Production of long chain alkyl esters from carbon dioxide and electricity by a two-stage bacterial process

Harnessing CO2 for sustainable bioelectricity: An engineered two-stage microbial co-culture approach with enhanced acetate metabolism

Climate change driven by rising atmospheric CO2 levels underscores the urgent need for sustainable energy solutions. This study investigates the dual potential of CO2 as a primary carbon source and acetate as an intermediate to simultaneously mitigate atmospheric CO2 levels and generate bioelectricity using microbial fuel cells (MFCs). A synthetic microbial co-culture was developed, combining Clostridium ljungdahlii for CO2 sequestration and Shewanella oneidensis MR-1 for bioelectricity production. To optimize MFC performance, S. oneidensis was modularly engineered to enhance acetate metabolism and electron transfer efficiency. Key modifications included upregulating ATP synthesis, introducing an ATP-independent acetate metabolic pathway, increasing NADH availability, and optimizing pili-based artificial conductive nanowires. These advancements achieved a maximum cell density (OD600 = 0.611), a record output voltage of 351.3 mV, and a record power density of 94.9 mW/m2 using acetate as the substrate. Furthermore, a two-stage biocatalytic system utilizing CO2 as the primary carbon source yielded an output voltage of 209.3 mV and a power density of 65.0 mW/m2. These results highlight the potential of engineered microbial co-culture for efficient CO2-based bioelectricity generation, offering a scalable and sustainable pathway toward carbon-neutral energy production.

Carbon-wise utilization of lignin-related compounds by synergistically employing anaerobic and aerobic bacteria

BACKGROUND

Lignin is a highly abundant but strongly underutilized natural resource that could serve as a sustainable feedstock for producing chemicals by microbial cell factories. Because of the heterogeneous nature of the lignin feedstocks, the biological upgrading of lignin relying on the metabolic routes of aerobic bacteria is currently considered as the most promising approach. However, the limited substrate range and the inefficient catabolism of the production hosts hinder the upgrading of lignin-related aromatics. Particularly, the aerobic O-demethylation of the methoxyl groups in aromatic substrates is energy-limited, inhibits growth, and results in carbon loss in the form of CO2.

RESULTS

In this study, we present a novel approach for carbon-wise utilization of lignin-related aromatics by the integration of anaerobic and aerobic metabolisms. In practice, we employed an acetogenic bacterium Acetobacterium woodii for anaerobic O-demethylation of aromatic compounds, which distinctively differs from the aerobic O-demethylation; in the process, the carbon from the methoxyl groups is fixed together with CO2 to form acetate, while the aromatic ring remains unchanged. These accessible end-metabolites were then utilized by an aerobic bacterium Acinetobacter baylyi ADP1. By utilizing this cocultivation approach, we demonstrated an upgrading of guaiacol, an abundant but inaccessible substrate to most microbes, into a plastic precursor muconate, with a nearly equimolar yields (0.9 mol/mol in a small-scale cultivation and 1.0 mol/mol in a one-pot bioreactor cultivation). The process required only a minor genetic engineering, namely a single gene knock-out. Noticeably, by employing a metabolic integration of the two bacteria, it was possible to produce biomass and muconate by utilizing only CO2 and guaiacol as carbon sources.

CONCLUSIONS

By the novel approach, we were able to overcome the issues related to aerobic O-demethylation of methoxylated aromatic substrates and demonstrated carbon-wise conversion of lignin-related aromatics to products with yields unattainable by aerobic processes. This study highlights the power of synergistic integration of distinctive metabolic features of bacteria, thus unlocking new opportunities for harnessing microbial cocultures in upgrading challenging feedstocks.

