Dynamic modeling of syngas fermentation in a continuous stirred-tank reactor: Multi-response parameter estimation and process optimization

Syngas fermentation is one of the bets for the future sustainable biobased economies due to its potential as an intermediate step in the conversion of waste carbon to ethanol fuel and other chemicals. Integrated with gasification and suitable downstream processing, it may constitute an efficient and competitive route for the valorization of various waste materials, especially if systems engineering principles are employed targeting process optimization. In this study, a dynamic multi-response model is presented for syngas fermentation with acetogenic bacteria in a continuous stirred-tank reactor, accounting for gas–liquid mass transfer, substrate (CO, H₂) uptake, biomass growth and death, acetic acid reassimilation, and product selectivity. The unknown parameters were estimated from literature data using the maximum likelihood principle with a multi-response nonlinear modeling framework and metaheuristic optimization, and model adequacy was verified with statistical analysis via generation of confidence intervals as well as parameter significance tests. The model was then used to study the effects of process conditions (gas composition, dilution rate, gas flow rates, and cell recycle) as well as the sensitivity of kinetic parameters, and multiobjective genetic algorithm was used to maximize ethanol productivity and CO conversion. It was observed that these two objectives were clearly conflicting when CO-rich gas was used, but increasing the content of H₂ favored higher productivities while maintaining 100% CO conversion. The maximum productivity predicted with full conversion was 2 g·L⁻¹·hr⁻¹ with a feed gas composition of 54% CO and 46% H₂ and a dilution rate of 0.06 hr⁻¹ with roughly 90% of cell recycle.     

Membrane inlet mass spectrometry — measurement of dissolved gases in fermentation liquids

The measurement of gas concentrations in fermenters is vital for monitoring and controlling a great variety of biotechnological processes. At present, most systems analyse the content of inflowing and outflowing gas streams. The information obtained in this way has proved to be very useful, but gas phase analyses suffer from a considerable disadvantage; the gas composition of the outflow does not precisely reflect the gas composition of the microbes' environment at the time the measurements are made. To overcome this problem, new systems have been developed which measure the concentration of gases (particularly O₂, CO₂ and H₂) dissolved in fermentation liquids.     

Advances in systems metabolic engineering of autotrophic carbon oxide-fixing biocatalysts towards a circular economy

High levels of anthropogenic CO₂ emissions are driving the warming of global climate. If this pattern of increasing emissions does not change, it will cause further climate change with severe consequences for the human population. On top of this, the increasing accumulation of solid waste within the linear economy model is threatening global biosustainability. The magnitude of these challenges requires several approaches to capture and utilize waste carbon and establish a circular economy. Microbial gas fermentation presents an exciting opportunity to capture carbon oxides from gaseous and solid waste streams with high feedstock flexibility and selectivity. Here we discuss available microbial systems and review in detail the metabolism of both anaerobic acetogens and aerobic hydrogenotrophs and their ability to utilize C1 waste feedstocks. More specifically, we provide an overview of the systems-level understanding of metabolism, key metabolic pathways, scale-up opportunities and commercial successes, and the most recent technological advances in strain and process engineering. Finally, we also discuss in detail the gaps and opportunities to advance the understanding of these autotrophic biocatalysts for the efficient and economically viable production of bioproducts from recycled carbon.     

Incorporating hydrodynamics into spatiotemporal metabolic models of bubble column gas fermentation

Gas fermentation has emerged as a technologically and economically attractive option for producing renewable fuels and chemicals from carbon monoxide (CO) rich waste streams. LanzaTech has developed a proprietary strain of the gas fermentating acetogen Clostridium autoethanogenum as a microbial platform for synthesizing ethanol, 2,3-butanediol, and other chemicals. Bubble column reactor technology is being developed for the large-scale production, motivating the investigation of multiphase reactor hydrodynamics. In this study, we combined hydrodynamics with a genome-scale reconstruction of C. autoethanogenum metabolism and multiphase convection–dispersion equations to compare the performance of bubble column reactors with and without liquid recycle. For both reactor configurations, hydrodynamics was predicted to diminish bubble column performance with respect to CO conversion, biomass production, and ethanol production when compared with bubble column models in which the gas phase was modeled as ideal plug flow plus axial dispersion. Liquid recycle was predicted to be advantageous by increasing CO conversion, biomass production, and ethanol and 2,3-butanediol production compared with the non-recycle reactor configuration. Parametric studies performed for the liquid recycle configuration with two-phase hydrodynamics showed that increased CO feed flow rates (more gas supply), smaller CO gas bubbles (more gas–liquid mass transfer), and shorter column heights (more gas per volume of liquid per time) favored ethanol production over acetate production. Our computational results demonstrate the power of combining cellular metabolic models and two-phase hydrodynamics for simulating and optimizing gas fermentation reactors.     

