture. Measurements of oxygen permeability were made with a polarographic oxygen electrode in pure PFCs and in emulsions with various PFC volume fractions. Comparison of the experimental results with the theoretically derived values of relative oxygen permeability clearly indicates that the mass transfer resistance caused by the interfacial surfactant layer in PFC emulsions is insignificant. Therefore, oxygen dissolved in the enclosed PFC phase is readily available to cells growing in the aqueous media and FlurO(2) emulsions with very fine emulsion particles (< 0.2 mum) can be used to effectively enhance gas/liquid interfacial oxygen transfer in bioreactors. The inadequacy in describing mass transfer in heterogeneous systems, such as the PFC emulsions, by conventional concentration-based oxygen diffusion coefficients has also been discussed.     

Polar organic phase liquid chromatography with packed capillary columns using a vancomycin chiral stationary phase

Vancomycin immobilized on silica served as the chiral stationary phase (CSP) in this investigation with polar organic solvents as the mobile phase in liquid chromatography (LC). It was shown that trace amounts of water were beneficial for improving peak shape and efficiency. To regulate the retention and selectivity an acid and/or base were added to the mobile phase where an excess of acid was shown to be preferential for enantioseparation. An unusual increase in selectivity with increasing temperature was shown for the acidic drug, thalidomide. Additionally, nonlinear van't Hoff plots were obtained for metoprolol enantiomers that showed increased retention with increasing temperature. Metoprolol also showed unusual behavior in the polar organic phase when water was added to resemble reversed-phase chromatography, with minimum retention observed at high water or high methanol concentrations. In both instances a high degree of electrostatic interaction between metoprolol and vancomycin was concluded. Metoprolol and ten of its analogs were examined on this CSP to evaluate the enantiorecognition process. A comparison in enantioselectivity for a number of acidic and basic drugs using this CSP was also carried out using the polar organic phase, reversed phase, and normal phase LC which were all compared to the results obtained in supercritical fluid chromatography (SFC). Polar organic phase LC offered a better separation of basic molecules while reversed phase LC was preferred for the resolution of acids. SFC showed the broadest enantioselectivity overall and normal phase LC indicated similar properties, as expected, to SFC but with lower column efficiency. Copyright 2000 Wiley-Liss, Inc.     

Rouleaux formation as a measure of the phase separating ability of plasma

The increased erythrocyte sedimentation rate (ESR) occurring in various diseases reflects a change in certain plasma proteins which causes erythrocytes to aggregate into rapidly sedimenting “piles of coins”, or rouleaux. In spite of some 300 years of study, the mechanism of the phenomenon and the adaptive significance, if any, of the change in properties of plasma, remain elusive. One hypothesis on the mechanism is that rouleaugenic agents in plasma act as multivalent “agglomerins”, which react with the erythrocyte surface and cross-link cells. Alternatively, a “phase separation” hypothesis can be derived by analogy with the phase separation of high molecular weight polymers from polymer mixtures at high polymer concentrations. Considering the cell surface to resemble that of a large polymer, it is postulated that there should be a separation of a cell phase from a solution phase in the presence of high concentrations of a high molecular weight polymer. In keeping with the available data, both hypotheses predict that rouleaux formation should increase with increasing polymer size. In addition, the phase separation hypothesis predicts (i) no need for reaction of a rouleaugenic agent with the erythrocyte surface, and (ii) that cells from different species, when mixed in the presence of a rouleaugenic agent, will form independent rouleaux. Current evidence is consistent with both predictions. We suggest that an increased ESR reflects a change in the physical properties of plasma such that particulate material (e.g. viruses, tumour cells), will tend to spontaneously aggregate in regions of stagnant blood flow (such as the sinusoids of the spleen). This change in the physical properties of plasma, tending to favour phase separations, will also favour antigen-antibody and other intermolecular reactions.     

Oil-in-water emulsions characterization by laser granulometry and impact on γ-decalactone production in <Emphasis Type="Italic">Yarrowia lipolytica</Emphasis>

Oil-in-water emulsions composed of methyl ricinoleate (MR) or castor oil (CO) as the organic phase, stabilized by Tween 80, are in the basis of the biotechnological production of γ-decalactone. Yarrowia lipolytica was used due to its ability to grow on hydrophobic substrates and to carry out the biotransformation. The characterization of oil droplets size distribution by laser granulometry was performed under different oil concentrations. The impact of the presence of cells on droplets size was also analyzed as well as the relevance of washing inoculum cells. Furthermore, the granulometric characterization of the emulsions was related with γ-decalactone production and it was observed that, in the presence of non-washed cells, the smaller droplets disappeared, using both oils, which increased γ-decalactone concentration. This suggests that the access of cells to the substrate occurs by their adhesion around larger oil droplets.     