Genetic tools for the electrotroph Sporomusa ovata and autotrophic biosynthesis

Sporomusa ovata is a Gram-negative acetogen of the Sporomusaceae family with a unique physiology. This anerobic bacterium is a core microbial catalyst for advanced CO2-based biotechnologies including gas fermentation, microbial electrosynthesis, and hybrid photosystem. Until now, no genetic tools exist for S. ovata, which is a critical obstacle to its optimization as an autotrophic chassis and the acquisition of knowledge about its metabolic capacities. Here, we developed an electroporation protocol for S. ovata. With this procedure, it became possible to introduce replicative plasmids such as pJIR751 and its derivatives into the acetogen. This system was then employed to demonstrate the feasibility of heterologous expression by introducing a functional β-glucuronidase enzyme under the promoters of different strengths in S. ovata. Next, a recombinant S. ovata strain producing the non-native product acetone both from an organic carbon substrate and from CO2 was constructed. Finally, a replicative plasmid capable of integrating itself on the chromosome of the acetogen was developed as a tool for genome editing, and gene deletion was demonstrated. These results indicate that S. ovata can be engineered and provides a first-generation genetic toolbox for the optimization of this biotechnological workhorse.IMPORTANCES. ovata harbors unique features that make it outperform most microbes for autotrophic biotechnologies such as a capacity to acquire electrons from different solid donors, a low H2 threshold, and efficient energy conservation mechanisms. The development of the first-generation genetic instruments described in this study is a key step toward understanding the molecular mechanisms involved in these outstanding metabolic and physiological characteristics. In addition, these tools enable the construction of recombinant S. ovata strains that can synthesize a wider range of products in an efficient manner.

Microbial electrosynthesis from carbon dioxide feedstock linked to yeast growth for the production of high-value isoprenoids

The difficulty in producing multi-carbon and thus high-value chemicals from CO₂ is one of the key challenges of microbial electrosynthesis (MES) and other CO₂ utilization technologies. Here, we demonstrate a two-stage bioproduction approach to produce terpenoids (>C₂₀) and yeast biomass from CO₂ by linking MES and yeast cultivation approaches. In the first stage, CO₂ (C₁) is converted to acetate (C₂) using Clostridium ljungdahlii via MES. The acetate is then directly used as the feedstock to produce sclareol (C₂₀), β-carotene (C₄₀), and yeast biomass using Saccharomyces cerevisiae in the second stage. With the unpurified acetate-containing (1.5 g/L) spent medium from MES reactors, S. cerevisiae produced 0.32 ± 0.04 mg/L β-carotene, 2.54 ± 0.91 mg/L sclareol, and 369.66 ± 41.67 mg/L biomass. The primary economic analysis suggests that sclareol and biomass production is feasible using recombinant S. cerevisiae and non-recombinant S. cerevisiae, respectively, directly from unpurified acetate-containing spent medium of MES.

Sporomusa ovata as Catalyst for Bioelectrochemical Carbon Dioxide Reduction: A Review Across Disciplines From Microbiology to Process Engineering

Sporomusa ovata is a bacterium that can accept electrons from cathodes to drive microbial electrosynthesis (MES) of acetate from carbon dioxide. It is the biocatalyst with the highest acetate production rate described. Here we review the research on S. ovata across different disciplines, including microbiology, biochemistry, engineering, and materials science, to summarize and assess the state-of-the-art. The improvement of the biocatalytic capacity of S. ovata in the last 10 years, using different optimization strategies is described and discussed. In addition, we propose possible electron uptake routes derived from genetic and experimental data described in the literature and point out the possibilities to understand and improve the performance of S. ovata through genetic engineering. Finally, we identify current knowledge gaps guiding further research efforts to explore this promising organism for the MES field.

Acinetobacter baylyi ADP1-naturally competent for synthetic biology

Acinetobacter baylyi ADP1 is a non-pathogenic soil bacterium known for its metabolic diversity and high natural transformation and recombination efficiency. For these features, A. baylyi ADP1 has been long exploited in studying bacterial genetics and metabolism. The large pool of information generated in the fundamental studies has facilitated the development of a broad range of sophisticated and robust tools for the genome and metabolic engineering of ADP1. This mini-review outlines and describes the recent advances in ADP1 engineering and tool development, exploited in, for example, pathway and enzyme evolution, genome reduction and stabilization, and for the production of native and non-native products in both pure and rationally designed multispecies cultures. The rapidly expanding toolbox together with the unique features of A. baylyi ADP1 provide a strong base for a microbial cell factory excelling in synthetic biology applications where evolution meets rational engineering.

