Title of Invention

A STABLE CONTINUOUS METHOD FOR PRODUCING ETHANOL FROM MICROBIAL FERMENTATION OF GASEOUS SUBSTRATE.

Abstract A STABLE CONTINUOUS METHOD FOR PRODUCING ETHANOL FROM THE ANAEROBIC BACTERIAL FERMENTATION OF A GASEOUS SUBSTRATE, THE METHOD COMPRISING : CULTURING IN A BIOREACTOR AN ANEROBIC, ACETOGENIC BACTERIUM WHICH IS CAPABLE OF PRODUCING ETHANOL IN A LIQUID NUTRIENT MEDIUM; SUPPLYING TO SAID BIOREACTOR SAID GASEOUS SUBSTRATE COMPRISING CARBON MONOXIDE; FEEDING CALCIUM PANTOTHENATE INTO SAID BIOREACTOR AT AN AMOUNT OF 2 TO 50 UG/GRAMS OF DRY CELL OF BACTERIA PRODUCED IN SAID BIOREACTOR; AND MAINTAINING THE SPECIFIC RATE OF CO UPTAKE IN SAID BIOREACTOR AT AN AMOUNT OF AT LEAST 0.3 MMOL CO/GRAM CELL DRY WEIGHT OF BACTERIA/MINUTE; WHEREIN FREE ACETIC ACID IS PRODUCED IN SAID BIOREACTOR AT A CONNECNTRATION OF LESS THAN 5 G/L FREE ACID, SAID ETHANOL IS PRODUCED AT A PRODUCTIVITY GREATER THAN 10 G/L PER DAY AND WHEREIN BOTH ETHANOL AND ACETATE ARE PRODUCED IN SAID FERMENTATION BROTH IN SAID BIOREACTOR AT A RATIO OF ETHANOL TO ACETATE RANGING FROM 1:1 TO 20:1.
Full Text METHODS FOR INCREASING THE PRODUCTION OF
ETHNOL FROM MICRONIOAL FERMENTATION
FIELD OF INVENTION
The present invention is directed to improvements in microbial fermentation
methods for the production of ethanol from a gaseous substrate containing at least
one reducing gas using anaerobic (or facultative) acetogenic bacteria
BACKGROUND OF THE INVENTION
Methods for producing ethanol, among other organic acids, alcohols,
hydrogen and organic acid salts, from the microbial fermentation of gaseous substrates
in media containing suitable nutrients and trace minerals using certain anaerobic
bacteria have been disclosed by these inventors. For example, the inventors have
previously disclosed that dilute gas mixtures are introduced into a bioreactor
containing one or more strains of anaerobic bacteria that utilize the waste gas
components by a direct pathway to produce a desired compound. The compound is -
recovered from the aqueous phase in a separate vessel or vessels, utilizing a suitable
recovery method for the compound produced. Examples of recovery methods include
extraction, distillation or combinations thereof, or other efficient recovery methods.
The bacteria can be removed from the aqueous phase and recycled to the bioreactor to
maintain high cell concentrations, thus maximizing productivity. Cell separation, if
desired, is accomplished by centrifugation, membranous filtration, or other techniques.
See, for example, International Patent Application No. WO98/00558, published
January 8, 1998; U.S. Patent No. 5,807,722; U.S. Patent No. 5,593,886 and U.S.
Patent No. 5,821,111.
In addition to its major product, acetic acid, strains of the anaerobic bacterium
Clostridium Ijungdahlii are able to also produce ethanol as a product in the
conversion of carbon monoxide (CO), hydrogen (H2) and carbon dioxide (CO2). The
production of acetic acid (CH3COOH) and ethanol (C2H5OH) from CO, CO2 and H2
are shown by the following overall stoichiometric equations:
4CO +2 H2O ? CH3COOH + 2CO2(1)
4H2+2 CO2 ? CH3COOH + 2H2O(2)
6CO +3 H2O ? C2H5OH + 4CO2(3)
6H2 + 2 CO2 ? C2H5OH + 3H2O(4)
Several exemplary strains of C. Ijimgdahlii include strain PETC (U.S. Patent
No. 5,173,429); strain ERI2 (U.S. Patent No. 5,593,886) and strains C-01 and O-52
(U.S. Patent No. 6,136,577). These strains are each deposited in the American Type
Culture Collection, 10801 University Boulevard, Manassas, VA 20110-2209, under
Accession Nos.: 55383 (formerly ATCCNo. 49587), 55380, 559S8, and 55989
respectively. Each of the strains of C. Ijumgdahlii is an anaerobic, gram-positive
bacterium with a guanine and cytosine (G+C) nucleotide content of about 22 mole%.
These bacteria use a variety of substrates for growth, but not methanol or lactate.
These strains differ in their CO tolerance, specific gas uptake rates and specific
productivities. In the "wild" strains found in nature, very little ethanol production is
noted. Strains of C. Ijimgdahlii operate ideally at 37°C, and typically produce an
ethanol to acetyl (i.e. which refers to both free or molecular acetic acid and acetate
salts) product ratio of about 1:20 (1 part ethanol per 20 parts acetyl) in the "wild"
state. Ethanol concentrations are typically only 1-2 g/L. While this ability to produce
ethanol is of interest, because of low ethanol productivity the "wild" bacteria cannot
be used to economically produce ethanol on a commercial basis.
With minor nutrient manipulation the above-mentioned C. Ijungdahlii strains
have been used to produce ethanol and acetyl with a product ratio of 1.1 (equal parts
ethanol and acetyl), but the ethanol concentration is less than 10 g/L, a level that
results in low productivity, below 10 g/L-day. In addition culture stability is an issue,
primarily due to the relatively high (8-10 g/L) concentration of acetyl (2.5-3g/L
molecular acetic acid) in combination with the presence of ethanol. Furthermore, as
the gas rate is increased in an effort to produce more ethanol, the culture is inhibited,
first by molecular acetic acid and then by CO. As a result, the culture becomes
unstable and fails to uptake gas and produce additional product. Further, early work
by the inventors showed difficulty in producing more than a 2:1 ratio of ethanol to
acetyl in a steady state operation. See, e.g., Klasson etal, 1990 Applied
Biochemistry and Biotechnology, Proceedings of the 11th Symposium on
Biotechnology for Fuels and Chemicals, 24/25: 857; Phillips et al, 1993 Applied
Biochemistry and Biotechnology, Proceedings of the 14th Symposium on
Biotechnology for Fuels and Chemicals, 39/40: 559, among others.
A large number of documents describe the use of anaerobic bacteria, other
than C- Ijungdahlii, in the fermentation of sugars that do not consume CO, CO2 and
H2 to produce solvents. In an attempt to provide high yields of ethanol, a variety of
parameters have been altered which include: nutrient types, microorganism, specific
addition of reducing agents, pH variations, and the addition of exogenous gases. See,
e.g., Rothstein et al, 1986 J. Bacteriol, 165(l):319-320; Lovitt et al, 1988 J.
Bacteriol., 170(6):2809; Taherzadeh et at, 1996 Appl. Microbiol. Biotechnol.,
46:116.
There remains a need in the art of the handling of industrial gaseous substrates,
the ability to extract valuable commodities from such gases, particularly waste gases,
such as H2, CO and CO2. There is a need to enhance the production of ethanol
relative to the production of the other products normally generated by the
fermentation of such gases by acetogenic bacteria.
SUMMARY OF THE INVENTION
In response to the need in the art, the present invention provides novel
methods which are continuous, steady state methods and which result in ethanol
concentrations greater than 10 g/L and acetate concentrations lower than about 8-10
g/L, while continuing to permit culture growth and good culture stability.
In one aspect, the invention provides a stable continuous method for
producing ethanol from the anaerobic bacterial fermentation of a gaseous substrate.
The method comprising the steps of culturing in a fermentation bioreactor anaerobic,
acetogenic bacteria in a liquid nutrient medium and supplying to the bioreactor the
gaseous substrate comprising at least one reducing gas selected from the group
consisting of CO and H2. The bacteria in the bioreactor are manipulated by reducing
the redox potential, or increasing the NAD(P)H TO NAD(P) ratio, in the fermentation
broth after the bacteria achieves a steady state, e.g., a stable cell concentration, in the
bioreactor. The free acetic acid concentration in the bioreactor is maintained at less
than 5 g/L free acid. The culturing and manipulating steps cause the bacteria in the
bioreactor to produce ethanol in a fermentation broth at a productivity greater than
10g/L per day. Both ethanol and acetate are produced in the fermentation broth in a
ratio of ethanol to acetate ranging from 1:1 to 20:1.
In one embodiment of this method, the manipulating step includes one or more
of the following steps: altering at least one parameter selected from the group
consisting of nutrient medium contents, nutrient feed rate, aqueous feed rate,
operating pressure, operating pH, gaseous substrate contents, gas feed rate,
fermentation broth agitation rate, product inhibition step, cell density, and substrate
inhibition.
In another embodiment of this method, the manipulating step comprises
supplying to said bioreactor said gaseous substrate comprising the reducing gas, CO,
at a desired rate of uptake. This rate is desirably from 0.3 to 2 mmol CO/gram of dry
cell of bacteria in said bioreactor/minute.
In still another embodiment of this method the manipulating step comprises
feeding into said fermentation bioreactor said nutrient medium comprising a limiting
amount of calcium pantothenate. The calcium pantothenate is desirably in a range of
from 0.5 to 50 µg/grams of dry cell of bacteria produced in the bioreactor.
In yet anotliei aspect, the invention provides Another embodiment of the
method includes supplying excess H2 reducing gas to said bioreactor prior to
providing the limiting amount of calcium pantothenate.
In yet a further aspect, the invention provides a method in which the
manipulating step of the method includes feeding into said fermentation bioreactor
said nutrient medium comprising a limiting amount of cobalt. Desirably, the amount
of cobalt is in a range of from 5 to 100 µg cobalt/grams of dry cell of bacteria
produced in said bioreactor.
In another embodiment, the method of the invention includes preventing
acclimation of said bacteria in said bioreactor to said amount of cobalt by maintaining
a constant cobalt concentration and adjusting one or more parameters, such as gas
rate, liquid rate, agitation rate and H2 gas partial pressure.
