Development of a feeding strategy for high cell and PHA density fed-batch fermentation of Ralstonia eutropha H16 from organic acids and their salts

Efficient polyhydroxybutyrate production using acetate by engineered Halomonas sp. JJY01 harboring acetyl-CoA acetyltransferase

Polyhydroxybutyrate (PHB) is a well-known biodegradable bioplastic synthesized by microorganisms and can be produced from volatile fatty acids (VFAs). Among VFAs acetate can be utilized by Halomonas sp. YLGW01 for growth and PHB production. In this study, Halomonas sp. JJY01 was developed through introducing acetyl-CoA acetyltransferase (atoAD) with LacIq-Ptrc promoter into Halomonas sp. YLGW01. The effect of expression of atoAD on acetate was investigated by comparison with acetate consumption and PHB production. Shake-flask study showed that Halomonas sp. JJY01 increased acetate consumption rate, PHB yield and PHB production (0.27 g/L/h, 0.075 g/g, 0.72 g/L) compared to the wild type strain (0.17 g/L/h, 0.016 g/g, 0.11 g/L). In 10 L fermenter scale fed-batch fermentation, the growth of Halomonas sp. JJY01 resulted in higher acetate consumption rate, PHB yield and PHB titer (0.55 g/L/h, 0.091 g/g, 4.6 g/L) than wild type strain (0.35 g/L/h, 0.067 h/h, 2.9 g/L). These findings demonstrate enhanced acetate utilization and PHB production through the introduction of atoAD in Halomonas strains.

Current advances and emerging trends in sustainable polyhydroxyalkanoate modification from organic waste streams for material applications

The current processes for producing polyhydroxyalkanoates (PHAs) are costly, owing to the high cost of cultivation feedstocks, and the need to sterilise the growth medium, which is energy-intensive. PHA has been identified as a promising biomaterial with a wide range of potential applications and its functionalization from waste streams has made significant advances recently, which can help foster the growth of a circular economy and waste reduction. Recent developments and novel approaches in the functionalization of PHAs derived from various waste streams offer opportunities for addressing these issues. This study focuses on the development of sustainable, efficient, and cutting-edge methods, such as advanced bioprocess engineering, novel catalysts, and advances in materials science. Chemical techniques, such as epoxidation, oxidation, and esterification, have been employed for PHA functionalization, while enzymatic and microbial methods have indicated promise. PHB/polylactic acid blends with cellulose fibers showed improved tensile strength by 24.45-32.08 % and decreased water vapor and oxygen transmission rates while PHB/Polycaprolactone blends with a 1:1 ratio demonstrated an elongation at break four to six times higher than pure PHB, without altering tensile strength or elastic modulus. Moreover, PHB films blended with both polyethylene glycol and esterified sodium alginate showed improvements in crystallinity and decreased hydrophobicity.

Using an aromatic amide as nucleating agent to enhance the crystallization and dimensional stability of poly(3-hydroxybutyrate-co-3-hydroxyhexanate)

Biosynthesized poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBHHx) has emerged as a promising biodegradable polymer with a great potential to compete with traditional petroleum-based plastics, however, the poor crystallization ability makes it challenge to transform into high-performance products via common melt-processing methods. Herein, we demonstrate that N,N'-dicyclohexyl-2,6-naphthalenedicarboxamide (TMB) can serve as an efficient nucleating agent to significantly enhance the crystallization and resulting storage stability of PHBHHx. The results indicate that PHBHHx with small amounts of TMB (0.3-0.5 wt%) can crystallize completely even under a rapid cooling rate of 100 °C/min and the isothermal crystallization time is greatly reduced. As a result, the crystallinity of the injection-molded PHBHHx products is increased from 24.5 % to 39.5 %, without secondary crystallization after being stored at room temperature for 6 h. The products exhibit superior dimensional stability and the post-shrinkage can be decreased to as low as 0.1 %. Our work offers a feasible method to develop high-performance PHBHHx materials with remarkably enhanced crystallization ability.