Direct utilization of industrial carbon dioxide with low impurities for acetate production via microbial electrosynthesis

The present study aimed to demonstrate the utilization of unpurified industrial CO₂ with low impurities for acetate production via microbial electrosynthesis (MES) for the first time. In MES experiments with CO₂-rich brewery gas, the enriched mixed culture dominated by Acetobacterium produced 1.8 ± 0.2 g/L acetic acid at 0.26 ± 0.03 g/L_catholyte/d rate and outperformed a pure culture of Clostridium ljungdahlii (1.1 ± 0.02 g/L; 0.138 ± 0.004 g/L_catholyte/d). The electron recovery in acetic acid was also more for mixed culture (84 ± 13%) than C. ljungdahlii (42 ± 14%). Electrochemical analysis of biocathodes suggested the role of microbial biofilm in improved hydrogen electrocatalysis. In comparative gas fermentation tests, the mixed culture outperformed C. ljungdahlii and produced acetic acid at a similar level with both industrial and pure CO₂ feedstocks. These results suggest the robustness and capability of the mixed microbial community for utilizing slightly impure industrial CO₂ for bioproduction and presents a major advancement in MES technology.

Integrating Syngas Fermentation into a Single-Cell Microbial Electrosynthesis (MES) Reactor

This study presents a series of experiments to test the integration of syngas fermentation into a single-cell microbial electrosynthesis (MES) process. Minimal gas–liquid mass transfer is the primary bottleneck in such gas-fermentation processes. Therefore, we hypothesized that MES integration could trigger the thermodynamic barrier, resulting in higher gas–liquid mass transfer and product-formation rates. The study was performed in three different phases as batch experiments. The first phase dealt with mixed-culture fermentation at 1 bar H2 headspace pressure. During the second phase, surface electrodes were integrated into the fermentation medium, and investigations were performed in open-circuit mode. In the third phase, the electrodes were poised with a voltage, and the second phase was extended in closed-circuit mode. Phase 2 demonstrated three times the gas consumption (1021 mmol) and 63% more production of acetic acid (60 mmol/L) than Phase 1. However, Phase 3 failed; at –0.8 V, acetic acid was oxidized to yield hydrogen gas in the headspace.

Bacterial wax synthesis

Biological wax esters offer a sustainable, renewable and biodegradable alternative to many fossil fuel derived chemicals including plastics and paraffins. Many species of bacteria accumulate waxes with similar structure and properties to highly desirable animal and plant waxes such as Spermaceti and Jojoba oils, the use of which is limited by resource requirements, high cost and ethical concerns. While bacterial fermentations overcome these issues, a commercially viable bacterial wax production process would require high yields and renewable, affordable feedstock to make it economically competitive and environmentally beneficial. This review describes recent progress in wax ester generation in both wild type and genetically engineered bacteria, with a focus on comparing substrates and quantifying obtained waxes. The full breadth of wax accumulating species is discussed, with emphasis on species generating high yields and utilising renewable substrates. Key areas of the field that have, thus far, received limited attention are highlighted, such as waste stream valorisation, mixed microbial cultures and efficient wax extraction, as, until effectively addressed, these will slow progress in creating commercially viable wax production methods.