Additional optional steps of these methods include subjecting a sample of the
broth to centrifugation to eliminate cells and to gas chromatography to monitor the
maintenance of the ratio and/or productivity values.
In another embodiment, the method comprises feeding as the gaseous
substrate an amount of H2 in slight excess of the stoichiometric amount for ethanol
production. In still another embodiment, the gaseous substrate further comprises an
amount of CO in slight excess of the amounts required by the bacteria, wherein uptake
of H2 by the bacteria is inhibited and the NAD(P)H to NAD(P) ratio in the broth is
increased.
In yet another embodiment of the method, a step is provided in which
inhibition by molecular acetic acid is reduced by increasing the aqueous feed rate
when the molecular acetic acid present in the fermentation broth approaches or
exceeds 2g/L.
In another embodiment of the method, the manipulating step may include
agitating the medium, bacteria.and gaseous substrate in the bioreactor at a selected
agitation rate. For example, reduction in the agitation rate reduces the amount of CO
transferred to the fermentation broth. This reduction in the rate of CO transfer causes
an increase in H2 conversion, so that the reducing gas, H2, is present in the bioreactor
in excess of the growth requirements of the bacteria. The gas rate may also be
similarly reduced to decrease the amount of CO transferred, thereby increasing H2
conversion, so that the reducing gas, H2, is present in the fermentation bioreactor in
excess of the growth requirements of the bacteria.
In still another embodiment of the method, the bacterial culture may initially be
brought to the desired cell concentration in the bioreactor before limiting the calcium
pantothenate or cobalt concentration of the nutrient medium.
In another embodiment of the method of this invention, a two stage CSTR
(bioreactor) is used which consists of a growth reactor which feeds the fermentation
broth to a production reactor in which most of the ethanol is produced.
In another aspect of the invention, the method described above includes the
optional steps of: recovering ethanol by removing the fermentation broth from the
bioreactor; distilling ethanol from the broth; and recovering the ethanol. Additionally
or preferably, a sample of the broth is subjected to centrifugation to eliminate cells;
and the maintenance of the ratio is monitored using gas chromatography.
In still another aspect, the method of the invention may farther employ an
additional step of recycling water (containing up to 5 g/L acetyl) from the ethanol
production back to the reactor so that an equilibrium is established between the
ethanol and acetyl in the reactor. As a result, more of the CO, CO2 and H2 fed to the
reactor and converted to products results in ethanol production.
Other aspects and advantages of the present invention are described further in
the following detailed description of the preferred embodiments thereof.
BRIEF DESCRIPTION OF THE/DRAWINGS
Fig. 1 is a schematic diagram illustrating a continuous fermentation method
with product recovery according to this invention. Gaseous substrate 1 and liquid
phase nutrient medium 2 are fed to bioreactor 3 containing the subject bacterial
culture. Conversion of the gaseous substrate to ethanol and acetic acid takes place in
the bioreactor 3. Exhaust gas 4 containing gases other than CO, CO, and H2 and
unconverted CO, CO2 and H2 from bioreactor 3 are vented, combusted as fuel or
flared. With cell recycle, liquid effluent 5 is sent to cell separator 6 where the cells 7
and cell-free permeate 8 are separated. Cells 7 are sent back to bioreactor 3 and
permeate 8 is sent to product recovery. Ethanol can be recovered from the permeate
8 (or alternatively from the effluent 5 if cell separation is not employed). Permeate 8
is separated in distillation column 9 to produce 95% ethanol overhead 10, and water
11 for recycle back to bioreactor 3. The 95% ethanol overhead 10 is sent to a
molecular sieve 12 where anhydrous ethanol 13, the desired final product, is separated
from dilute ethanol 14 which is sent back to the distillation column 9.
Fig. 2 is a schematic diagram of a two-stage, continuously stirred reactor
(CSTR) system for improved culture stability. Growth stage CSTR 1 is fed liquid
medium 2. Unconverted gas 3 from the Production Stage CSTR is fed to Growth
Stage CSTR 1. Production Stage CSTR 4 is fed a fresh gas feed 5, and fresh medium
feed 6 as well as culture feed 7 from Growth Stage CSTR 1. Cell recycle 8 is used to
get the most production out of the cells 9 sent to Production Stage CSTR 4. Cells 9
are not recycled to the Growth Stage CSTR. Liquid Product 10 consisting of dilute
ethanol in the fermentation broth is produced as the final distillation product, and is
recovered as anhydrous ethanol as in Fig. 1.
DETAILED DESCRIPTION OF THE INVENTION
The present invention involves methods for the anaerobic fermentation of
gaseous substrates containing at least one reducing gas, particularly the gaseous
components of industrial waste and synthesis gases (e.g., CO, CO2 and H2) to ethanol.
These methods yield ethanol productivities greater than 10 g/L day by manipulating
the biological pathways of the subject bacteria. One method of the invention causes
an abundance of NAD(P)H over NAD(P). The oxidation of NAD(P)H to NAD(P)
causes acetic acid produced by the culture to be reduced to ethanol. Alternatively,
other methods for the production of high concentrations of ethanol in an anaerobic
fermentation of this invention involve reducing the redox potential of the fermentation
broth, and thereby reducing acetic acid to ethanol. The methods of this invention
produce high ethanol concentrations (i.e., greater than about 10 g/L, and preferably
greater than about 15 g/L) and low acetate concentrations (i.e. less than about 5 g/L
free acetic acid in the bioreactor). These methods also maintain and control method
conditions for continuous ethanol and acetic acid production to help the system
recover rapidly from method upsets. Further, the methods of this invention help
prevent culture acclimation to low nutrient concentration, which can be detrimental to
culture performance. The present invention provides a viable commercial method for
ethanol production.
I. Definitions
Unless otherwise defined, the following terms as used throughout this
specification are defined as follows.
The term "continuous method" as used herein refers to a fermentation method
which includes continuous nutrient feed, substrale feed, cell production in the
bioreactor, cell removal (or purge) from the bioreactor, and product removal. This
continuous feeds, removals or cell production may occur in the same or in different
streams. A continuous process results in the achievement of a steady state within the
bioreactor. By "steady state" is meant that all of these measurable variables (i.e., feed
rates, substrate and nutrient concentrations maintained in the bioreactor, cell
concentration in the bioreactor and cell removal from the bioreactor, product removal
from the bioreactor, as well as conditional variables such as temperatures and
pressures) are constant over time.
The term "gaseous substrates" as used herein means CO alone, CO and H2,
CO2 and H2, or CO, CO2 and H2, optionally mixed with other elements or compounds,
including nitrogen and methane in a gaseous state. Such gaseous substrates include
gases or streams, which are typically released or exhausted to the atmosphere either
directly or through combustion. In some embodiments of this method the gaseous
substrate comprises CO. In other embodiments of this method, the gaseous substrate
comprises CO2 and H2. In still other embodiments, the gaseous substrate comprises
CO and H2. In a particularly preferred embodiment, the gaseous substrate comprises
CO, CO2 and H2. Still other substrates of the invention may include those
components mentioned above and at least one gas of nitrogen, CO2, ethane and
methane. Thus, such substrates include what is conventionally referred to as "syngas"
or synthesis gas from the gasification of carbon products (including methane), as well
as waste gases from a variety of industrial methods.
The term "reducing gas" means either or both CO or H2. By the phrase "an
amount of reducing gas greater than that required for growth of the bacteria" is mean
that amount of reducing gas that exceeds the amount that the bacteria can use for
growth or metabolism, given the nutrient medium ingredients. This amount can be
achieved by increasing the net amount of reducing gas, or by reducing key nutrient
ingredients, so that the excess amount of gas is achieved without increasing the gas,
or by increasing the rate of gas delivery to the bacteria. When the bacteria are
exposed to more reducing gas than required for growth, the bacteria respond by
increasing the producing of ethanol.
"Subject bacteria" are acetogenic anaerobic (or facultative) bacteria, which are
able to convert CO and water or H2 and CO, into ethanol and acetic acid products.
Useful bacteria according to this invention include, without limitation, Acetogenium
kivai, Acetobacterium woodii, Acetoanaerobium noterae, Clostridium aceticum,
Butyribacterium methylotrophicum, C. acetobutylicum, C. thermoaceticun,
Eubacterium limosum, C. Ijungdahlii PETC, C Ijiungdahlii ERI2, C. ljungdahlii C-
01, C. Ijimgdahlii O-52, and Peptostreptococcus productus. Other acetogenic
anaerobic bacteria are selected for use in these methods by one of skill in the art.
By the term "mixed strains," it is meant a mixed culture of two or more of the
subject bacteria. Such "mixed strains" of the bacteria enumerated hereinabove are
utilized in the methods of this invention.
The terms "bioreactor," "reactor," or "fermentation bioreactor," include a
fermentation device consisting of one or more vessels and/or towers or piping
arrangement, which includes the Continuous Stirred Tank Reactor (CSTR),
Immobilized Cell Reactor (ICR), Trickle Bed Reactor (TBR), Bubble Column, Gas
lift Fermenter, Static Mixer, or other device suitable for gas-liquid contact. Preferably
for the method of this invention, the fermentation bioreactor comprises a growth
reactor which feeds the fermentation broth to a second fermentation bioreactor, in
which most of the product, ethanol, is produced.
"Nutrient medium" is used generally to describe conventional bacterial growth
media which contain vitamins and minerals sufficient to permit growth of a selected
subject bacteria. Sugars are not included in these media. Components of a variety of
nutrient media suitable to the use of this invention are known and reported in prior
publications, including those of the inventors. See, e.g. the nutrient media formulae
described in International Patent Application No. WO98/00558; U.S. Patent No.
5,807,722; U.S. Patent No. 5,593,886, and U.S. Patent No. 5,821,111, as well as in
the publications identified above. According to the present invention, a typical
laboratory nutrient medium for acetate production from CO, CO2, and H2 contains 0.9
mg/L calcium pantothenate. However, a typical laboratory nutrient medium for
ethanol production from CO, CO2, and H2 contains 0.02 mg/L calcium pantothenate.