Pilot-scale production of mcl-PHA by Pseudomonas citronellolis using acetic acid as the sole carbon source

Medium-chain-length polyhydroxyalkanoates (mcl-PHA) are biobased materials with promising properties for environmentally friendly applications. Due to high production costs, which are related to the cost of the carbon sources combined with conversion insufficiencies, currently only small quantities are produced. This results in a lack of reliable data on properties and application potential for the variety of polymers from different types of production strains. This study investigated the potential for the production of mcl-PHA from volatile fatty acids (VFA) at a larger scale, given their potential as low-cost and sustainable raw material within a carboxylate-platform based biorefinery. Pseudomonas citronellolis (DSMZ 50332) was chosen as the production strain, and acetic acid was selected as the main carbon and energy source. Nitrogen was limited to trigger polymer production, and a fed-batch process using a pH-stat feeding regime with concentrated acid was established. We report successful production, extraction, and characterization of mcl PHA, obtaining a total of 1.76 kg from two 500-litre scale fermentations. The produced polymer was identified as a copolymer of 3-hydroxydecanoate (60.7%), 3-hydroxyoctanoate (37.3%), and 3-hydroxyhexanoate (2.0%) with a weight average molecular weight (Mw) of 536 kDa. NMR analysis indicates the presence of unsaturated side chains, which may offer additional possibilities for modification. The results confirm that there is a potential to produce significant amounts of mcl-PHA with interesting rubber-like properties from waste-derived VFA.

Simultaneous production of Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) from recovered volatile fatty acid with treatment of leachate by Pilot-Scale Mechanical Vapor Recompression

Serious global problems faced due to many petroleum-based materials in the last century, which is called the plastic age, constitute the main motivation of this research. Considering wastewater treatment from this perspective, both the recovery of organic acids from wastewater and their conversion into bioplastics are extremely important in terms of reducing petroleum dependency. In this study, while the treatment of landfill leachate was provided with biological process integrated into Mechanical Vapor Recompression (MVR), simultaneously PHBV production was carried out with 84.9% recovered VFA as carbon source. The effects of C/N/P ratio and feeding regime on PHBV storage were investigated by Cupriavidus necator. PHBV storage of 96% (g PHBV/g DCW) was maximized by 2-stage feeding and nitrogen restriction. The ratio of 3HV to 3HB of PHBV was 45%. In addition, extracted PHBV was compared with standard PHA in terms of thermal and chemical properties with FTIR, XRD, TGA and DSC analyses.

The General Composition of Polyhydroxyalkanoates and Factors that Influence their Production and Biosynthesis

Polyhydroxyalkanoates (PHAs) have been a current research topic for many years. PHAs are biopolymers produced by bacteria under unfavorable growth conditions. They are biomaterials that exhibit a variety of properties, including biocompatibility, biodegradability, and high mechanical strength, making them suitable for future applications. This review aimed to provide general information on PHAs, such as their structure, classification, and parameters that affect the production process. In addition, the most commonly used bacterial strains that produce PHAs are highlighted, and details are provided on the type of carbon source used and how to optimize the parameters for bioprocesses. PHAs present a challenge to researchers because a variety of parameters affect biosynthesis, including the variety of carbon sources, bacterial strains, and culture media. Nevertheless, PHAs represent an opportunity to replace plastics, because they can be produced quickly and at a relatively low cost. With growing environmental concerns and declining oil reserves, polyhydroxyalkanoates are a potential replacement for nonbiodegradable polymers. Therefore, the study of PHA production remains a hot topic, as many substrates can be used as carbon sources. Both researchers and industry are interested in facilitating the production, commercialization, and application of PHAs as potential replacements for nonbiodegradable polymers. The fact that they are biocompatible, environmentally biodegradable, and adaptable makes PHAs one of the most important materials available in the market. They are preferred in various industries, such as agriculture (for bioremediation of oil-polluted sites, minimizing the toxicity of pollutants, and environmental impact) or medicine (as medical devices). The various bioprocess technologies mentioned earlier will be further investigated, such as the carbon source (to obtain a biopolymer with the lowest possible cost, such as glucose, various fatty acids, and especially renewable sources), pretreatment of the substrate (to increase the availability of the carbon source), and supplementation of the growth environment with different substances and minerals). Consequently, the study of PHA production remains a current topic because many substrates can be used as carbon sources. Obtaining PHA from renewable substrates (waste oil, coffee grounds, plant husks, etc.) contributes significantly to reducing PHA costs. Therefore, in this review, pure bacterial cultures (Bacillus megaterium, Ralstonia eutropha, Cupriavidus necator, and Pseudomonas putida) have been investigated for their potential to utilize by-products as cheap feedstocks. The advantage of these bioprocesses is that a significant amount of PHA can be obtained using renewable carbon sources. The main disadvantage is that the chemical structure of the obtained biopolymer cannot be determined in advance, as is the case with bioprocesses using a conventional carbon source. Polyhydroxyalkanoates are materials that can be used in many fields, such as the medical field (skin grafts, implantable medical devices, scaffolds, drug-controlled release devices), agriculture (for polluted water cleaning), cosmetics and food (biodegradable packaging, gentle biosurfactants with suitable skin for cosmetics), and industry (production of biodegradable biopolymers that replace conventional plastic). Nonetheless, PHA biopolymers continue to be researched and improved and play an important role in various industrial sectors. The properties of this material allow its use as a biodegradable material in the cosmetics industry (for packaging), in the production of biodegradable plastics, or in biomedical engineering, as various prostheses or implantable scaffolds.