Overflow metabolism at the thermodynamic limit of life: How carboxydotrophic acetogens mitigate carbon monoxide toxicity

Carboxydotrophic metabolism is gaining interest due to its applications in gas fermentation technology, enabling the conversion of carbon monoxide to fuels and commodities. Acetogenic carboxydotrophs play a central role in current gas fermentation processes. In contrast to other energy-rich microbial substrates, CO is highly toxic, which makes it a challenging substrate to utilize. Instantaneous scavenging of CO upon entering the cell is required to mitigate its toxicity. Experiments conducted with Clostridium autoethanogenum at different biomass-specific growth rates show that elevated ethanol production occurs at increasing growth rates. The increased allocation of electrons towards ethanol at higher growth rates strongly suggests that C. autoethanogenum employs a form of overflow metabolism to cope with high dissolved CO concentrations. We argue that this overflow branch enables acetogens to efficiently use CO at highly variable substrate influxes by increasing the conversion rate almost instantaneously when required to remove toxic substrate and promote growth. In this perspective, we will address the case study of C. autoethanogenum grown solely on CO and syngas mixtures to assess how it employs acetate reduction to ethanol as a form of overflow metabolism.     

Enhanced hydrogen and 1,3‐propanediol production from glycerol by fermentation using mixed cultures

The conversion of glycerol into high value products, such as hydrogen gas and 1,3‐propanediol (PD), was examined using anaerobic fermentation with heat‐treated mixed cultures. Glycerol fermentation produced 0.28 mol‐H₂/mol‐glycerol (72 mL‐H₂/g‐COD) and 0.69 mol‐PD/mol‐glycerol. Glucose fermentation using the same mixed cultures produced more hydrogen gas (1.06 mol‐H₂/mol‐glucose) but no PD. Changing the source of inoculum affected gas production likely due to prior acclimation of bacteria to this type of substrate. Fermentation of the glycerol produced from biodiesel fuel production (70% glycerol content) produced 0.31 mol‐H₂/mol‐glycerol (43 mL H₂/g‐COD) and 0.59 mol‐PD/mol‐glycerol. These are the highest yields yet reported for both hydrogen and 1,3‐propanediol production from pure glycerol and the glycerol byproduct from biodiesel fuel production by fermentation using mixed cultures. These results demonstrate that production of biodiesel can be combined with production of hydrogen and 1,3‐propanediol for maximum utilization of resources and minimization of waste. Biotechnol. Bioeng. 2009; 104: 1098–1106. © 2009 Wiley Periodicals, Inc.     

Night and day: short‐term variation in nitrogen chemistry and nitrous oxide emissions from streams

1. Diel variation in metabolism contributes to variation in oxygen (O₂) concentrations in streams. This variation in O₂ and other parameters (e.g. pH) can in turn affect the rates of microbial nitrogen (N) processing, concentrations of nitrogenous solutes and production of the greenhouse gas nitrous oxide (N₂O). We investigated diel variability in emissions of N₂O and the magnitude of short‐term variability in N solutes across 10 streams. 2. Nitrous oxide fluxes varied on average 2.3‐fold over diel cycles. Concentrations would be underestimated by sampling around noon, but N₂O fluxes would not show a consistent bias. Time‐weighted mean daily N₂O flux was strongly related to nitrate concentration (r² = 0.58). Diel patterns in N₂O and dissolved N species were often complex (rather than simple sinusoidal curves), probably reflecting complex underlying processes. 3. Reliance on samples obtained around noon would overestimate daily mean nitrate concentrations by 5% and underestimate ammonium by 32% (average bias across all streams and dates). 4. Dissolved organic N did not show consistent day–night variation. However, the magnitude of diel variability was similar to that observed for dissolved inorganic N. Organic and inorganic N concentrations were often similar. Both appear to be dynamic components of stream N budgets. 5. The Intergovernmental Panel on Climate Change (IPCC) relies upon an emission factor to estimate indirect agricultural N₂O emissions from streams and ground water. The measured emission factor (defined as the ratio of concentrations of N₂O‐N to ‐N) was typically below the recently revised IPCC default figure. Measured values varied on average 1.8‐fold over approximately 24‐h periods and were slightly higher at night than by day. The emission factor was actually highest in streams that were net sinks for N₂O, highlighting a conceptual problem in the current IPCC method. 6. Typical sampling programmes rely on daytime‐only sampling, which might cause bias in results. In our study streams, the bias was generally small. Diel variation in nitrate concentrations was related to mean temperature; variation in ammonium and N₂O concentrations was greatest at low concentrations of nitrite and ammonium.     