The terms "limiting substrate" or "limiting nutrient" define a substance in the
nutrient medium or gaseous substrate which, during bacterial culture growth in the
bioreactor, is depleted by the culture to a level which no longer supports steady state
or stable bacterial growth in the bioreactor. All other substances in the nutrient
medium or gas substrate are thus present in excess, and are "non-limiting". The
evidence for limitation is that an increase in the rate of addition of the limiting
substrate, i.e. in the nutrient feed rate or gas feed rate, to the culture causes a
corresponding increase in the rate of gas uptake (mmol/min of gas) due to increase in
cell density.
Unless stated otherwise, the term "acetate" is used to describe the mixture of
molecular or free acetic acid and acetate salt present in the fermentation broth. The
ratio of molecular acetic acid to acetate is dependent upon the pH of the system, i.e.,
at a constant "acetate" concentration, the lower the pH, the higher the molecular
acetic acid concentration relative to acetate salt.
"Cell concentration" in this specification is based on dry weight of bacteria
per liter of sample. Cell concentration is measured directly or by calibration to a
correlation with optical density.
The term "natural state" describes any compound, element, or pathway having
no additional electrons or protons that are normally present. Conversely, the term
"reduction state" describes any compound, element, or pathway having an excess of
one or more electrons. The "reduction state" is achieved by adding one or more
electrons to the "natural state", i.e. by lowering the redox potential of the
fermentation broth.
"Ethanol productivity" is the volumetric productivity of ethanol, calculated as
the ratio of the steady state ethanol concentration and the liquid retention time (LRT)
in continuous systems, or the ratio of the ethanol concentration and the time required
to produce that concentration in batch systems. The phrase "high ethanol
productivity" describes a volumetric ethanol productivity of greater than 10 g/L•day.
The phrase "high concentration of ethanol" means greater than about 10 g/L,
preferably greater than 15 g/L ethanol in fermentation broth or a product ratio of
ethanol to acetate of 5:1 or more.
"Excess H2" is available for ethanol production when the ratio of the moles of
H2 in the feed gas to the sum of two times the moles of CO converted and three times
the moles of CO2 converted is greater than 1.0. If this ratio is less than 1.0, excess H2
is not available and ethanol can only be produced through a different controlling
mechanism.
II. The Biological Pathways Utilized in the Method of this Invention
Without wishing to be bound by theory, the inventors theorize that the
methods for increasing the anaerobic production of ethanol from the methods
described herein are based upon the biological pathways involving the conversion of
NAD(P)H to NAD(P) in the basic pathway cycles of the acetogenic pathway for
autotrophic growth. The invention involves manipulating those pathways to enable
continuous production and maintenance of high concentrations of ethanol with low
acetate concentrations under stable operating conditions, thereby providing
commercially useful methods for ethanol production from industrial gases.
The essential involvement of NAD(P)H to NAD(P) in the biological pathways
is described as follows: The production of ethanol from gaseous components, such as
CO, CO2, and H2 occurs in a three step biological method. In the first step, the
substrates CO and H2 are oxidized and, in doing so, release NAD(P)H:
NAD(P)? NAD(P)H
CO + H2 + H2O? CO2 + 4H+
The products of step 1 are then converted to acetic acid, a step that requires
NAD(P)H:
NAD(P)H? NAD(P)
CO + CO2 + 6 H+ ? CH3COOH + H2O
Finally, if excess NAD(P)H is available because the reaction of step 1 proceeds at a
faster rate than the reaction of step 2, acetic acid is reduced to ethanol.
NAD(P)H? NAD(P)
CH3COOH + 4H+ ? C2H5OH + H2O
Thus, the availability of excess NAD(P)H from substrate oxidation leads to the
production of ethanol from acetic acid.
There are two known basic pathway cycles in the acetogenic pathway: (1) the
Acetyl-CoA cycle and (2) the THF cycle, in which CO, is reduced to a methyl group.
The sequence for the generation of ethanol and acetic acid therefrom is illustrated in J.
R. Phillips et al., 1994 Applied Biochemistry and Biotechnology, 45/46:145. The
Acetyl-CoA cycle has an inner cycle, referred to herein as the CO cycle. As the CO
cycle normally reacts clockwise, ferredoxin is reduced. Ferredoxin can also be
reduced by H2 as it is oxidized on the enzyme hydrogenase. As a result, the Acetyl-
CoA cycle also reacts clockwise, and ferredoxin is oxidized. If the inner CO cycle and
the Acetyl-CoA cycle react at the same rates, ferredoxin is in a redox-state
equilibrium. If however, these two cycles do not occur at the same rate, i.e., the CO
cycle reacts at a faster rate than the Acetyl-CoA cycle, reduced ferredoxin is built up.
Also with excess H2, reduced ferredoxin can also be produced in excess. This excess
reduced ferredoxin causes the NAD(P) to be regenerated (reduced) to NAD(P)H,
which builds an excess that must be relieved to equilibrium and in doing so, reduces
acetic acid to ethanol.
The THF cycle functions for cell growth and is necessary for a continuous
culture; therefore it cannot be completely stopped. Reducing the THF cycle rate also
serves to cause a higher NAD(P)H to NAD(P) ratio. NAD(P)H is oxidized in two
places. By limiting this oxidation, which would keep the total cellular NAD(P)H to
NAD(P) ratio in balance, the NAD(P)H is used to reduce acetic acid to ethanol
A second basic method of causing acetic acid to be reduced to ethanol is by
directly lowering the redox potential of the fermentation broth. A reduction state
sufficiently lower than the natural state of the culture causes NAD(P)H to be in
abundance and promote the reduction of acetic acid to ethanol.
III. The Methods of the Invention
The basic steps of the method include the following: A continuous
fermentation method with product recovery is described by reference to Fig. 1 and
exemplified in Example 1 below. A continuous flow of gaseous substrate 1
comprising at least one reducing gas, e.g., CO or H2, is supplied at a selected gas feec
rate and a continuous flow of liquid phase nutrient medium 2 at a selected nutrient
feed rate are supplied to a fermentation bioreactor 3 containing a subject bacteria. In
the bioreactor 3, the medium and gaseous substrate are fermented by the bacteria to
produce ethanol and acetate acid. Once a stable cell concentration is achieved under
steady state conditions, the components of the continuous system are manipulated to
reduce the redox potential, or increase the NAD(P)H to NAD(P) ratio, in the
fermentation broth, while keeping the free acetic acid concentration in the bioreactor
less than 5g/L. The methods of this invention are designed to permit and maintain
production of ethanol and acetate in the fermentation broth such that the ethanol
productivity is greater than 10 g/L•day at an ethanol to acetate ratio of between 1:1
and 20:1. In one embodiment, that ratio is greater than 3:1. In another embodiment,
that ratio is greater than 5:1. In still another embodiment, that ratio is greater than
10:1. In still another embodiment that ratio is greater than 15:1. The method of this
invention is alternatively effective in enhancing stable continuous (steady state)
production of high ethanol concentrations (15-35 g/L ethanol) and low acetate
concentrations (0-5 g/L acetate), i.e., ethanol to acetate product ratio of 3:1 or more,
from CO, CO2, and H2 with good method stability.
Periodically, during the course of the methods of this invention, samples of th
broth are removed to determine the ratio by a conventional assay method. For
example, the cells are separated from the sample, e.g., by centrifugation and the cell-
free sample is then subject to an assay method, such as the preferred method of gas
chromatography. However, other conventional assay methods are selected by one of
skill in the art. The additional optional steps of the method are added to achieve
and/or maintain the ratio. Example 2 demonstrates such an assay method.
Steps used to manipulate the system components and maintain and/or achieve
the desired ethanol productivity or the ethanol to acetate ratio include at least one,
and desirably, combinations of the following steps: altering nutrient medium contents,
nutrient feed rate, aqueous feed rate, operating pressure, operating pH, gaseous
substrate contents, gas feed rate, fermentation broth agitation rate, avoiding product
inhibition step, decreasing cell density in the bioreactor, or preventing substrate
inhibition. Some preferred manipulations include supplying the bioreactor with liquid
phase nutrient (pantothenate or cobalt) limitation, a slight excess of CO and H2 in the
feed gas, minimizing acetate concentration, avoiding culture acclimation to low liquid
phase nutrient concentrations, bringing the culture to a suitable cell concentration at a
relatively fast rate, raising the pH of the culture above 4.5, purging bacterial cells from
the bioreactor to a cell concentration less than the stable steady state concentration
that utilizes all reducing gas or nutrient substrates in the bioreactor and increasing the
aqueous feed rate when the free acetic acid portion of the acetate present in the
fermentation bioreactor broth exceeds 2g/L, thereby inhibiting any unwanted increase
in the concentration of free acetic acid. All of these steps are described in detail
below.
Exhaust gas 4 containing gases other than CO, CO2 and H2 and unconverted
CO, CO2 and H2 from the reactor are vented from the reactor and are used for their
fuel value. If excess H2 as a controlling mechanism is employed, the H2 partial
pressure in the outlet gas and ratio of H2 partial pressure to CO2 partial pressure in the
exit gas are used to identify the control of the ethanol to acetate ratio by that step.
Cell recycle is used (but is not required) to increase the concentration of cells inside
the bioreactor, and thus provide more biocatalyst for CO, CO2 and H2 conversion.
With cell recycle, liquid effluent from the reactor 5 is sent to a cell separator 6 where
the cells 7 and permeate (cell free liquid) 8 are separated. The cells 7 are sent back to
the bioreactor and the permeate 8 is sent to product recovery.
Cell separation is accomplished by using a continuous centrifuge, hollow fiber
or spiral wound filtration system, ceramic filter system or other solid/liquid separator.
Ethanol can be recovered from the permeate (or alternatively the effluent from the
reactor 5 if cell separation is not employed) by a variety of techniques including
distillation and adsorption. Permeate 8 is separated in a distillation column to produce
95% ethanol overhead 10, and water 11 for recycle back to the reactor 3. The recycle
water 11 contains excess nutrients not used in the fermentation, but any excess
vitamins from fermentation or cell lysis are destroyed by thermal distillation. The 95%
ethanol overhead 10 is sent to a molecular sieve 12 where anhydrous ethanol 13, the
desired final product, is separated from dilute ethanol 14 which is sent back to the
distillation column 9.