High Cell Density Cultivation of Paracoccus sp. on Sugarcane Juice for Poly(3-hydroxybutyrate) Production

High cell density cultivation is a promising approach to reduce capital and operating costs of poly (3-hydroxybutyrate) (PHB) production. To achieve high cell concentration, it is necessary that the cultivation conditions are adjusted and controlled to support the best growth of the PHB producer. In the present study, carbon to nitrogen (C/N) ratio of a sugarcane juice (SJ)-based medium, initial sugar concentration, and dissolved oxygen (DO) set point, were optimized for batch cultivation of Paracoccus sp. KKU01. A maximum biomass concentration of 55.5 g/L was attained using the C/N ratio of 10, initial sugar concentration of 100 g/L, and 20% DO set point. Fed-batch cultivation conducted under these optimum conditions, with two feedings of SJ-based medium, gave the final cell concentration of 87.9 g/L, with a PHB content, concentration, and yield of 36.2%, 32.1 g/L, and 0.13 g/g-sugar, respectively. A medium-based economic analysis showed that the economic yield of PHB on nutrients was 0.14. These results reveal the possibility of using SJ for high cell density cultivation of Paracoccus sp. KKU01 for PHB production. However, further optimization of the process is necessary to make it more efficient and cost-effective.

Cell Retention as a Viable Strategy for PHA Production from Diluted VFAs with Bacillus megaterium

The production of biodegradable and biocompatible materials such as polyhydroxyalkanoates (PHAs) from waste-derived volatile fatty acids (VFAs) is a promising approach towards implementing a circular bioeconomy. However, VFA solutions obtained via acidification of organic wastes are usually too diluted for direct use in standard batch or fed-batch processes. To overcome these constraints, this study introduces a cell recycle fed-batch system using Bacillus megaterium uyuni S29 for poly(3-hydroxybutyrate) (P3HB) production from acetic acid. The concentrations of dry cell weight (DCW), P3HB, acetate, as well as nitrogen as the limiting substrate component, were monitored during the process. The produced polymer was characterized in terms of molecular weight and thermal properties after extraction with hypochlorite. The results show that an indirect pH-stat feeding regime successfully kept the strain fed without prompting inhibition, resulting in a dry cell weight concentration of up to 19.05 g/L containing 70.21% PHA. After appropriate adaptations the presented process could contribute to an efficient and sustainable production of biopolymers.

Advanced PHB fermentation strategies with CO2-derived organic acids

Over the past decade, formic acid and acetic acid have gained increasing attention as alternative feedstocks for poly-3-hydroxybutyrate (PHB) production as these potentially CO₂-derived molecules are naturally assimilated by Cupriavidus necator. Both organic acids were individually evaluated in fed-batch fermentations at bioreactor scale. Acetic acid was revealed as the most promising carbon source yielding 42.3 g L^-1 PHB, whereas no significant amount of PHB was produced from formic acid. Hence, acetic acid was further used as the substrate during process intensification. Key performance characteristics, including process stability, PHB titer, and productivity were optimized by introducing NH₄-acetate as the nitrogen source, extending the growth phase, and implementing a repeated fed-batch procedure, respectively. These advanced fermentation strategies resulted in the establishment of a stable fermentation process reaching 58.5 g L^-1 PHB, while doubling the productivity to 0.93 g L^-1 h^-1 PHB.