Leaf litter breakdown budgets in streams of various trophic status: effects of dissolved inorganic nutrients on microorganisms and invertebrates

1. We investigated the effect of trophic status on the organic matter budget in freshwater ecosystems. During leaf litter breakdown, the relative contribution of the functional groups and the quantity/quality of organic matter available to higher trophic levels are expected to be modified by the anthropogenic release of nutrients. 2. Carbon budgets were established during the breakdown of alder leaves enclosed in coarse mesh bags and submerged in six streams: two oligotrophic, one mesotrophic, two eutrophic and one hypertrophic streams. Nitrate concentrations were 4.5–6.7 mg L⁻¹ and the trophic status of each stream was defined by the soluble reactive phosphorus concentration ranging from 3.4 (oligotrophic) to 89 μg L⁻¹ (hypertrophic). An ammonium gradient paralleled the phosphate gradient with mean concentrations ranging from 1.4 to 560 μg L⁻¹ NH₄‐N. The corresponding unionised ammonia concentrations ranged from 0.08 to 19 μg L⁻¹ NH₃‐N over the six streams. 3. The dominant shredder taxa were different in the oligo‐, meso‐ and eutrophic streams. No shredders were observed in the hypertrophic stream. These changes may be accounted for by the gradual increase in the concentration of ammonia over the six streams. The shredder biomass dramatically decreased in eu‐ and hypertrophic streams compared with oligo‐ and mesotrophic. 4. Fungal biomass increased threefold from the most oligotrophic to the less eutrophic stream and decreased in the most eutrophic and the hypertrophic. Bacterial biomass increased twofold from the most oligotrophic to the hypertrophic stream. Along the trophic gradient, the microbial CO₂ production followed that of microbial biomass whereas the microbial fine particulate organic matter and net dissolved organic carbon (DOC) did not consistently vary. These results indicate that the microorganisms utilised the substrate and the DOC differently in streams of various trophic statuses. 5. In streams receiving various anthropogenic inputs, the relative contribution of the functional groups to leaf mass loss varied extensively as a result of stimulation and the deleterious effects of dissolved inorganic compounds. The quality/quantity of the organic matter produced by microorganisms slightly varied, as they use DOC from stream water instead of the substrate they decompose in streams of higher trophic status.     

Effect of partial pressure of CO2 on the production of thermostable α-amylase and neutral protease by Bacillus caldolyticus

Controlling the concentration of dissolved oxygen is a standard feature in aerobic fermentation processes but the measurement of dissolved CO₂ concentrations is often neglected in spite of its influence on the cellular metabolism. In this work room air and room air supplemented with 5 and 10% carbon dioxide were used for aeration during the cultivation of the thermophilic microorganism Bacillus caldolyticus (DSM 405) on starch to produce α-amylase (E.C. 3.2.1.1) and neutral protease (E.C. 3.4.24.27/28). The increased CO₂ concentrations resulted in a 22% raise in activity of secreted α-amylase and a 43% raise in protease activity when compared with aeration with un-supplemented room air. There was no effect on the final biomass concentration. Furthermore, the lag-phase of fermentation was reduced by 30%, further increasing the productivity of α-amylase production. Determinations of dissolved CO₂ in the culture broth were conducted both in situ with a probe as well as using exhaust gas analysis and both the methods of quantification showed good qualitative congruence.     