The continuous combination of growth, death and cell purge maintains a
constant cell concentration, such that a continuous method used in producing ethanol
(and small amounts of acetic acid) can operate for many months by being fed CO, CO2
and H, along with nutrients without additional culture supplementation. The methods
of this invention maintain and control conditions for continuous ethanol and acetic
acid production and prevent or correct rapidly for method upsets. The methods of
this invention also help prevent culture acclimation to low nutrient concentration,
which can be detrimental to culture performance. In the descriptions below and in the
examples, unless otherwise indicated, the pressure used is 1 atmosphere and the
temperature used is between 36-41°C. Desirable temperatures and pressures may be
determined by one of skill in the art, depending on the microorganism selected for use
in the bioreactor.
A variety of manipulations, described specifically below, added to the basic
steps of this invention permit the enhanced production of ethanol. Preferably, liquid
phase nutrient limitation (pantothenate or cobalt) or the use of excess H2 or CO are
the method steps of the invention, described in detail below, used to achieve and
maintain the desired ethanol productivity and permit production of stable
concentrations and ratios of ethanol to acetate in the fermentation broth. These
conditions permit production of stable concentrations of ethanol and acetate in the
fermentation broth. In a preferred embodiment, the ethanol to acetate product ratio
produced in the fermentation broth is greater than 10:1 and the ethanol concentration
is greater than 15 g/L.
A. Calcium Pantothenate Limitation
In one specific embodiment of this invention, the method for manipulating the
biological pathways to favor ethanol production and limit acetic acid production
involves limiting the amount of calcium pantothenate in the nutrient medium to an
amount which is less than required to maintain the bacteria at a stable, steady state
concentration that would fully utilize the calcium pantothenate provided.
Pantothenate is a component of Acetyl-CoA and therefore, by limiting calcium
pantothenate in the nutrient medium, the Acetyl-CoA cycle rate is reduced relative to
the CO cycle rate. This causes a build-up of reduced ferredoxin and the reduction of
NAD(P) to NAD(P)H, and thereby increases the production of ethanol as the final
product.
Pantothenate limitation is observed when the micrograms (g) of calcium
pantothenate fed to the reactor per gram (g) of cells (dry weight) produced in the
reactor is in the range of 0.5 to 100. A more desirable pantothenate limitation is in the
range of 2 to 75 µg of calcium pantothenate per gram (g) of dry cells produced in the
reactor. Still a preferred pantothenate limitation is in the range of 0.5 to 50 µg of
calcium pantothenate per gram (g) of cells produced in the reactor. Another
embodiment of this limitation is at about 1-25 µg of calcium pantothenate per gram
(g) of cells produced in the reactor. Another embodiment of this limitation is at about
10-30 µg of calcium pantothenate per gram (g) of cells produced in the reactor. This
amount of the nutrient maintains ethanol production in preference to acetate
production. One embodiment of this method is illustrated in Example 4.
In another aspect of this method, the acclimation of the bacteria in the
fermentation bioreactor to low limiting calcium pantothenate concentration is avoided
by regulating or adjusting the fermentation parameters, so that a constant calcium
pantothenate concentration is maintained, while at least one, and sometimes more than
one, parameter of gas feed rate, liquid feed rate, agitation rate, or H2 partial pressure
is adjusted. Major changes in nutrients are avoided, but a relatively constant nutrient
feed concentration is maintained. If the culture is allowed to acclimate to low liquid
phase limiting nutrients, poor product ratios of 1.0 g ethanol/g acetate or less occurs
in an irreversible method. Thus, reactor shut down and reinoculation is necessary.
Preferably, the biological pathway is controlled to favor ethanol production and limit
acetic acid production by first supplying excess H2 in the feed gas to the bioreactor,
and then limiting calcium pantothenate in the nutrient medium as described above.
In fact, at start-up, the normally limiting liquid phase nutrient calcium
pantothenate is kept in excess to avoid acclimation to low nutrient concentrations, a
condition that can result in very poor performance and the loss of the culture"s ability
to produce achieve high ethanol productivities of more than 10 g/L•day if excess H2 is
not employed. An example of such regulation of fermentation parameters for a
particular bacterial culture is illustrated in Example 17.
B. Cobalt Limitation
In another embodiment of this invention, the method for manipulating the
biological pathways to favor ethanol production and limit acetic acid production
involves limiting the amount of cobalt in the nutrient medium to an amount which is
less than required to maintain the bacteria at a stable steady state concentration that
would fully utilize the cobalt provided. Cobalt limitation is observed when the
micrograms (µg) of cobalt fed to the reactor per gram (g) of cells (dry weight)
produced in the bioreactor is in the range of 5 to 100. Preferably, a cobalt limitation
involves providing between about 20 to 50 µg of cobalt to the reactor per gram of
cells produced in the reactor. This amount of cobalt maintains ethanol production in
preference to acetate in the process. Example 15 illustrates an embodiment of the
method of limiting cobalt to the reactor according to this method.
Limiting cobalt in the fermentation broth may also reduce the Acetyl-CoA
cycle rate. Because cobalt is used to transfer a methyl group from the THF cycle to
the Acetyl-CoA cycle, limiting the amount of cobalt in the fermentation broth also
reduces the THF cycle function by not permitting the transfer. Cobalt limitation
reduces the THF cycle rate, which also causes a higher NAD(P)H to NAD(P) ratio,
thereby producing ethanol.
The method is further manipulated by preventing acclimation to low limiting
cobalt concentration. In much the same manner as acclimation to low pantothenate
concentrations is avoided, a constant cobalt concentration is maintained while
adjusting one or more of the fermentation parameters (gas rate, liquid rate, agitation
rate, CO2 content, and H2 gas partial pressure). Major changes in nutrients is avoided,
but instead a relatively constant nutrient feed concentration is maintained. An
example of such regulation of fermentation parameters for a particular bacterial
culture is illustrated in Example 19.
Preferably, the biological pathway is controlled to favor ethanol production
and limit acetic acid production by first feeding excess H2 to the reactor and then
limiting cobalt in the nutrient medium as described above. At start-up, the limiting
liquid phase nutrient cobalt is kept in excess to avoid acclimation to low nutrients
concentration, a condition that can result in very poor culture performance and the
loss of the culture"s ability to produce product ratios greater than 1:1.
C. Oversupplving Hydrogen
In still another embodiment, the method for manipulating the biological
pathways to favor ethanol production and limit acetic acid production involves feeding
excess H2 in the feed gas or limiting gaseous carbon which results in excess H2, which
is then used by the biological pathway. Preferably, the H2 reducing gas is in excess
relative to CO, and the excess H2 causes the bacteria to produce a high ethanol to
acetate ratio in the fermentation broth. If the ratio of the H2 (moles of gas fed) to the
sum of two times the CO ( in moles of gas) converted and three times the CO, (in
moles of gas) converted is greater than 1, the fermenter is carbon limited. The H2
partial present in the exit gas is preferably greater than 0.4 atm. Finally the ratio of H2
partial pressure to CO2 partial pressure must be greater than 3.0 to assure that
sufficient H2 is available to use all the CO2. If the CO, partial pressure is greater than
0.1 atm, it is likely that growth has been otherwise limited. See, Example 20 for an
illustration of this method step.
During start-up, the use of excess H2 is favored over nutrient limitation, mainly
because it is easier to control. The benefits of employing excess H2 are that it avoids
excess acetic acid production, which can lead to poor product ratios and potential
acetic acid inhibition, as well as acclimation to low nutrient concentrations.
D. Oversupplying Carbon Monoxide
Another way of manipulating the components of the method involves
oversupplying the reducing gas, CO, in the gaseous substrate for use in the pathway,
which serves to directly lower the redox potential in the fermentation broth. Thus,
according to this embodiment, the bioreactor is suppled with gaseous substrate
comprising CO where the amount of CO present in the bioreactor is greater than the
amount required to maintain the bacteria at a stable, steady state concentration that
would fully utilized the CO provided. CO oversupply as a method of favoring ethanol
production over acetic acid production when the specific rate of CO uptake
(millimoles of CO per gram of cells (dry weight) in the reactor per minute, or mmol/g
cell"min) is greater than 0.3. More preferably, this step involves a specific rate of CO
uptake of greater than 0.5. This means that each cell on the average is utilizing CO in
its metabolism at a rate of at least 0.3 mmol/g•min., or more ideally at a rate of at least
0.5 mmol/g•min. Preferably, the CO is provided at a rate at which the CO uptake is
from 0.3 to 2 mmol CO/gram cell (dry weight) of bacteria/minute. In another
embodiment, the CO is provided at a rate of from 0.5 to 1.5 mmol CO/gram cell (dry
weight) of bacteria/minute. In another embodiment, the CO is provided at a rate of
about 1 mmol CO/gram cell (dry weight) of bacteria/minute. Example 24 provides an
illustration of one embodiment of this method step.
This rate of CO uptake maintains ethanol production in preference to acetate
production. If CO is supplied such that the dissolved CO in the fermentation broth is
significant by gas pressure or extremely good mass transfer, the fermentation broth
becomes more reduced. Oversupply of CO has two additional benefits. Excess CO
may cause the CO cycle to operate at a faster rate, and if the Acetyl-CoA. cycle is
otherwise limited and cannot keep up with the CO cycle, reduced ferredoxin builds-
up. CO may also slow down step 2 (production of the intermediate acetic acid) in the
overall three-step method through substrate inhibition. This decreased rate of step 2
in relation to step 1 causes an excess of NAD(P)H, which leads to ethanol production
in favor of acetic acid.
Although excess CO can result in increased ethanol production by directly
reducing the redox potential of the fermentation broth, the presence of excess CO also
inhibits growth by inhibiting the CO-dehydrogenase and therefore the uptake of H2.