Biosynthesis of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) in metabolically recombinant Escherichia coli

In this study, a phaC_R gene encoding PHA synthase was identified in Rhodoligotrophos defluvii which was adjacent to β-ketothiolase encoded by phaA_R gene and acetoacetyl-CoA reductase encoded by phaB_R gene. Amino acid comparison of PhaC_R showed the highest homology of 65.98% with PhaC of R. appendicifer, while its homology with typical class I PHA synthase in Cupriavidus necator was only 42.54%. PHA synthesis genes were then transformed into E. coli harboring phaCAB_R and phaC_RAB_C which were cultured with 15 g/L glucose respectively, and 20.46 wt% and 16.95 wt% of CDW for poly(3-hydroxybutyrate) (PHB) were accumulated respectively. To further explore the effect of substrate specificity for PHA production, the ptsG gene was then deleted and 15 g/L glucose and 1.5 g/L propionate were co-employed as carbon sources, which enabled the synthesis of poly(3HB-co-3HV) copolymer. As a result, poly(3HB-co-3HV) was accumulated up to 24.74 wt% of CDW, and the highest content of 3-hydroxyvalerate (3HV) was 10.86 mol%. The T_d5 was 260 °C, which implied that it possessed good thermal stability, and the M_w of GPC in recombinant strains were between 22 and 26 × 10⁴ g/mol, and the highest PDI was 3.771. The structure of poly (3HB-co-3HV) copolymer was determined through ¹H NMR analysis.

A novel rotating wide gap annular bioreactor (Taylor-Couette type flow) for polyhydroxybutyrate production by Ralstonia eutropha using carob pod extract

An annular bioreactor (ABR) with wide gap was used for PHB production from Ralstonia eutropha. Hydrodynamic studies demonstrated the uniform distribution of fluid in the ABR due to the Taylor-Couette flow. Thereafter, the ABR was operated at different agitation and sparging rates to study its effect on R. eutropha growth and PHB production. The ABR operated at 500 rpm with air sparge rate of 0.8 vvm yielded a maximum PHB concentration of 14.89 g/L, which was nearly 1.4 times that obtained using a conventional stirred-tank bioreactor (STBR). Furthermore, performances of the bioreactors were compared by operating the reactors under fed-batch mode. At the end of 90 h of operation, the ABR resulted in a very high PHB production of 70.8 g/L. But STBR resulted in a low PHB concentration of 44.2 g/L. The superior performance was due to enhanced oxygen and nutrient mass transfer in the ABR.

Biodegradable polyhydroxyalkanoates production from wheat straw by recombinant Halomonas elongata A1

Waste straw bio-transformation of high value-added macromolecule polyhydroxyalkanoates (PHAs) was significance to environmental sustainable development. As a member of the PHA family, poly-β-hydroxybutyrate (PHB) could be synthesized by Halomonas elongata A1 with maximal yields of 22.8% and 11.8% of bacterial weights using glucose and carboxymethyl cellulose as carbon sources, respectively. To improve PHB production, we generated three recombinant strains, the H. elongata P2 with highest PHB biosynthesis ability. When wheat straw, mixed substrate and oleic acid were individually used as single carbon source, the maximal PHA polymer accumulation in the H. elongata P2 reached 5.2%, 16.5% and 27.5%, respectively, after 84 h of cultivation. This hardness, toughness and crystallization properties of the PHA macromolecule altered dependent on starting substrates, when analyzed by scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FTIR) and differential scanning calorimetry (DSC). In terms of the hardness and roughness, the PHA produced from mixed substrates was much softer than that from wheat straw but harder than that from oleic acid. The long-chain carbon improved the softness and strength of the produced PHA. Our data indicate that economical substrates, such as straw and waste oil, can be used in the synthesis of multi-functional plastic products with biodegradable properties.