A robust soft sensor based on artificial neural network for monitoring microbial lipid fermentation processes using Yarrowia lipolytica

Microbial oils produced by Yarrowia lipolytica offer an environmentally friendly and sustainable alternative to petroleum as well as traditional lipids from animals and plants. The accurate measurement of fermentation parameters, including the substrate concentration, dry cell weight, and lipid accumulation, is the foundation of process control, which is indispensable for industrial lipid production. However, it remains a great challenge to measure the complex parameters online during the lipid fermentation process, which is nonlinear, multivariate, and characterized by strong coupling. As a type of AI technology, the artificial neural network model is a powerful tool for handling extremely complex problems, and it can be employed to develop a soft sensor to monitor the microbial lipid fermentation process of Y. lipolytica. In this study, we first analyzed and emphasized the volume of sodium hydroxide and dissolved oxygen concentration as central parameters of the fermentation process. Then, a soft sensor based on a four-input artificial neural network model was developed, in which the input variables were fermentation time, dissolved oxygen concentration, initial glucose concentration, and additional volume of sodium hydroxide. This provides the possibility of online monitoring of dry cell weight, glucose concentration, and lipid production with high accuracy, which can be extended to similar fermentation processes characterized by the addition of bases or acids, as well as changes of the dissolved oxygen concentration.     

Microbial CO Conversions with Applications in Synthesis Gas Purification and Bio-Desulfurization

ABSTRACT

Recent advances in the field of microbial physiology demonstrate that carbon monoxide is a readily used substrate by a wide variety of anaerobic micro-organisms, and may be employed in novel biotechnological processes for production of bulk and fine chemicals or in biological treatment of waste streams. Synthesis gas produced from fossil fuels or biomass is rich in hydrogen and carbon monoxide. Conversion of carbon monoxide to hydrogen allows use of synthesis gas in existing hydrogen utilizing processes and is interesting in view of a transition from hydrogen production from fossil fuels to sustainable (CO₂-neutral) biomass. The conversion of CO with H₂O to CO₂ and H₂ is catalyzed by a rapidly increasing group of micro-organisms. Hydrogen is a preferred electron donor in biotechnological desulfurization of wastewaters and flue gases. Additionally, CO is a good alternative electron donor considering the recent isolation of a CO oxidizing, sulfate reducing bacterium. Here we review CO utilization by various anaerobic micro-organisms and their possible role in biotechnological processes, with a focus on hydrogen production and bio-desulfurization.     

Exhaust gas purification using biocatalysts (fixed bacteria monocultures) — the influence of biofilm diffusion rate (O2) on the overall reaction rate

Summary This paper presents results of experiments on the influence of O₂ and substrate (pollutant) concentration on the overall reaction rate of a trickle-bed reactor used for biological waste gas purification. The biocatalyst was a pollutant-specific bacterial monoculture fixed on porous glass carriers. The conversion of acetone and propionaldehyde, as model pollutants that are easily soluble in water, was measured. Under constant hydrodynamic conditions (gas and liquid flow rates) the inlet pollutant concentration was varied. The O₂ partial pressure in the model gas was increased to investigate the influence of O₂ supply on pollutant conversion. At higher pollutant concentrations (>117 mg acetone.m^-3 gas and > 150 mg propionaldehyde.m^-3 gas) higher concentrations of dissolved O₂ led to a significant rise in the maximum degradation capacity of the reactor. This maximum reaction rate was independent of the pollutant mass flow. It seems that the diffusion of O₂ in the biofilm is rate-determining. The reaction rate at lower inlet concentrations was not affected by the improved O₂ supply. Here the external mass transfer through the liquid film limits the reaction rate and the maximum separation efficiency of about 80% at a residence time of 1.2s (space velocity 3000h^-1) is achieved.     