Fixing CO2 into β-oxopropylcarbamates in neat condition by ionic gelation/Ag(i) supported on dendritic fibrous nanosilica

In this research, a novel approach to produce a novel nanocatalyst, AgBr supported on an ionic gelation (IG)-based nanomaterial, was developed through the aqueous coprecipitation approach for the dendritic fibrous nanosilica (DFNS) production and the wet impregnation method for IG coating, taking into account TPP as the cross-linking agent. In addition, DFNS/IG@Ag(i) had heterogeneous features that contributed to the quick improvement of the catalyst by filtration separation. The catalytic activity of DFNS/IG@Ag(i) was examined to synthesize β-oxopropylcarbamates through a multicomponent coupling of CO2, amines and propargyl alcohols in moderate conditions. The DFNS/IG@Ag(i) NPs were completely investigated by taking advantage of TG, TEM, FESEM and FT-IR spectroscopy analyses. The DFNS/IG@Ag(i) nanocatalyst indicated high stability in the reaction for five cycles without considerable loss of some properties like activity, which could be because of the high loading of IG on the catalyst surface.

Carbon dioxide and organic waste valorization by microbial electrosynthesis and electro-fermentation

Carbon-rich waste materials (solid, liquid, or gaseous) are largely considered to be a burden on society due to the large capital and energy costs for their treatment and disposal. However, solid and liquid organic wastes have inherent energy and value, and similar as waste CO₂ gas they can be reused to produce value-added chemicals and materials. There has been a paradigm shift towards developing a closed loop, biorefinery approach for the valorization of these wastes into value-added products, and such an approach enables a more carbon-efficient and circular economy. This review quantitatively analyzes the state-of-the-art of the emerging microbial electrochemical technology (MET) platform and provides critical perspectives on research advancement and technology development. The review offers side-by-side comparison between microbial electrosynthesis (MES) and electro-fermentation (EF) processes in terms of principles, key performance metrics, data analysis, and microorganisms. The study also summarizes all the processes and products that have been developed using MES and EF to date for organic waste and CO₂ valorization. It finally identifies the technological and economic potentials and challenges on future system development.

CO2 to succinic acid - Estimating the potential of biocatalytic routes

Microbial carbon dioxide assimilation and conversion to chemical platform molecules has the potential to be developed as economic, sustainable processes. The carbon dioxide assimilation can proceed by a variety of natural pathways and recently even synthetic CO2 fixation routes have been designed. Early assessment of the performance of the different carbon fixation alternatives within biotechnological processes is desirable to evaluate their potential. Here we applied stoichiometric metabolic modeling based on physiological and process data to evaluate different process variants for the conversion of C1 carbon compounds to the industrial relevant platform chemical succinic acid. We computationally analyzed the performance of cyanobacteria, acetogens, methylotrophs, and synthetic CO2 fixation pathways in Saccharomyces cerevisiae in terms of production rates, product yields, and the optimization potential. This analysis provided insight into the economic feasibility and allowed to estimate the future industrial applicability by estimating overall production costs. With reported, or estimated data of engineered or wild type strains, none of the simulated microbial succinate production processes showed a performance allowing competitive production. The main limiting factors were identified as gas and photon transfer and metabolic activities whereas metabolic network structure was not restricting. In simulations with optimized parameters most process alternatives reached economically interesting values, hence, represent promising alternatives to sugar-based fermentations.

Expanding the product spectrum of value added chemicals in microbial electrosynthesis through integrated process design-A review

Microbial electrosynthesis (MES) is a novel microbial electrochemical technology proposed for chemicals production with the storage of sustainable energy. However, the practical application of MES is currently restricted by the limited low market value of products in one-step conversion process, mostly acetate. A theme that is pervasive throughout this review is the challenges associated with the expanded product spectrum. Several recent research efforts to improve acetate production, using novel reactor configuration, renewable power supply, and various 3-D cathode are summarized. The importance of genetic modification, two-step hybrid process, as well as input substrates other than CO₂ are highlighted in this review as the future research paths for higher value chemicals production. At last, how to integrate MES with existing biochemicals processes is proposed. Definitely, more studies are encouraged to evaluate the overall performances and economic efficiency of these integrated process designs to make MES more competitive.