Emergent Approaches to Efficient and Sustainable Polyhydroxyalkanoate Production

Petroleum-derived plastics dominate currently used plastic materials. These plastics are derived from finite fossil carbon sources and were not designed for recycling or biodegradation. With the ever-increasing quantities of plastic wastes entering landfills and polluting our environment, there is an urgent need for fundamental change. One component to that change is developing cost-effective plastics derived from readily renewable resources that offer chemical or biological recycling and can be designed to have properties that not only allow the replacement of current plastics but also offer new application opportunities. Polyhydroxyalkanoates (PHAs) remain a promising candidate for commodity bioplastic production, despite the many decades of efforts by academicians and industrial scientists that have not yet achieved that goal. This article focuses on defining obstacles and solutions to overcome cost-performance metrics that are not sufficiently competitive with current commodity thermoplastics. To that end, this review describes various process innovations that build on fed-batch and semi-continuous modes of operation as well as methods that lead to high cell density cultivations. Also, we discuss work to move from costly to lower cost substrates such as lignocellulose-derived hydrolysates, metabolic engineering of organisms that provide higher substrate conversion rates, the potential of halophiles to provide low-cost platforms in non-sterile environments for PHA formation, and work that uses mixed culture strategies to overcome obstacles of using waste substrates. We also describe historical problems and potential solutions to downstream processing for PHA isolation that, along with feedstock costs, have been an Achilles heel towards the realization of cost-efficient processes. Finally, future directions for efficient PHA production and relevant structural variations are discussed.

Evaluation of Fed-Batch Fermentation for Production of Polyhydroxybutyrate With a Banana Pulp Juice Substrate From an Agro Industrial By-Product

Pollution resulting from the persistence of plastics in the environment has driven the development of substitutes for these materials through fermentation processes using agro-industrial wastes. Polyhydroxybutyrate (PHB) is a rapidly biodegradable material with chemical and mechanical properties comparable to those of some petroleum-derived plastics. PHB accumulates intracellularly as an energy reserve in a wide variety of microorganisms exposed to nutritionally imbalanced media. The objective of this study was to evaluate the use of a banana waste product as a carbon source for PHB production. PHB was extracted by acid methanolysis and detected by gas chromatography-mass spectrometry. Eleven bacterial strains with potential for PHB production were evaluated by in vitro fermentation in a culture broth containing fructose as the carbon source and limited nitrogen. A 22 central composite rotational design was applied to optimize the concentrations of banana juice and ammonium chloride needed to maximize the PHB-producing biomass concentration. The process was then carried out in a 3 L fed-batch fermentation system that included an initial stage of biomass growth. Banana juice was used as the carbon source and fructose pulses were added to maintain the test sugar concentrations of 30, 40, and 50 g/L. The control strain, Cupriavidus necator (ATCC 17699), produced 2.816 g/L of PHB, while productivity of the most promising isolate, C. necator (CR-12), was 0.495 g/L. Maximum biomass production was obtained using 5% banana juice and 2 g/L ammonium chloride. PHB production was not detected in fed-batch fermentations supplemented with 30 or 40 g/L of fructose, while the mean PHB production in fermentations with 50 g/L of fructose was 1.3 g/L.

Enhanced production of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) biopolymer by recombinant Bacillus megaterium in fed-batch bioreactors

Polyhydroxyalkanoates (PHAs) are biodegradable polyesters accumulated in a wide variety of microorganisms as intracellular carbon and energy storage compounds. Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) is one of the most valuable biopolymers because of its superior mechanical properties. Here, we developed a bioprocess utilizing recombinant Bacillus megaterium strain for PHBV over-production from glucose, without any precursor addition. PHA production was performed in a controlled bioreactor by batch and fed-batch modes using wild-type B. megaterium and rec-B. megaterium cells overexpressing the native phaC gene. The effect of oxygen transfer rate on biomass formation and PHA accumulation was also investigated, under different dissolved oxygen levels. Structural and thermal properties of PHA were characterized by GC-FID, ¹H-NMR, TGA and DSC analyses. Significantly, the copolymer produced from glucose as the carbon source in rec-B. megaterium was composed of 58 mol% of 3-hydroxyvalerate monomers. After 66 h, rec-B. megaterium cells in fed-batch fermentation with a pre-determined growth rate µ₀ = 0.1 h^-1 produced the highest CDW (7.7 g L^-1) and PHA concentration (6.1 g L^-1). Moreover, an exponential glucose feeding profile resulted in 2.2-fold increase in PHA yield compared to batch cultivation. Overall, this study paves the way to an enhanced biopolymer production process in B. megaterium cells, where the highest product yield on cell was obtained as Y_P/X = 0.8 g g^-1.