The presence of excess CO unfortunately also results in poor H2 conversion, which
may not be economically favorable. The consequence of extended operation under
substrate inhibition is poor H2 uptake. This eventually causes cell lysis and necessary
restarting of the reactor. Where this method has an unintended result of CO substrate
inhibition (the presence of too much CO for the available cells) during the initial
growth of the culture or thereafter, the gas feed rate and/or agitation rate is reduced
until the substrate inhibition is relieved. An illustration of how to adjust the gas rate
or agitation rate to accomplish this effect is illustrated in Example 21.
E Additional Manipulating Steps
In addition to the major method enhancing steps described above, several
method steps are desirably included in the ethanol production method.
J. Increasing Mass Transfer
One such additional embodiment involves ensuring that the mass
transfer of the CO or H2 from the gas feed to the liquid fermentation broth is faster
than the ability of the bacteria to utilize the dissolved gases. For example, if a
bioreactor containing C. Ijungdahlii is fed CO, CO2 and H2 and is operated without
limitation on nutrients (such as pantothenate or cobalt) or the presence of excess H2,
cell growth is limited by the amount of gas transferred into the liquid phase and the
system produces acetic acid as the product. If the culture is fed a slight amount of CO
or H2 in excess of that required for culture growth, it produces ethanol. However, if
too much gas is transferred into the liquid phase for the culture to use, substrate
inhibition occurs, which can lead to culture upset and cell death. Thus, there is a very
narrow range of operation with excess mass transfer. Example 22 provides an
illustration of this method.
With reference to the Acetyl-CoA cycle, in order for the excess
reduced ferredoxin to be produced, the CO cycle or the reduction of ferredoxin
through hydrogenase must occur faster than the Acetyl-CoA cycle. The methods
described herein limit the rate at which the organisms can utilize the dissolved gases
by restricting the rate at which essential nutrients, e.g., calcium pantothenate or cobalt,
or other substrates, such as CO, gas, are available to the bacteria, or by providing
excess substrate, H2 or CO to the culture.
A theoretical rate of mass transfer, which is faster than the rate at
which the bacteria can use substrate, even without other limitations, can be calculated.
That rate, when achieved, is limited by the natural growth rate of the organism.
Therefore, the most productive embodiment is where the mass transfer (gas flow rate
or agitation rate) is faster than the rate at which the highest possible concentration of
cells can utilize the substrate without any limitation. There would be a very narrow
operating range since substrate inhibition could quickly cause cell death and a
resulting by-product concentration which is toxic to the culture.
2. Supplying excess CO and H2
In another embodiment of a method of this invention, stability in the
high ethanol concentration/limited acetic acid production is achieved in the methods
which limit cobalt or calcium pantothenate, or provide an abundance of H2 or CO.
According to this step, as the culture uses the gaseous substrates CO, H2 and CO2 as
the carbon and energy sources, CO and H2 are supplied in slight excess. A slight
excess of CO and H2 is achieved by attaining steady operation and then gradually
increasing the gas feed rate and/or agitation rate (10% or less increments) until the
CO and H2 conversions just start to decline. This is one means of avoiding mass
transfer limitation, which favors acetic acid production, and supplying excess reduced
ferredoxin in order to reduce NAD(P) to NAD(P)H and produce ethanol. If CO and
H2 are not supplied in slight excess, mass transfer limitation occurs, and the pathway
is balanced. This results in poor ethanol to acetate product ratios (high acetate
concentrations). High acetate concentrations can ultimately result in acetic acid
inhibition, which limits the ability of the bacterium to take up H2 and can eventually
lead to culture failure.
Steps to avoid mass transfer limitation include an increase in the
agitation rate or gas rate to transfer more CO and H2 into the liquid phase, and thus
return to the presence of a slight excess CO and H2. If product inhibition occurs as a
result of mass transfer limitation, it is necessary to increase the liquid feed rate to clear
the acetic acid inhibition, by diluting to a lower resulting acetate concentration. Since
increasing the medium feed rate would increase the µg pantothenate or cobalt/g-cell
produced, this must be done only briefly or the excess pantothenate or cobalt must be
eliminated by adjusting the medium concentration or increasing the water feed rate.
3. Controlling acetic acid product inhibition
Where in the methods described above, acetic acid product inhibition
can occur if too much molecular acetic acid, i.e., >2 g/L, accumulates in the
bioreactor to allow cell growth and further ethanol production. Another manipulating
step is used to avoid culture failure. One modification involves briefly increasing the
liquid or aqueous feed rate to reduce the liquid phase concentration of inhibiting acetic
acid to lower than 2 g/L. An illustration of this step for a particular culture in a
reactor is demonstrated in Example 23.
4. Water recycle step
Still another optional method step for maintaining a stable culture
which produces ethanol as the only product with no net acetic acid production in the
methods of this invention involves adding water recycle from distillation back to the
fermentation reactor (see, e.g., Example 15). As was noted earlier, water (contair ng
up to 5 g/L acetate) recycle has the benefit of recycling the produced acetate back to
the reactor so that no net acetic acid is produced. An equilibrium is thus established
between the ethanol and acetate in the reactor. As a result, all CO, CO2 and H2 fed tc
the reactor and converted to products results in ethanol production, except for that
used for culture maintenance.
5. Reducing Cell Density
Still another manipulating step useful in the method is to initiate
periodic or continuous purging of bacterial cells from the bioreactor to reduce the cell
concentration in the bioreactor. This manipulation serves to reduce the cell
concentration to less than a stable, steady state cell concentration that utilizes all
reducing gas or nutrient substrates in the bioreactor. By thus, altering the cell density,
the production of ethanol is favored over the production of acetate in the bioreactor.
See, e.g., Example 25.
6. Two Stage CSTR
One of the problems associated with ethanol production with medium
limitation is the ability or tendency of the culture to eventually adapt to the limiting
conditions and not continue to produce ethanol after several months of operation.
Instead acetate iscome eventually the dominant product. This acclimation to low
limiting nutrient concentrations results in a culture which produces more acetic acid
than ethanol (ethanol to acetate product ratio of 1.0 or less), and yields low ethanol
concentrations (sometimes as low as 1 g/L). Adaptation most likely occurs when the
culture is not provided with sufficient nutrients during start-up, where growth rate is
more important than ethanol production rate. Additionally, there is a danger that the
culture can be acclimated to low limiting nutrient concentrations during steady state
operation particularly as the limiting nutrient concentrations are adjusted downward to
rid the reaction system of acetate.
To avoid this adaptation when using the pantothenate or cobalt limiting
steps above, instead of allowing the culture to grow with the available nutrients, and
the danger mentioned above, another modification of the method can be employed. A
two-stage CSTR system where primarily good culture growth occurs in the first stage
on a slight excess of limiting nutrients (perhaps with accompanying acetic acid
production), followed by a production stage where the culture from the first stage is
now limited by the limiting nutrient and is used to produce high concentrations of
ethanol, is another modification of the method. This modification enables the
maintenance of a stable culture, which does not acclimate to reduced pantothenate or
cobalt concentrations. This modification involves operating a two-stage CSTR, in
which a growth reactor (Stage 1) to feed a production reactor (Stage 2) where the
bulk of the ethanol production occurs. The growth reactor is not operated with the
nutrient limitation steps described above, so the culture is not as susceptible to
acclimation to a limited condition.
A schematic diagram of this two-stage CSTR system is shown in Fig.
2, and the following description has reference to that figure. According to this
embodiment, the Growth Stage is operated at a liquid retention time (LRT) of about
24 hours. The Growth Stage CSTR 1 is fed enough pantothenate or cobalt in the
medium 2 to yield a healthy culture (and may produce some acetic acid as well).
Thus, excess acetic acid is produced in the reactor, but with increased stability. This
pantothenate or cobalt concentration is in excess of what would normally be fed to a
single CSTR used to produce ethanol. The gas feed to this reactor is unconverted gas
3 from the Production Stage 4 and the liquid feed is fresh medium 2 The Growth
Stage CSTR is operated without cell recycle. The purpose of this Growth Stage
reactor is to provide a healthy culture for later ethanol production that does not
acclimate to low pantothenate concentrations.
The Production stage reactor 4 is operated at a nominal LRT of less
than 20 hours. This CSTR with cell recycle is fed a fresh gas feed 5, and may have
low conversions. It is fed fresh medium feed 6 as well as culture feed 7 from the
Growth Stage. Minimal pantothenate or cobalt is fed to this reactor since the excess
from the Growth Stage is available. Cell recycle 8 is used in this reactor in order to
get the most production out of the cells sent back to the reactor 9. The exit ethanol
concentration in the liquid product 10 should be greater than 20 g/L. The features of
the two-stage CSTR system include little change for acclimation to low pantothenate
or cobalt concentrations; an overall LRT of less than or equal to 30 hours; an
expected greater ethanol productivity and higher ethanol concentration than from a
single CSTR of the same size.
7. Start-up modifications
Still other method steps, which are preferably utilized in the practice of
this invention, involve cell production in the initial start-up of the fermentation culture.
The start-up of a bioreactor fed CO, CO2 and H2 to produce ethanol and acetic acid is
accomplished by batch inoculation from stock culture (Example 11) or by employing a
continuous inoculum from an existing reactor as culture feed (Example 12). As noted
earlier in the discussion of avoiding culture acclimation to low pantothenate or cobalt
concentrations, the culture is most desirably brought up to a high cell concentration
prior to limiting nutrients, but supplying excess H2 to the culture. This rapid start-up
avoids culture acclimation and yields good product ratios (high ethanol and low
acetate concentrations). If the rapid start-up is not employed, poor product ratios can
occur and the culture can acclimate to low liquid phase nutrient concentrations and
require reactor reinoculation.
The reactor is started with a batch liquid phase (liquid medium is not
initially fed continuously to the reactor), at low agitation rates (perhaps 400-600 rpm
in a laboratory New Brunswick Scientific Bioflo® reactor) and at the desired pH. The
liquid phase in the reactor thus consists of a batch of nutrient medium containing
vitamins and salts, with a nominal concentration of limiting nutrient, either calcium
pantothenate or cobalt (20 µg/L pantothenate or 75 ppb cobalt as an example). If
continuous inoculum from an existing reactor is employed, batch liquid phase
operation likely is not necessary. In this case, gas is fed continuously to the reactor
during initial start-up at a slow rate. Ideally, the gas phase at start-up would be CO2-
free, H2-abundant and the gas rate and agitation rate would be kept at low levels to
avoid CO substrate inhibition.