Dynamic decoupling of biomass and wax ester biosynthesis in Acinetobacter baylyi by an autonomously regulated switch

For improving the microbial production of fuels and chemicals, gene knock-outs and overexpression are routinely applied to intensify the carbon flow from substrate to product. However, their possibilities in dynamic control of the flux between the biomass and product synthesis are limited, whereas dynamic metabolic switches can be used for optimizing the distribution of carbon and resources. The production of single cell oils is especially challenging, as the synthesis is strictly regulated, competes directly with biomass, and requires defined conditions, such as nitrogen limitation. Here, we engineered a metabolic switch for redirecting carbon flow from biomass to wax ester production in Acinetobacter baylyi ADP1 using acetate as a carbon source. Isocitrate lyase, an essential enzyme for growth on acetate, was expressed under an arabinose inducible promoter. The autonomous downregulation of the expression is based on the gradual oxidation of the arabinose inducer by a glucose dehydrogenase gcd. The depletion of the inducer, occurring simultaneously to acetate consumption, switches the cells from a biomass mode to a lipid synthesis mode, enabling the efficient channelling of carbon to wax esters in a simple batch culture. In the engineered strain, the yield and titer of wax esters were improved by 3.8 and 3.1 folds, respectively, over the control strain. In addition, the engineered strain accumulated wax esters 19% of cell dry weight, being the highest reported among microbes. The study provides important insights into the dynamic engineering of the biomass-dependent synthesis pathways for the improved production of biocompounds from low-cost and sustainable substrates.

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Efficient conversion of acetate to storage lipids (wax ester) is demonstrated.

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AraC-pBAD promoter coupled with glucose dehydrogenase was used as a dynamic switch.

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The autonomous switch allowed dynamic shift from biomass to lipid synthesis mode.

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Wax ester yield and titer were improved by 3–4 folds over the wild type strain.

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The highest amount of wax esters produced in microbes, 19% of CDW, was achieved.

Production of alkanes from CO2 by engineered bacteria

BACKGROUND

Microbial biosynthesis of alkanes is considered a promising method for the sustainable production of drop-in fuels and chemicals. Carbon dioxide would be an ideal carbon source for these production systems, but efficient production of long carbon chains from CO₂ is difficult to achieve in a single organism. A potential solution is to employ acetogenic bacteria for the reduction of CO₂ to acetate, and engineer a second organism to convert the acetate into long-chain hydrocarbons.

RESULTS

In this study, we demonstrate alkane production from CO₂ by a system combining the acetogen Acetobacterium woodii and a non-native alkane producer Acinetobacter baylyi ADP1 engineered for alkane production. Nine synthetic two-step alkane biosynthesis pathways consisting of different aldehyde- and alkane-producing enzymes were combinatorically constructed and expressed in A. baylyi. The aldehyde-producing enzymes studied were AAR from Synechococcus elongatus, Acr1 from A. baylyi, and a putative dehydrogenase from Nevskia ramosa. The alkane-producing enzymes were ADOs from S. elongatus and Nostoc punctiforme, and CER1 from Arabidopsis thaliana. The performance of the pathways was evaluated with a twin-layer biosensor, which allowed the monitoring of both the intermediate (fatty aldehyde), and end product (alkane) formation. The highest alkane production, as indicated by the biosensor, was achieved with a pathway consisting of AAR and ADO from S. elongatus. The performance of this pathway was further improved by balancing the relative expression levels of the enzymes to limit the accumulation of the intermediate fatty aldehyde. Finally, the acetogen A. woodii was used to produce acetate from CO₂ and H₂, and the acetate was used for alkane production by the engineered A. baylyi, thereby leading to the net production of long-chain alkanes from CO₂.

CONCLUSIONS

A modular system for the production of drop-in liquid fuels from CO₂ was demonstrated. Among the studied synthetic pathways, the combination of ADO and AAR from S. elongatus was found to be the most efficient in heterologous alkane production in A. baylyi. Furthermore, limiting the accumulation of the fatty aldehyde intermediate was found to be beneficial for the alkane production. Nevertheless, the alkane productivity of the system remained low, representing a major challenge for future research.