Unraveling the camel rumen microbiome through metaculturomics approach for agriculture waste hydrolytic potential

Cellulose is the most abundant natural polymer present on Earth in the form of agriculture waste. Hydrolysis of agriculture waste for simple fermentable reducing sugars is the bottleneck in the area of biofuel generation and other value-added products. The present study aims to utilize the camel rumen as a bioreactor for potent cellulolytic and hemicellulolytic bacteria by altering the feed types with varying cellulosic concentrations. A total of 6716 bacterial cultures were subjected to three layers of screening, where plate zymography and chromophoric substrate screening served as primary screening method for cellulolytic and hemicellulolytic potential. The potential isolates were genetically grouped using RAPD, and 51 representative isolates from each group were subjected to molecular identification through 16S rDNA sequencing, followed by quantification of various cellulolytic and hemicellulolytic enzymes. Out of 51 potent isolates, 5 isolates had high endoglucanase activity ranging from 0.3 to 0.48 U/ml. The selected five key isolates identified as Pseudomonas, Paenibacillus, Citrobacter, Bacillus subtilis, and Enterobacter were employed for hydrolyzing the various agriculture residues and resulted in approximately 0.4 mg/ml of reducing sugar. Furthermore, the metaculturomics approach was implemented to deduce the total cultured diversity through 16S rRNA amplicon library sequencing. The metaculturomics data revealed the dominance of proteobacteria and unidentified bacterial population in all four feed types, which indicates the possibility of culturing novel cellulose-deconstructing bacteria. Moreover, the presence of diverse hydrolytic enzymes in cultured isolates supports the usage of these bacteria in bio-processing of agriculture waste residues and obtaining the biofuels and other value-added products.

Microwave-assisted cascade exploitation of giant reed (Arundo donax L.) to xylose and levulinic acid catalysed by ferric chloride

The present work aimed to investigate and optimize the selective exploitation of hemicellulose and cellulose fractions of the energy crop Arundo donax L. (giant reed), to give xylose and levulinic acid, respectively. In order to improve the sustainability of this process, a microwave-assisted hydrolysis in the presence of FeCl₃ was implemented using as substrate the raw biomass without any pretreatment process. The effects of the hydrolysis reaction conditions, such as temperature, reaction time, salt amount and biomass loading, on giant reed exploitation were investigated. In the first step, under the optimized conditions (150 °C, 2.5 min and 1.6 wt% FeCl₃), the xylose yield reached 98.2 mol%. In the second step, under the best conditions (190 °C, 30 min and 2.4 wt% FeCl₃), the levulinic acid yield was 57.6 mol%. This novel cascade approach ensured an extensive exploitation of giant reed polysaccharides working in the respect of Green Chemistry principles.

A Process Engineering Approach to Improve Production of P(3HB) byCupriavidus necatorfrom Used Cooking Oil

Different feeding strategies, namely, exponential feeding and DO-stat mode, were implemented for the production of poly(3-hydroxybutyrate), P(3HB), byCupriavidus necatorDSM 428 with used cooking oil (UCO) as the sole carbon source. With the exponential feeding strategy, a cell dry mass of 21.3 ± 0.9 g L−1was obtained, with a polymer content of 84.0 ± 4.5 wt.%, giving an overall volumetric productivity of 4.5 ± 0.2 g L−1 day−1. However, the highest P(3HB) volumetric productivity, 12.6 ± 0.8 g L−1 day−1, was obtained when the DO-stat mode was implemented together with the use of ammonium hydroxide for pH control, which served as an additional nitrogen source and allowed to reach higher cell dry mass (7.8 ± 0.6 g L−1). The P(3HB) obtained in all experiments had a high molecular mass, ranging from 0.6 × 105to 2.6 × 105 g mol−1, with low polydispersity indexes of 1.2-1.6. Melting and glass transition temperatures were also similar for the polymer produced with both cultivation strategy, 174°C and 3.0-4.0°C, respectively. The polymer exhibited a crystallinity ranging from 52 to 65%. The DO-stat strategy to feed oil containing substrates as the sole carbon sources was reported for the first time in this study, and the preliminary results obtained show that it is a promising strategy to improve P(3HB) production. Nevertheless, the process requires further optimization in order to make it economically viable.