Three different examples of enzymatic bioconversion in liquid membrane reactors

Three different examples of enzyme emulsions are presented. The enzymes are immobilized in liquid surfactant membranes. The effect of the organic membrane phase is discussed as well as the influence of the membrane composition on the transport of substrates and products through the membrane. An enzyme emulsion system for the production of l-leucine with continuous co-factor regeneration is described. It is not necessary to increase the molecular weight of the co-factor by linking it to a soluble high molecular weight compound (e.g., PEG), since the coenzyme cannot pass the liquid membrane without a suitable carrier. Also, a product (6-APA) can be enriched in the internal phase of the liquid membrane. The separation effect is not based on differences in molecular weight, but on the chemical behavior of the substances to be separated.     

Effects of visible and UV light on the characteristics and properties of crude oil-in-water (O/W) emulsions

The effects of visible and UV light on the characteristics and properties of Prudhoe Bay (PB) and South Louisiana (SL) emulsions were investigated to better understand the role of sunlight on the fate of spilled crude oils that form emulsions with a dispersant in the aquatic environment. Before irradiation, crude oil emulsions showed the presence of dispersed crude oil micelles in a continuous water phase and crude oil components floating on the surface. The crude oil micelles decreased in size with irradiation, but emulsions retained their high degree of polydispersity. UV irradiation reduced the stability of emulsions more effectively than visible light. The reduction of micelles size caused the viscosity of emulsions to increase and melting point to decrease. Further, irradiation increased acid concentrations and induced ion formation which lowered the pH and increased the conductivity of emulsions, respectively. Ni and Fe in PB emulsions were extracted from crude oil with UV irradiation, which may provide an efficient process for metal removal. The emulsions were stable toward freeze/thaw cycles and their melting temperatures generally decreased with irradiation. Evidence of ˙OH production existed when emulsions were exposed to UV but not to visible light. The presence of H(2)O(2) enhanced the photodegradation of crude oil. Overall, the changes in emulsion properties were attributed to direct photodegradation and photooxidation of crude oil components.     

Industrial potential of organic solvent tolerant bacteria

Most bacteria and their enzymes are destroyed or inactivated in the presence of organic solvents. Organic solvent tolerant bacteria are a relatively novel group of extremophilic microorganisms that combat these destructive effects and thrive in the presence of high concentrations of organic solvents as a result of various adaptations. These bacteria are being explored for their potential in industrial and environmental biotechnology, since their enzymes retain activity in the presence of toxic solvents. This property could be exploited to carry out bioremediation and biocatalysis in the presence of an organic phase. Because a large number of substrates used in industrial chemistry, such as steroids, are water-insoluble, their bioconversion rates are affected by poor dissolution in water. This problem can be overcome by carrying out the process in a biphasic organic-aqueous fermentation system, wherein the substrate is dissolved in the organic phase and provided to cells present in the aqueous phase. In bioprocessing of fine chemicals such as cis-diols and epoxides using such cultures, organic solvents can be used to extract a toxic product from the aqueous phase, thereby improving the efficiency of the process. Bacterial strains reported to grow on and utilize saturated concentrations of organic solvents such as toluene can revolutionize the removal of such pollutants. It is now known that enzymes display striking new properties in the presence of organic solvents. The role of solvent-stable enzymes in nonaqueous biocatalysis needs to be explored and could result in novel applications.     

Auxiliary phase guidelines for microbial biotransformations of toxic substrate into toxic product

When an industrial process is developed using the microbial transformation of a precursor into a desired chemical compound, high concentrations of substrate and product will be involved. These compounds may become toxic to the cells. In situ product removal (ISPR) may be carried out, using auxiliary phases such as extractants or adsorbents. Simultaneously, in situ substrate addition (ISSA) may be performed. It is shown that for uncharged substrates and products, the aqueous solubilities of substrate and product can be used to predict if ISPR might be required. When a particular auxiliary phase is selected and the distribution coefficients of substrate and product are known, it is possible to estimate a priori if this auxiliary phase might be good enough and how much of it might be needed for an efficient (fed-)batch biotransformation process. For biotransformation products of intermediate polarity (aqueous solubility of about 1-10 g/L) there seems to be a lack of extractants and adsorbents with the capacity to raise the product concentrations to commercially more interesting levels.     

Immobilization of enzymes in liquid membranes for enantioselective hydrolysis

Summary The enantioselective hydrolysis of racemic 4-acetoxy-cyclopentenone by immobilized enzymes is described. Liquid membrane emulsions were used to encapsulate the enzyme. This technique combines the specific enzymatic reaction with a selective transport through the organic phase. The product (–)-4-hydroxy-cyclopentenone was produced with an enantiomeric excess of 82%. The immobilization techniques and all reaction steps, as well as a mathematical model for the complete process are discussed in this report.     