An exemplary general start-up protocol for producing and sustaining
commercially viable ethanol concentrations from CO, CO2 and H2 consists of three
distinct phases: (a) initial start-up, where cell production is critical; (b) start-up where
production rate becomes critical; and (c) steady state operation. Essentially, initial
start-up is characterized by inoculation of a batch liquid, with a nominal limiting
nutrient, selected from cobalt (75 ppb) or calcium pantothenate (20 µg/L) at a desired
pH (typically 4.5-5.5) To facilitate start-up, the gas feed rate and agitation rate are
preferentially kept low, while H, is fed in excess. The cause of ethanol production
during start-up is excess H2; nutrient limitation occurs later. Thus, excess liquid
nutrients are actually present during start-up to avoid unwanted culture acclimation to
low nutrients. As the fermentation proceeds over a period of several hours after
inoculation, CO2 is produced and H2 is consumed. The changes in these rates
indicated that the agitation rate should be nominally increased slowly (perhaps by 200-
300 rpm in a laboratory reactor, over a period of 2-3 days) to avoid mass transfer
limitation.
This onset of CO2 production occurs much more rapidly in systems
employing continuous inoculation as opposed to batch inoculation from stock culture.
However, if the agitation rate is increased too fast, CO substrate inhibition occurs.
This procedure of watching H2 conversion (or CO2 production) while nominally
increasing agitation rate occurs at a relatively rapid rate until the target agitation rate
is reached. During this time of increasing agitation rate in batch liquid culture, cell
production instead of product formation is of utmost importance.
Once the target agitation rate is reached (800-1000 rpm in laboratory
New Brunswick Scientific Bioflo® reactor), the culture is allowed to steady to confirm
H2 uptake. The start-up shifts to a mode in which production rate becomes important.
It is desirable to have CO conversions exceeding 80% and a high H2 partial pressure in
the exit gas (at least 0.55 atm) to assure ethanol production while limiting acetate and
the free molecular acetic acid concentration. The liquid medium feed rate is then
turned on (for systems having batch inoculation from stock culture) to initiate
continuous liquid feed and the gas rate is increased in 10% increments toward the
target flow rate. H2 remains in excess to avoid excess acetic acid production. As the
gas rate is increased, the liquid phase nutrients are limited (calcium pantothenate or
cobalt), and the effect of such limitation is a small drop in H2 conversion, at the target
production.
At steady state operation, production of 15-35 g/L ethanol and 0-5 g/L
acetate is reached. At this stage, small adjustments in limiting nutrients, liquid feed
rates and gas feed rates are needed, and are chosen by one of skill in the art with
resort to knowledge extant in the art as well as the teachings of this invention. If cell
recycle is to be added to the method of ethanol production, it is added at this time
along with an adjustment in gas rate (increase) and nutrient concentration (decrease).
The above described methods of continuously producing and maintaining high
concentrations of ethanol with low by-product acetate concentrations under stable
operating conditions enhance the use of the subject bacteria on a commercial scale for
ethanol production. The steps outlined in the methods above overcome the limitation:
of utilizing the subject bacteria for commercial ethanol production from CO, CO2 and
H2. Preferably the method employs a continuous bioreactor, although batch and fed-
batch fermentation methods are also used, but are not likely to be economically viable
for large-scale ethanol production.
The following examples illustrate various aspects, methods and method steps
according to this invention. These examples do not limit the invention, the scope of
which is embodied in the appended claims.
EXAMPLE 1. AN EXEMPLARY METHOD OF THE PRESENT INVENTION
A synthesis or waste gas containing CO and/or CO2/H2 is continuously
introduced into a stirred tank bioreactor containing a strain of C. Ijungdahlii, along
with a conventional liquid medium containing vitamins, trace metals and salts. One
desirable nutrient medium is reported in Table 1 below.
During method start-up using a culture inoculum of 10% or less the reactor is
operated with a batch liquid phase, where the liquid medium is not fed continuously t
the reactor. The liquid phase in the reactor thus consists of a batch of nutrient
medium with a nominal concentration of limiting nutrient, either calcium pantothenat
or cobalt. Alternatively, a rich medium containing yeast extract, trypticase or other
complex nutrients can also be employed.
Ideally, the gas phase at start-up is CO2-free and contains excess H2. The gas
rate and agitation rate are kept at low levels (less than 500 rpm in a New Brunswick
Scientific Bioflo® fermentation bioreactor) to yield CO and H2 in slight excess, but at
the same time, avoiding CO substrate inhibition. In a one-liter laboratory New
Brunswick Scientific Bioflo® fermentation bioreactor, as an example, where the feed
gas composition is 63% H2, 32% CO and 5% CH4, the agitation rate to initiate start-
up is 400 rpm and the gas rate is 20 ml/min. The cause of ethanol production during
start-up is excess H2; limitation on nutrients occurs later. Thus, excess liquid nutrients
(pantothenate, cobalt) are actually present during start-up to avoid unwanted culture
acclimation to low nutrients.
As the fermentation proceeds over a period of several hours after inoculation,
CO2 is produced from the conversion of CO, and H2 is consumed along with the CO2,
which is a signal to nominally increase the agitation rate to avoid gas mass transfer
limitation. In the New Brunswick Scientific Bioflo® CSTR, the exit gas is 25% CO,
67% H2, 2% CO2, and 6% CH4. If the agitation rate is increased too fast, CO
substrate inhibition occurs, as evidenced by a decrease in methane concentration after
an increase in agitation. Thus the agitation rate might typically be increased by 200
rpm in 24 hours. This procedure of monitoring CO2 production (or H2 conversion)
while nominally increasing agitation rate occurs at a relatively rapid rate until the
target agitation rate is reached. A typical target agitation rate in the New Brunswick
Scientific Bioflo* fermentation bioreactor is 900 rpm. During this time of increasing
agitation rate in batch liquid culture, cell production instead of product formation is o".
utmost importance. Thus, cell concentrations of about 1.5g/L are attained, while
typical product concentrations are 10g/L ethanol and 2g/L acetate from the batch
culture.
Once the target agitation rate is reached, the system is allowed to grow to
maximum H, uptake. It is desirable to have very high H, exit concentrations (typicall;
> 60%) to assure ethanol production while limiting acetic acid production. The liquid
medium feed is then turned on (for systems having batch inoculation from stock
culture) to initiate continuous liquid feed and the gas feed rate is increased toward the
target flow rate. In the laboratory New Brunswick Scientific Bioflo® fermentation
bioreactor the liquid feed rate is typically 0.5 ml/min, while the gas flow rate is
increased by 10 to 15% every 24 hours toward a target rate of 125 ml/min.
It is important to provide excess H2 in the feed gas to avoid excess acetic acid
production. As the gas flow rate is increased, cell production increases until the
reactor is eventually limited on liquid phase nutrients (calcium pantothenate or cobalt"
as evidenced by a small drop in H2 conversion, at the target productivity. In the New
Brunswick Scientific Bioflo® CSTR, this is recognized by a 10% drop in H2
conversion at a target productivity of 20 g/L•day.
The production method and reactor system are then maintained at a steady
state producing 15 to 35 g/L ethanol and 0 to 5 g/L acetate as products, with only
occasional small adjustments in limiting nutrients, liquid rates and gas rate. Typical
steady state conditions in the laboratory New Brunswick Scientific Bioflo®
fermentation bioreactor without cell recycle, are a gas retention time (gas flow
rate/reactor liquid volume) of 20 minutes, a liquid retention time (liquid flow
rate/reactor liquid volume) of 30 hours and an agitation rate of 900 rpm, yielding CO
conversions of 92% and H2 conversions of 60% with pantothenate limitation.
In an embodiment of this method in which cell recycle is added to the reactor
system, it is added at this time along with an adjustment in gas rate (increase) and
nutrient concentration (decrease). With cell recycle in the New Brunswick Scientific
Bioflo® CSTR, the gas retention time is typically 8 minutes, the liquid retention time
12 hours, the cell retention time is 40 hours and the agitation rate is 900 rpm. These
conditions typically yield a CO conversion of 92% and a H2 conversion of 50% with
pantothenate limitation.
EXAMPLE 2. SAMPLE ANALYSIS VIA GAS CHROMATOGRAPHY
To achieve and/or maintain proper productivity and ratio, a sample of the
fermentation broth in the fermentation bioreactor must be periodically sampled. A
sample greater than 1.5 ml of culture is taken from the culture in the bioreactor. The
sample is placed in a microcentrifuge tube and the tube is placed in a Fisher Scientific
Micro 14 centrifuge with necessary ballast for balancing. The sample is subjected to
8000 rpm for 1.5 minutes. A 0.500 ml sample of supernatant is placed into a 1.5 ml
vial designed for use in a gas chromatograph autosampler. A 0.500 ml sample of an
internal standard solution containing 5 g/L of n-propanol and 5% v/v, 85% phosphoric
acid in deionized water. The phosphoric acid assures the all acetate is converted to
acetic acid and is detected by gas chromatography.
One µl of the prepared sample is then injected by autosampler into a Hewlett-
Packard 5890 Series II Gas Chromatograph equipped with a 007 FFA Quadrex 25m x
0.53mm ID fused silica capillary column. The analysis is conducted with a helium
carrier gas in split-flow mode with 66 ml/min split-flow and 7.93 ml/min injector
purge. The column head pressure is set to 4 psig which yields a column carrier flow
of 7 ml/min. The temperature program is 75°C for 0.2 minutes, a ramp to 190°C at a
rate of 30°C/minute, and a hold time at 190°C for 5.17 minutes. The resulting runtime
is 8 minutes. The instrument is calibrated for ethanol (0 - 25 g/L), acetic acid (0-25
g/L), n-butanol (0-5 g/L) and butyric acid (0-5 g/L). Five standards, prepared from
reagent grade materials, are used for the calibration. If the sample is outside the
calibration range of concentration (e.g , >25 g/L ethanol), 0.250 ml of the sample and
0.250 ml of deionized water are placed into the vial with 0.500 ml of the internal
standard and the dilution factor is included in the analysis.