Hydrogen and polyhydroxybutyrate production from wheat straw hydrolysate using Caldicellulosiruptor species and Ralstonia eutropha in a coupled process

This report presents an integrated biorefinery concept in which wheat straw hydrolysate was treated with co-cultures of osmotolerant thermophilic bacterial strains, Caldicellulosiruptor saccharolyticus and C. owensensis to obtain hydrogen, while the liquid effluent containing acetate and residual glucose was used as feed for polyhydroxybutyrate (PHB) production by Ralstonia eutropha. The Caldicellulosiruptor spp. co-culture consumed 10.8 g/L of pretreated straw sugars, glucose and xylose, producing 134 mmol H₂/L. PHB accumulation by R. eutropha was first studied in minimal salts medium using acetate with/without glucose as carbon source. Addition of salts promoted cell growth and PHB production in the effluent. Fed-batch cultivation in a nitrogen limited medium with 40% (v/v) aeration resulted in a cell density of 15.1 g/L with PHB content of 80.1% w/w and PHB concentration of 12.1 g/L, while 20% aeration gave a cell density of 11.3 g/L with 83.4% w/w PHB content and 9.4 g/L PHB concentration.

Bioreactor Operating Strategies for Improved Polyhydroxyalkanoate (PHA) Productivity

Microbial polyhydroxyalkanoates (PHAs) are promising biodegradable polymers that may alleviate some of the environmental burden of petroleum-derived polymers. The requirements for carbon substrates and energy for bioreactor operations are major factors contributing to the high production costs and environmental impact of PHAs. Improving the process productivity is an important aspect of cost reduction, which has been attempted using a variety of fed-batch, continuous, and semi-continuous bioreactor systems, with variable results. The purpose of this review is to summarize the bioreactor operations targeting high PHA productivity using pure cultures. The highest volumetric PHA productivity was reported more than 20 years ago for poly(3-hydroxybutryate) (PHB) production from sucrose (5.1 g L⁻¹ h⁻¹). In the time since, similar results have not been achieved on a scale of more than 100 L. More recently, a number fed-batch and semi-continuous (cyclic) bioreactor operation strategies have reported reasonably high productivities (1 g L⁻¹ h⁻¹ to 2 g L⁻¹ h⁻¹) under more realistic conditions for pilot or industrial-scale production, including the utilization of lower-cost waste carbon substrates and atmospheric air as the aeration medium, as well as cultivation under non-sterile conditions. Little development has occurred in the area of fully continuously fed bioreactor systems over the last eight years.

Acetic Acid as an Indirect Sink of CO2 for the Synthesis of Polyhydroxyalkanoates (PHA): Comparison with PHA Production Processes Directly Using CO2 as Feedstock

White biotechnology is promising to transform CO2 emissions into a valuable commodity chemical such as the biopolymer polyhydroxyalkanaotes (PHA). Our calculations indicated that the indirect conversion of acetic acid from CO2 into PHA is an interesting alternative for the direct production of PHA from CO2 in terms of CO2 fixation, H2 consumption, substrate cost, safety and process performance. An alternative cultivation method using acetic acid as an indirect sink of CO2 was therefore developed and a proof-of-concept provided for the synthesis of both the homopolymer poly(3-hydroxybutyrate) (PHB) and the copolymer poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV). The aim was to compare key performance parameters with those of existing cultivation methods for direct conversion of CO2 to PHA. Fed-batch cultivations for PHA production were performed using a pH-stat fed-batch feeding strategy in combination with an additional Dissolved Oxygen (DO)-dependent feed. After 118 h of fermentation, 60 g/L cell dry matter (CDM) containing 72% of PHB was obtained, which are the highest result values reported so far. Fed-batch cultivations for PHBV production resulted in 65 g/L CDM and 48 g/L PHBV concentration with a 3HV fraction of 27 mol %. Further research should be oriented towards process optimisation, whole process integration and design, and techno-economic assessment.