Bioproduction of the aroma compound 2‐Phenylethanol in a solid–liquid two‐phase partitioning bioreactor system by Kluyveromyces marxianus

The rose‐like aroma compound 2‐phenylethanol (2‐PE) is an important fragrance and flavor ingredient. Several yeast strains are able to convert l ‐phenylalanine (l ‐phe) to 2‐PE among which Kluyveromyces marxianus has shown promising results. The limitation of this process is the low product concentration and productivity primarily due to end product inhibition. This study explored the possibility and benefits of using a solid–liquid Two‐Phase Partition Bioreactor (TPPB) system as an in situ product removal technique. The system applies polymer beads as the sequestering immiscible phase to partition 2‐PE and reduce the aqueous 2‐PE concentration to non‐inhibitory levels. Among six polymers screened for extracting 2‐PE, Hytrel® 8206 performed best with a partition coefficient of 79. The desired product stored in the polymer was ultimately extracted using methanol. A 3 L working volume solid–liquid batch mode TPPB using 500 g Hytrel® as the sequestering phase generated a final overall 2‐PE concentration of 13.7 g/L, the highest reported in the current literature. This was based on a polymer phase concentration of 88.74 g/L and aqueous phase concentration of 1.2 g/L. Even better results were achieved via contact with more polymers (approximately 900 g) with the aqueous phase applying a semi‐continuous reactor configuration. In this system, a final 2‐PE concentration (overall) of 20.4 g/L was achieved with 1.4 g/L in the aqueous and 97 g/L in the polymer phase. The overall productivities of these two reactor systems were 0.38 and 0.43 g/L h, respectively. This is the first report in the literature of the use of a polymer sequestering phase to enhance the bioproduction of 2‐PE, and exceeds the performance of two‐liquid phase systems in terms of productivity as well as ease of operation (no emulsions) and ultimate product recovery. Biotechnol. Bioeng. 2009; 104: 332–339 © 2009 Wiley Periodicals, Inc.     

Separation and purification of benzylpenicillin produced by fermentation using coupled ultrafiltration and nanofiltration technologies

The purpose of this study was to evaluate the capacity of using coupled ultrafiltration-nanofiltration technologies for separation and purification of benzylpenicillin (BP). More specifically, we verified the efficiency of three ultrafiltration (UF) membranes (cut-off of 5000, 30,000 and 100,000 Da) to remove impurities that cause stable emulsion during the chemical extraction of the antibiotic. We also tested the effectiveness of a nanofiltration (NF) membrane (cut-off of 300 Da) to concentrate the benzylpenicillin recovered from permeates and to decrease the osmotic pressure by reducing the ionic charge of the broth. Results have shown that high recovery (89.0-91.0%) can be obtained in permeate generated by the 30,000 and 100,000 UF membranes, but a slight emulsion will be formed during phase separation. With the 5000 UF membrane, lower recovery is obtained (81.0%) but no emulsion is produced, leading to a high solvent extraction yield (94.6%). The nanofiltration of 30,000 and 100,000 UF permeates leads to very high recovery (98.0%), but stable emulsions are formed, reducing the chemical extraction yield (80.0-82.6%). For the nanofiltration of 5000 UF permeate, excellent recovery of the antibiotic is noted (97.4%) leading to high extraction yield (92.4%) with no emulsion formed. Diafiltration step should be applied during UF procedure in order to increase the antibiotic recovery in the generated permeates.     

Solubilizing poorly soluble antimy cotic agents by emulsification via a solvenent-free process

The purpose of this study was to formulate itraconazole and ketoconazole as oil/water emulsions for parenteral delivery by using a solvent-free homogenization process, namely SolEmuls (solubilization by emulsification) technology. The drugs were incorporated in the commercial emulsion Lipofundin MCT 20%, composed of a medium-chain triglyceride/long-chain triglyceride (MCT/LCT) oil phase (1∶1) and stabilized with 1.2% lecithin. Different parameters such as drug-loading capacity, long-term physical stability, and completeness of drug dissolution were investigated. Up to 10.0 mg/mL complete drug dissolution was achieved with itraconazole; at 20 mg/mL hybrid dispersion was obtained. Itraconazole-loaded emulsions were physically stable for 9 months (data up to now). Ketoconazole showed physical instability in the Lipofundin emulsion, which was stabilized with only 1.2% lecithin. Stabilization of ketoconazole-loaded emulsions was achieved using additionally Tween 80 as steric stabilizer. Higher concentrations of ketoconazole (ie, 10.0 mg/mL concentrated ketoconazole emulsions) were also produced with additional 2.0% Tween 80. Ketoconazole-loaded emulsions, 1 mg/mL, which were stabilized with 2.0% Tween 80, were stable for a period of 6 months. It can be concluded, after formulating amphotericin B and carbamazepine with SolEmuls technology, that SolEmuls was also applicable to the antimycotic agents itraconazole and ketoconazole, yielding IV-applicable emulsions with cost-effective production technologies.     