EXAMPLE 3: ACID PRODUCTION IN A LABORATORY CSTR WITH CELL
RECYCLE
A New Brunswick Scientific Bioflo® laboratory fermentation bioreactor was
operated with cell recycle using Clostridium Ijungdahlii, strain ERI2, ATCC 55380
for the production of acetic acid from CO, CO2 and H2. The gas feed contained 40%
H2, 50% CO and 10% N,, and the gas retention time to the one-liter reactor was 7.7
to 8.6 minutes. Liquid medium containing vitamins, salts and trace elements was fed
at a liquid retention time of 2.6 to 2.9 hours. The pH was 5.1 to 5.2, the agitation
rate was 1000 rpm and the cell retention time was about 40 hours. Under these
conditions of mass transfer limitation (and not nutrient limitation), the CO conversion
was 94 to 98% and the H2 conversion was 80 to 97%. The cell concentration was 4
to 8 g/L, and acetate was produced at 10 to 13 g/L. No ethanol was produced.
Although the reactor was operated under mass transfer limitation (limited by the
ability to transfer gas to the culture) and thus produced only acetic acid as the
product, the parameters for ethanol production through pantothenate limitation,
cobalt limitation or the presence of excess H2 or CO were monitored to serve as
comparisons for when ethanol is produced as the dominant product.
As shown in Table 2, the Ca-d-pantothenate fed per unit of cells produced was
1575 to 3150 micro-grams per gram of cells produced mg/g-cell produced). Similarly
the cobalt fed per gram of cells produced was 1734 to 3468 mg/g-cell produced).
The specific CO uptake rate was 0.35 to 0.61 mmole/g-cell•minute. The ratio of the
moles of H2 fed to the sum of two times the moles of CO converted and three times
the moles of CO2 converted was less than 0.46. Thus, none of the parameters were in
the desired operating range for ethanol production by the culture.
It is realized that pantothenate and cobalt were fed in large excess to the
reactor above when making acetic acid as the product under mass transfer limitation.
That is, the pantothenate and/or cobalt levels could be decreased significantly and still
be above the levels for pantothenate or cobalt limitation. To illustrate this, the
medium fed to the 1-liter New Brunswick Scientific Bioflo® fermentation bioreactor
was modified to significantly decrease cobalt addition to a level that was just above
the concentration of cobalt for cobalt limitation. The reactor again contained C.
Ijungdahlii strain ERI2 for production of acetic acid from CO, CO2 and H2. The gas
feed contained 55% H2, 25% CO, 15% CO2 and 5% CH4 (reference gas), and the gas
retention time was 7.5 to 8.0 minutes. Liquid medium containing salts, vitamins and
trace elements was fed at a liquid retention time of 3.0 to 3.5 hours, and the cell
retention time was 40 hours. The pH was 5.0 to 5.3 and the agitation rate was 900 to
1000 rpm. Under these conditions the CO conversion was 95 to 99% and the H2
conversion was 94 to 9S%. The cell concentration was 2.5 to 4.0 g/L and acetate was
the only product at 10 to 14 g/L.
The Ca-d-pantothenate fed to the reactor per gram of cells was 2250 to 3600
µg pantothenate/g-cells produced. The cobalt fed per unit of cells produced was
reduced to a range of 62.0 to 99.2 µg cobalt/g-cells produced. The specific CO
uptake rate was 0.325 to 0.4 mmole/g-cell•minute. The ratio of H2 fed to the sum of
two times the CO converted and three times the CO, converted was 0.875.
EXAMPLE 4. ETHANOL PRODUCTION IN LABORATORY CSTRs WITH
PANTOTHENATE LIMITATION
A New Brunswick Scientific Bioflo® II laboratory fermentation bioreactor was
operated as a straight through CSTR (without cell recycle) using C. ljungdahlii, strain
C-01 ATCC 55988 for the production of ethanol from CO, CO2 and H2, limited on
pantothenate. The gas feed to the reactor contained 63.3% H2, 31.4% CO and 5.3%
C2H6, (reference gas); fed at a gas retention time of 27 minutes. Liquid medium
containing excess salts and trace elements and a limited supply of pantothenate was
fed to the 1.55 liter reactor at a liquid retention time of 31.4 hours. The pH was 4.6
to 4.7, and the agitation rate was 650 rpm. Under these operating conditions the CO
conversion was 9S%, the H2 conversion was S3% and the cell concentration was 1.5
to 2.0 g/L. Ethanol was produced at a concentration of 15 to 19 g/L, and acetate was
produced at 1.5 g/L. The ethanol productivity ranged from 11.5 to 14.5 g/L"day.
In analyzing the parameters for ethanol production, pantothenate limitation
was seen by operating with a pantothenate feed to cell production ratio of 17.7 to
23.6 µg pantothenate/g-cell produced. Compare this ratio to the 2-50 to 3600 µg
pantothenate/g-cell produced and 1575-3150 µg pantothenate/g-cell produced in
Example 3 for acid production. The cobalt fed per unit of cells produced was 5000 to
6000 µg cobalt/g-cell produced, a level that is even greater than in Example 3 and
assures no cobalt limitation. The specific CO uptake rate was 0.23 to 0.30 mmole/g-
cell"minute. The ratio of H2 fed to the sum of two times the CO converted and three
times the CO2 converted was 1.03, and the H2 partial pressure in the exit gas was
0.55-0.64 atm. It is possible that either excess H, or limited pantothenate caused
ethanol production.
Pantothenate limitation for ethanol production was also addressed in another
New Brunswick Scientific Bioflo® II laboratory reactor operated with cell recycle
using C. ljungdahlii, strain C-01 ATCC 55988. This reactor was fed gas containing
61.7% H2, 30.6% CO and 5.2% C2H6 (reference gas) at a gas retention time of 12.3
minutes. Liquid medium containing a limited supply of pantothenate along with
excess salts and trace elements was fed to the 2.4 liter reactor at a liquid retention
time of 24.8 hours. Cell recycle was provided by employing a 0.2 mm hollow fiber
membrane, and the cell retention time was 69 hours. The pH was 4.6, and the
agitation rate was 650 rpm. Under these conditions the CO conversion was 90%, the
H2 conversion was 53% and the cell concentration was 2.5 g/L. The ethanol
concentration was 18 g/L and the acetate concentration was 3 g/L. The ethanol
productivity was 17.4 g/L•day.
In analyzing the parameters for ethanol production (Table 2), the ratio of
pantothenate fed per unit of cells produced was 8.08 µg pantothenate/g-cell produced.
Again, pantothenate limitation was assured by operating at a level far less than that
required for acetate production. The cobalt fed per unit of cells produced was 3960
µg cobalt/g-cell produced. The specific CO uptake rate was 0.33 mmole/g-
cell-minute. The ratio of H2 fed to the sum of two times the CO converted and three
times the CO2 converted was 1.14, and the H2 partial pressure in the exit gas was
0.60-0.65 atm. Excess H2 could be a potential reason for ethanol production;
however, the high CO, content in the exit gas (0.14 atm) shows that growth was
limited by pantothenate.
In another experiment, C. Ijungdahlii, strain ERI2 was fed 1500 to 3600 µg
pantothenate/g cells produced during acetic acid production from CO, CO2 and H2, a
condition where the reactor was not limited on pantothenate (or any other limitation
except for the ability to transfer gas to the culture), and no ethanol was found in the
product stream.
During limitation on pantothenate for ethanol production from CO, CO2 and
H2, C. Ijimgdahlii, strain C-01 was fed 8 to 24 µg pantothenate/g cells produced,
while maintaining all other nutrients in excess. Under these conditions, strain C-01
produced 15 to 19 g/L ethanol and 1.5 to 3.0 g/L acetate.
EXAMPLE 5. ETHANOL PRODUCTION IN LABORATORY CSTRS WITH
COBALT LIMITATION
A New Brunswick Scientific Bioflo® II laboratory fermentation bioreactor was
operated as a straight through CSTR (with no cell recycle) using C. ljungdahlii, strain
C-Ol, ATCC 55988 for the production of ethanol from CO, CO2 and H2 with cobalt
limitation. The gas fed to the reactor contained 60% H2, 35% CO and 5% CH4
(reference gas), and was fed at a gas retention time of 14 minutes. Liquid medium
containing excess salts, vitamins and trace metals (except for cobalt, which was
limiting) was fed to the 2.5 L reactor at a liquid retention time of 40 hours. The pH
was 4.9 and the agitation rate was 650 rpm. Under these conditions the CO
conversion was 91%, while the H2 conversion varied from 20 to 80%, but was
nominally 55%. Ethanol was produced at 26 g/L, acetate was produced at 4g/L and
the cell concentration was 2.5 g/L. The ethanol productivity was 15.6 g/L•day.
In analyzing the parameters for ethanol production, the ratio of the
pantothenate fed to the cell production was 15.2 µg pantothenate/g-cell produced.
This level was quite low, such that cobalt limitation might not be assured in favor of
pantothenate limitation. Cobalt limitation was seen by operating with 33.3 µg
cobalt/g-cell produced, a level which is 100 times less than used in reactors without
cobalt limitation. The ratio of the H2 fed to the sum of two times the CO converted
and three times the CO2 converted was 0.94. The specific CO uptake rate was 0.37
mmole/g-cell•minute.
Cobalt limitation for ethanol production was also demonstrated in a CSTR
with cell recycle using C. ljungdahlii, strain C-Ol ATCC 55988. This experiment was
run to demonstrate cobalt limitation in the presence of excess pantothenate, in
contrast to the previous reactor in this example. The New Brunswick Scientific
Bioflo* 2000 laboratory fermentation bioreactor with a 0.2 µm hollow fiber
membrane for cell recycle, was fed gas containing 60% H2, 35% CO and 5% CH4
(reference gas) at a gas retention time of 5 minutes. Liquid medium containing excess
salts, vitamins and trace metals (again, except for cobalt which is limiting) was fed to
the 1.2 liter reactor at a liquid retention time of 16 hours. The pH was 5.1 and the
agitation rate was 825 rpm. The cell retention time in this CSTR with hollow fiber for
cell recycle was 40 hours. Under these conditions the CO conversion was 83%, the
H2 conversion was 50% and the cell concentration was 4.2 g/L. The ethanol
concentration was 18 g/L and the acetate concentration was 4 g/L. The ethanol
productivity was 27 g/L•day.