不同生境微生物转化H2/CO2产乙酸及其在合成气发酵中应用

【目的】合成气发酵对大力开发可再生资源和促进国家可持续发展具有重要意义,研究旨在探究不同生境微生物转化H2/CO2产乙酸及其合成气发酵的潜力。【方法】采集剩余污泥、牛粪、产甲烷污泥和河道底物样品在中温(37 °C)条件下生物转化H2/CO2气体,将来源于牛粪样品的H2/CO2转化富集物用于合成气发酵,通过454高通量技术和定量PCR技术分析复杂微生物群落的组成,GC气相色谱法检测气体转化产生的挥发性脂肪酸(VFAs)浓度。【结果】牛粪和剩余污泥微生物利用H2/CO2气体生成乙酸、乙醇和丁酸等,最高乙酸浓度分别为63 mmol/L和40 mmol/L,明显高于河道底物和产甲烷污泥样品的最高乙酸浓度3 mmol/L和16 mmol/L。牛粪和剩余污泥微生物中含有种类多样化的同型产乙酸菌,剩余污泥中同型产乙酸菌主要为Clostridium spp.、Sporomusa malonica和Acetoanaerobium noterae,牛粪中则为Clostridium spp.、Treponema azotonutricium和Oxobacter pfennigii。【结论】同型产乙酸菌的丰富度和数量两个因素都对复杂微生物群落转化H2/CO2产乙酸效率至关重要;转化H2/CO2得到的富集物可用于合成气发酵产乙酸和乙醇,这为基于混合培养技术的合成气发酵提供了依据。     

Engineering Clostridium ljungdahlii as the gas-fermenting cell factory for the production of biofuels and biochemicals

Clostridium ljungdahlii is a representative autotrophic gas-fermenting acetogen capable of converting CO₂ and CO into biomass and multiple metabolites. The carbon fixation and conversion based on C. ljungdahlii have great potential for the sustainable production of bulk biochemicals and biofuels using industrial syngas and waste gases. With substantial recent advances in genetic manipulation tools, it has become possible to study and improve the metabolic capability of C. ljungdahlii in gas fermentation. The product scope of C. ljungdahlii has been expanded through the introduction of heterologous production pathways followed by the modification of native metabolic networks. In addition, progress has been made in understanding the physiological and metabolic mechanisms of this anaerobe, contributing to strain designs for expected phenotypes. In this review, we highlight the latest research progresses regarding C. ljungdahlii and discuss the next steps to comprehensively understand and engineer this bacterium for an improved bacterial gas bioconversion platform.     

Effect of partial pressure of CO2 on the production of thermostable alpha-amylase and neutral protease by Bacillus caldolyticus

Controlling the concentration of dissolved oxygen is a standard feature in aerobic fermentation processes but the measurement of dissolved CO2 concentrations is often neglected in spite of its influence on the cellular metabolism. In this work room air and room air supplemented with 5% and 10% carbon dioxide were used for aeration during the cultivation of the thermophilic microorganism Bacillus caldolyticus (DSM 405) on starch to produce alpha-amylase (E.C. 3.2.1.1) and neutral protease (E.C. 3.4.24.27/28). The increased CO2 concentrations resulted in a 22% raise in activity of secreted alpha-amylase and a 43% raise in protease activity when compared with aeration with un-supplemented room air. There was no effect on the final biomass concentration. Furthermore, the lag-phase of fermentation was reduced by 30%, further increasing the productivity of alpha-amylase production. Determinations of dissolved CO2 in the culture broth were conducted both in situ with a probe as well as using exhaust gas analysis and both the methods of quantification showed good qualitative congruence.     

Tracing carbon monoxide uptake by Clostridium ljungdahlii during ethanol fermentation using 13C-enrichment technique

Conversion of synthesis gas (CO and H₂) to ethanol can be an alternative, promising technology to produce biofuels from renewable biomass. To distinguish microbial utilization of carbon source between fructose and synthesis gas CO and to evaluate biological production of ethanol from CO, we adopted the ¹³C-enrichment of the CO substrate and hypothesized that the residual increase in δ¹³C of the cell biomass would reflect the increased contribution of ¹³C-enriched CO. Addition of synthesis gas to live culture medium for ethanol fermentation by Clostridum ljungdahlii increased the microbial growth and ethanol production. Despite the high ¹³C-enrichment in CO (99 atom % ¹³C), however, microbial δ¹³C increased relatively small compared to the microbial growth. The uptake efficiency of CO estimated using the isotope mass balance equation was also very low: 0.0014 % for the low CO and 0.0016 % for the high CO treatment. Furthermore, the fast production of ethanol in the early stage indicated that the presence of sugar in fermentation medium would limit the utilization of CO as a carbon source by C. ljungdahlii.     