Metabolic pairing of aerobic and anaerobic production in a one-pot batch cultivation

BACKGROUND

The versatility of microbial metabolic pathways enables their utilization in vast number of applications. However, the electron and carbon recovery rates, essentially constrained by limitations of cell energetics, are often too low in terms of process feasibility. Cocultivation of divergent microbial species in a single process broadens the metabolic landscape, and thus, the possibilities for more complete carbon and energy utilization.

RESULTS

In this study, we integrated the metabolisms of two bacteria, an obligate anaerobe Clostridium butyricum and an obligate aerobe Acinetobacter baylyi ADP1. In the process, a glucose-negative mutant of A. baylyi ADP1 first deoxidized the culture allowing C. butyricum to grow and produce hydrogen from glucose. In the next phase, ADP1 produced long chain alkyl esters (wax esters) utilizing the by-products of C. butyricum, namely acetate and butyrate. The coculture produced 24.5 ± 0.8 mmol/l hydrogen (1.7 ± 0.1 mol/mol glucose) and 28 mg/l wax esters (10.8 mg/g glucose).

CONCLUSIONS

The cocultivation of strictly anaerobic and aerobic bacteria allowed the production of both hydrogen gas and long-chain alkyl esters in a simple one-pot batch process. The study demonstrates the potential of 'metabolic pairing' using designed microbial consortia for more optimal electron and carbon recovery.

Improved fatty aldehyde and wax ester production by overexpression of fatty acyl-CoA reductases

Background

Fatty aldehydes are industrially relevant compounds, which also represent a common metabolic intermediate in the microbial synthesis of various oleochemicals, including alkanes, fatty alcohols and wax esters. The key enzymes in biological fatty aldehyde production are the fatty acyl-CoA/ACP reductases (FARs) which reduce the activated acyl molecules to fatty aldehydes. Due to the disparity of FARs, identification and in vivo characterization of reductases with different properties are needed for the construction of tailored synthetic pathways for the production of various compounds.

Results

Fatty aldehyde production in Acinetobacter baylyi ADP1 was increased by the overexpression of three different FARs: a native A. baylyi FAR Acr1, a cyanobacterial Aar, and a putative, previously uncharacterized dehydrogenase (Ramo) from Nevskia ramosa. The fatty aldehyde production was followed in real-time inside the cells with a luminescence-based tool, and the highest aldehyde production was achieved with Aar. The fate of the overproduced fatty aldehydes was studied by measuring the production of wax esters by a native downstream pathway of A. baylyi, for which fatty aldehyde is a specific intermediate. The wax ester production was improved with the overexpression of Acr1 or Ramo compared to the wild type A. baylyi by more than two-fold, whereas the expression of Aar led to only subtle wax ester production. The overexpression of FARs did not affect the length of the acyl chains of the wax esters.

Conclusions

The fatty aldehyde production, as well as the wax ester production of A. baylyi, was improved with the overexpression of a key enzyme in the pathway. The wax ester titer (0.45 g/l) achieved with the overexpression of Acr1 is the highest reported without hydrocarbon supplementation to the culture. The contrasting behavior of the different reductases highlight the significance of in vivo characterization of enzymes and emphasizes the possibilities provided by the diversity of FARs for pathway and product modulation.

Electronic supplementary material

The online version of this article (10.1186/s12934-018-0869-z) contains supplementary material, which is available to authorized users.

Hybrid photosynthesis-powering biocatalysts with solar energy captured by inorganic devices

The biological reduction of CO₂ driven by sunlight via photosynthesis is a crucial process for life on earth. However, the conversion efficiency of solar energy to biomass by natural photosynthesis is low. This translates in bioproduction processes relying on natural photosynthesis that are inefficient energetically. Recently, hybrid photosynthetic technologies with the potential of significantly increasing the efficiency of solar energy conversion to products have been developed. In these systems, the reduction of CO₂ into biofuels or other chemicals of interest by biocatalysts is driven by solar energy captured with inorganic devices such as photovoltaic cells or photoelectrodes. Here, we explore hybrid photosynthesis and examine the strategies being deployed to improve this biotechnology.