Targeted poly(3-hydroxybutyrate-co-3-hydroxyvalerate) bioplastic production from carbon dioxide

A microbial production process was developed to convert CO₂ and valeric acid into tailored poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) bioplastics. The aim was to understand microbial PHBV production in mixotrophic conditions and to control the monomer distribution in the polymer. Continuous sparging of CO₂ with pulse and pH-stat feeding of valeric acid were evaluated to produce PHBV copolyesters with predefined properties. The desired random monomer distribution was obtained by limiting the valeric acid concentration (below 1 gL^-1). ¹H-NMR, ¹³C-NMR and chromatographic analysis of the PHBV copolymer confirmed both the monomer distribution and the 3-hydroxyvalerate (3HV) fraction in the produced PHBV. A physical-based model was developed for mixotrophic PHBV production, which was calibrated and validated with independent experimental datasets. To produce PHBV with a predefined 3HV fraction, an operating diagram was constructed. This tool was able to predict the 3HV fraction with a very good accuracy (2% deviation).

Fed-Batch Strategies for Production of PHA Using a Native Isolate of Halomonas venusta KT832796 Strain

In this study, polyhydroxyalkanoates (PHA) accumulation by Halomonas venusta KT832796, a moderate halophilic bacteria isolated from marine source was studied. Both nutritional requirements and process parameters for submerged cultivation of the organism in bioreactor have been standardized. From the shake flask studies, glucose and ammonium citrate as carbon and nitrogen source produced maximum PHA at a ratio 20 with 3.52 g/L of dry cell weight and 70.56% of PHA content. However, ammonium sulfate as the nitrogen source was found to be more suitable for fed-batch cultivation. Several feeding strategies including pH-based fed-batch and variants of pulse feeding were studied to improve the PHA levels. pH-based feeding, although improved PHA level to 26 g/L, most of the carbon flux was diverted towards biomass formation; hence, the percent PHA was only 39.15% of the dry cell weight. Maximum PHA of 33.4 g/L, which corresponded to 88.12% of the dry cell, was obtained from high concentration single pulse method. There was a net 8.65-fold increase in PHA using this feeding strategy when compared to batch studies. According to our knowledge, this is the highest amount of PHA reported for a Halomonas venusta strain.

Controlling cell volume for efficient PHB production by Halomonas

Bacterial morphology is decided by cytoskeleton protein MreB and cell division protein FtsZ encoded by essential genes mreB and ftsZ, respectively. Inactivating mreB and ftsZ lead to increasing cell sizes and cell lengths, respectively, yet seriously reduce cell growth ability. Here we develop a temperature-responsible plasmid expression system for compensated expression of relevant gene(s) in mreB or ftsZ disrupted recombinants H. campaniensis LS21, allowing mreB or ftsZ disrupted recombinants to grow normally at 30°C in a bioreactor for 12h so that a certain cell density can be reached, followed by 36h cell size expansions or cell shape elongations at elevated 37°C at which the mreB and ftsZ encoded plasmid pTKmf failed to replicate in the recombinants and thus lost themselves. Finally, 80% PHB yield increase was achieved via controllable morphology manipulated H. campaniensis LS21. It is concluded that controllable expanding cell volumes (widths or lengths) provides more spaces for accumulating more inclusion body polyhydroxybutyrate (PHB) and the resulting cell gravity precipitation benefits the final separation of cells and product during downstream.

Bacterial polyhydroxyalkanoates: Still fabulous?

Bacterial polyhydroxyalkanoates (PHA) are polyesters accumulated as carbon and energy storage materials under limited growth conditions in the presence of excess carbon sources. They have been developed as biomaterials with unique properties for the past many years being considered as a potential substitute for conventional non-degradable plastics. Due to the increasing concern towards global climate change, depleting petroleum resource and problems with an utilization of a growing number of synthetic plastics, PHAs have gained much more attention from industry and research. These environmentally friendly microbial polymers have great potential in biomedical, agricultural, and industrial applications. However, their production on a large scale is still limited. This paper describes the backgrounds of PHAs and discussed the current state of knowledge on the polyhydroxyalkanoates. Ability of bacteria to convert different carbon sources to PHAs, the opportunities and challenges of their introduction to global market as valuable renewable products have been also discussed.