Novel bioconversion of wheat straw to bio-organic fertilizer in a solid-state bioreactor

In order to increase the eco-efficiency and overall availability of naturally renewable resource, the novel bioconversion of steam-exploded wheat straw to bio-organic fertilizer containing N₂-fixer, P and K solubilizers was investigated. The conversion was performed in solid-state fermentation (SSF) with periodic air-forced pressure oscillation (PAPO). The results showed that SSF-PAPO was competitive with the conventional solid-state fermentation (cSSF) in biomass accumulation and wheat straw digestion. With solid–liquid ratio 1:3, microbial biomass production at 72 h was high up to 2 × 10¹¹ cfu g⁻¹, nearly twice as that in cSSF. The degradation rate of cellulose, hemicellulose and lignin after fermentation in SSF-PAPO reached 48.57 ± 10.66, 84.77 ± 2.75 and 2.15 ± 10.11, respectively, which was greater than that of 29.30 ± 10.28%, 33.47 ± 4.85% and 0.53 ± 9.07% in cSSF, correspondingly. The SSF-PAPO system displayed unique advantage, by a novel gas phase control strategy on gas concentration and heat gradient, on the bioconversion of wheat straw to the bio-organic fertilizer.     

Comparison of glucose/xylose cofermentation of poplar hydrolysates processed by different pretreatment technologies

The inhibitory effects of furfural and acetic acid on the fermentation of xylose and glucose to ethanol in YEPDX medium by a recombinant Saccharomyces cerevisiae strain (LNH‐ST 424A) were investigated. Initial furfural concentrations below 5 g/L caused negligible inhibition to glucose and xylose consumption rates in batch fermentations with high inoculum (4.5–6.0 g/L). At higher initial furfural concentrations (10–15 g/L) the inhibition became significant with xylose consumption rates especially affected. Interactive inhibition between acetic acid and pH were observed and quantified, and the results suggested the importance of conditioning the pH of hydrolysates for optimal fermentation performance. Poplar biomass pretreated by various CAFI processes (dilute acid, AFEX, ARP, SO₂‐catalyzed steam explosion, and controlled‐pH) under respective optimal conditions was enzymatically hydrolyzed, and the mixed sugar streams in the hydrolysates were fermented. The 5‐hydroxymethyl furfural (HMF) and furfural concentrations were low in all hydrolysates and did not pose negative effects on fermentation. Maximum ethanol productivity showed that 0–6.2 g/L initial acetic acid does not substantially affect the ethanol fermentation with proper pH adjustment, confirming the results from rich media fermentations with reagent grade sugars. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2009     

Metabolic control of Clostridium thermocellum via inhibition of hydrogenase activity and the glucose transport rate

Clostridium thermocellum has the ability to catabolize cellulosic biomass into ethanol, but acetic acid, lactic acid, carbon dioxide, and hydrogen gas (H₂) are also produced. The effect of hydrogenase inhibitors (H₂, carbon monoxide (CO), and methyl viologen) on product selectivity was investigated. The anticipated effect of these hydrogenase inhibitors was to decrease acetate production. However, shifts to ethanol and lactate production are also observed as a function of cultivation conditions. When the sparge gas of cellobiose-limited chemostat cultures was switched from N₂ to H₂, acetate declined, and ethanol production increased 350%. In resting cell suspensions, lactate increased when H₂ or CO was the inhibitor or when the cells were held at elevated hyperbaric pressure (6.8 atm). In contrast, methyl-viologen-treated resting cells produced twice as much ethanol as the other treatments. The relationship of chemostat physiology to methyl viologen inhibition was revealed by glucose transport experiments, in which methyl viologen decreased the rate of glucose transport by 90%. C. thermocellum produces NAD⁺ from NADH by H₂, lactate, and ethanol production. When the hydrogenases were inhibited, the latter two products increased. However, excess substrate availability causes fructose 1,6-diphosphate, the glycolytic intermediate that triggers lactate production, to increase. Compensatory ethanol production was observed when the chemostat fluid dilution rate or methyl viologen decreased substrate transport. This research highlights the complex effects of high concentrations of dissolved gases in fermentation, which are increasingly envisioned in microbial applications of H₂ production for the conversion of synthetic gases to chemicals.     

Elevated temperature may intensify the positive effects of nutrients on microbial decomposition in streams

相似文献