Preparation of submicron liposomes exhibiting efficient entrapment of drugs by freeze-drying water-in-oil emulsions

A novel liposome preparation method is described as freeze-drying of water-in-oil emulsions containing sucrose in the aqueous phase (W) and phospholipids and poly(ethylene glycol)₁₅₀₀ (PEG) in the oil phase (O). The water-in-oil emulsions were prepared by sonication and then lyophilized to obtain dry products. Upon rehydration, the dry products formed liposomes with a size smaller than 200 nm and an encapsulation efficiency (EE) higher than 60% for model drugs. The presence of lyoprotectant and PEG was found to be a prerequisite for the formation of liposomes with desirable properties, such as a small particle size and high EE. The lyophilates were stable and could be rehydrated to form liposomes without any change in size or EE even after a storage period of 6 months. Also, the lipophilic drug-containing FWE liposomes were stable and could be stored for at least 6 months although the liposomes containing hydrophilic drugs showed significant leakage. Based on the vesicle size and EEs of the model drugs, as well as the scanning electron micrograph (SEM) and small angle X-ray scattering (SAXS) pattern of the lyophilates, a possible mechanism for the liposome formation is proposed.     

Toward High‐Temperature Stability of PTB7‐Based Bulk Heterojunction Solar Cells: Impact of Fullerene Size and Solvent Additive

The use of fullerene as acceptor limits the thermal stability of organic solar cells at high temperatures as their diffusion inside the donor leads to phase separation via Ostwald ripening. Here it is reported that fullerene diffusion is fully suppressed at temperatures up to 140 °C in bulk heterojunctions based on the benzodithiophene‐based polymer (the poly[[4,8‐bis[(2‐ethylhexyl)oxy]‐benzo[1,2‐b:4,5‐b′]dithiophene‐2,6‐diyl][3‐fluoro‐2‐[(2‐ethylhexyl)carbonyl]‐thieno[3,4‐b]thiophenediyl]], (PTB7) in combination with the fullerene derivative [6,6]‐phenyl‐C71‐butyric acid methyl ester (PC₇₀BM). The blend stability is found independently of the presence of diiodooctane (DIO) used to optimize nanostructuration and in contrast to PTB7 blends using the smaller fullerene derivative PC₇₀BM. The unprecedented thermal stability of PTB7:PC₇₀BM layers is addressed to local minima in the mixing enthalpy of the blend forming stable phases that inhibit fullerene diffusion. Importantly, although the nanoscale morphology of DIO processed blends is thermally stable, corresponding devices show strong performance losses under thermal stress. Only by the use of a high temperature annealing step removing residual DIO from the device, remarkably stable high efficiency solar cells with performance losses less than 10% after a continuous annealing at 140 °C over 3 days are obtained. These results pave the way toward high temperature stable polymer solar cells using fullerene acceptors.     

Novel type of in situ extraction: Use of solvent containing microcapsules for the bioconversion of 2-phenylethanol from L-phenylalanine by Saccharomyces cerevisiae

A novel in situ product removal (ISPR) method that uses microcapsules to extract inhibitory products from the reaction suspension is introduced into fermentation technology. More specifically, L-phenylalanine (L-Phe) was transformed by Saccharomyces cerevisiae to 2-phenylethanol (PEA), which is inhibitory toward the yeast. In order to continuously remove PEA from the vicinity of the cells, the reaction suspension was brought into contact with capsules of 2.2-mm diameter that had a hydrophobic core of dibutyl sebacate and an alginate-based wall. This novel process combines the advantages of a normal in situ extraction process (fast mass transfer and simple process set-up) with the benefits of a membrane-based process (reduction of the solvent toxicity and avoidance of stable emulsions). In particular, the microbial cells are shielded from the phase toxicity of the organic solvent by a hydrogel layer surrounding the organic core. By placing the microcapsules into the fermenter, the final overall concentration of PEA in a fed-batch culture was increased from 3.8 to 5.6 g/L because a part of the inhibitory product dissolved in the dibutyl sebacate core. In another fermentation experiment, the capsules were placed in a fluidized bed that was connected via a loop to the fermenter. In addition, the fluidized bed was connected via a second loop to a back-extractor to regenerate the capsules. By alternating the extraction and back-extraction cycles, it was possible to limit the PEA concentration of the fed-batch culture in the fermenter to 2.4 g/L while producing important quantities of PEA that accumulated in an external reservoir.