In addressing the parameters for ethanol production in this reactor (Table 2),
the ratio of pantothenate fed to cell production was 85.7 µg pantothenate/g-cells
produced, a level which is 5.5 times greater than in the previous reactor in this
example. Cobalt limitation was seen by operating with 47.6 µg cobalt/g-cells
produced. The ratio of H, fed to the sum of two times the CO converted and three
times the CO, converted was 1.03, and the H, partial pressure in the exit gas was 0.60
atm. Again, excess H2 could be a potential reason for ethanol production; however,
the high CO, content in the exit gas (0.1-0.15 atm) shows that growth was limited by
cobalt. The specific CO uptake was 0.50 mmol/g-cell-minute.
EXAMPLE 6. ETHANOL PRODUCTION IN LABORATORY CSTRs WHEN
OPERATING WITH EXCESS CO PRESENT
A high pressure AUTOKLAV™ reactor (Buchi) was operated as a CSTR
with culture circulation and cell recycle using C. ljungdahlii strain C-01 for the
production of ethanol from CO, CO, and H2 in the presence of excess CO for a period
of 50 hours. The reactor was operated at 25 psig and fed gas containing 57% H,,
36% CO and 6% C2H6. The gas retention time was variable, but was nominally 3.0
minutes. Liquid medium containing excess salts, vitamins (including pantothenate)
and trace metals was fed to the 600 ml reactor at a liquid retention time of 8.2 hours.
The cell retention time, obtained by passing the reactor effluent through a ceramic
hollow fiber filter, was 18.5 hours. The pH was 4.5, the agitation rate was 450 rpm
and the liquid recirculation rate was 0.4 to 0.5 gpm. Under these conditions, the gas
conversions were variable, but the CO conversion was nominally 72% and the H2
conversion was nominally 12%. The cell concentration was 2.7 g/L. Ethanol was
produced at 9.9 g/L and acetate was produced at 2.6 g/L. The ethanol productivity
was 29.0 g/L•day.
In analyzing the parameters for ethanol production, the ratio of the
pantothenate fed to the cell production was 97 µg pantothenate/g-cell produced. This
level is sufficiently high to assure that pantothenate was not limiting. The ratio of
cobalt fed to the cell production was 836 µg cobalt/g cell produced, again a level that
assures that cobalt was not limiting. The ratio of the H2 fed to the sum of two times
the CO converted and three times the CO2 converted was 1.09, and the H2 partial
pressure was 1.6 atm. The high CO, content in the exit gas (0.5 atm) assures that
excess H2 did not cause ethanol production. The specific CO uptake rate was 1.34
mmol/g-cell•min., a level that assures excess CO as a method of producing ethanol.
The technique of using excess CO for ethanol production was also
demonstrated in another experiment with C. Ijungdahlii, strain C-01 in the
AUTOKLAV™ reactor (Buchi) system, again with cell recycle and with culture
circulation, for a period of 24 hours. In this experiment the 600 ml reactor was fed
gas containing 15.8% H2, 36.5% CO, 38.4% N2 and 9.3% CO2 at a 1.4 minute gas
retention time. The reactor pressure was maintained at 40 psig. Liquid medium
containing excess salts, vitamins and trace metals was fed at a liquid retention time of
4.8 hours, and the cell retention time, obtained by passing effluent through a ceramic
hollow fiber filter, was 19.2 hours. The pH was 4.5, the agitation rate was 1000 rpm
and the liquid recirculation rate was 0.4 to 0.5 gpm. Under these conditions, the CO
conversion was 71.6% and the H2 conversion was 11.8%. The cell concentration was
7.1 g/L, ethanol was produced at 12.0 g/L and acetate was produced at 2.7 g/L. The
ethanol productivity was 60 g/L-day.
In analyzing the parameters for ethanol production (Table 2), the ratio of
pantothenate fed to the cell production was 294 µg pantothenate/g-cell produced.
This level is far in excess of the minimum level required to cause ethanol production
due to pantothenate limitation. The rate of cobalt fed to the cell production was 735
µg cobalt/g cell produced, again a level that ensures the cobalt was fed in excess. The
ratio of H2 fed to the sum of two times the CO converted and three times the CO,
converted was 0.3. The CO uptake rate was 0.67 mmol/g cell-min., a level that again
assures that excess CO is available as the method of causing ethanol to be produced.
EXAMPLE 7. ETHANOL PRODUCTION WITH EXCESS H2 PRESENT
A New Brunswick Scientific Bioflo laboratory fermentation bioreactor was
operated as a straight through CSTR (without cell recycle) using C. Ijungdahlii, strain
C-01 ATCC 55988 for the production of ethanol from CO, CO2 and H2 in the
presence of excess H2. The gas feed to the reactor contained 77% H2, 19% CO and
4% CH4 (reference gas), fed at a gas retention time of 30 minutes. Liquid medium
containing excess salts, vitamins and trace elements was fed to the reactor at a liquid
retention time of 36 hours. The pH was 5.0 and the agitation rate was 1000 rpm.
Under these operating conditions the CO conversion was 97-99% and the H2
conversion was 60-80%. The cell concentration was 0.8-1.0 g/L, the ethanol
concentration was 10g/L and the acetate concentration was 3.3 g/L. The ethanol
productivity was 6.7 g/L•day
In analyzing the parameters for ethanol production, the pantothenate feed to
cell production ratio was 900-1125 µg pantothenate/g cell produced, thus assuring
excess pantothenate was present. Similarly, the cobalt feed to cell production ratio
was 991-1239 µg cobalt/g cell produced, again assuring that excess cobalt was
present. The specific CO uptake rate was 0.25-0.35 mmol/g cell min, a level such that
excess CO was not causing ethanol production. The ratio of the moles of H2 fed to
the sum of 2 times the moles CO converted and three times the moles CO2 converted
was 1.96, a ratio that is above 1.0, the level where excess H2 is present and thus could
be controlling ethanol production. The H2 partial pressure in the exit gas was 0.70-
0.87 atm, and the ratio of the H2 partial pressure to CO2 partial pressure in the exit gas
was 65. Thus, the reactor was producing ethanol due to the presence of excess H2.
In a second experiment, a high pressure AUTOKLAV™ reactor (Buchi) was
operated as a CSTR with culture circulation and cell recycle using C. Ijungdahlii,
strain C-01 for the production of ethanol from CO, CO2 and H2 in the presence of
excess H2. The gas feed to the reactor contained 81% H2, 16% CO and 3% CH4
(reference gas), fed at a gas retention time of 2.21 minutes. Liquid medium
containing excess salts, vitamins and trace elements was fed to the reactor at a liquid
retention time of 8.97 hours. The cell retention time was 22.7 hours, the pH was 4.5
and the agitation rate was 800 rpm. Under these operating conditions the CO
conversion was 91.5% and the H2 conversion was 43.4%. The cell concentration was
5.5 g/L and the acetate concentration was 2.85 g/L. The ethanol productivity in the
reactor was 215-240 g/L•day.
In analyzing the parameters for ethanol production, the pantothenate feed to
cell production rate was 46 µg pantothenate/g cell produced, a level that may indicate
pantothenate limitation. The cobalt feed to cell production ratio was 460 µg cobatt/g
cell produced, a level which assures that cobalt was not limiting. The specific CO
uptake rate was 1.68 mmol/g-cell-min, a level that could indicate that excess CO were
present if it were not for the high H2 uptake rate of 4.14 mmol/g-cell-min, which
indicates that substrate inhibition to the H2 conversion was not occurring. The ratio
of the moles of H2 fed to the sum of two times the moles CO converted and three
times the moles CO2 converted was 5.67, a rate that is far above the required ratio of
1.0 for excess H2 to be present. The H, partial pressure in the exit gas 2.61 atm, and
the rate of H, partial pressure to CO2 partial pressure in the exit gas was 10.9. The
reactor was thus producing ethanol as a result of the presence of excess H2.
A summary comparison of method parameters and results for Examples 3
through 7 is shown in Table 2 below.
EXAMPLE 8. PRODUCT SHIFT IN C. LJUNGDAHLII STRAINS ERI2, C-01
AND PETC USING MEDIUM FORMULATIONS
The methods of this invention can be applied to any of the C. Ijungdahlii
strains. Results from medium manipulation experiments employing strains ERI2, C-
01 and PETC are shown in Table 3 below. The purpose of these experiments was to
demonstrate that each of the strains can be shifted from acetic acid production to
ethanol production merely by manipulating the medium. Thus, a culture was fed
excess nutrients (including pantothenate and cobalt) in order to produce acetic acid as
the dominant product, and then limited on pantothenate or cobalt to produce ethanol
as the dominant product. It should be emphasized that the only purpose of these
experiments was to demonstrate that medium manipulation can result in product shift
for each of the strains. Thus, attaining high product concentrations and productivities
was not a focus of these experiments.
The reactor was operated as a straight through CSTR (no cell recycle) for
each of the culture experiments. The gas retention time was nominally set at 50
minutes, the liquid retention time was nominally set at 40 hours and the agitation rate
was nominally set at 1000 rpm. These conditions were chosen to allow comparisons
of the strains, but not to achieve high productivities.
As noted in Table 3, strain ERI2 was subjected to five changes in medium
which shifted the products back and forth from acetic acid as the dominant product to
ethanol as the dominant product. Both pantothenate limitation and cobalt limitation
were demonstrated for ethanol production by this strain. Strain C-01 was shifted
three times using medium manipulation, again with both pantothenate limitation and
cobalt limitation demonstrated as the mechanism for ethanol production. Strain PETC
was shifted only once, with ethanol production due to cobalt limitation. Each of the
strains showed higher H, conversions when producing acetic acid, rather than ethanol,
as the dominant product. This occurs because acetic acid is produced under mass
transfer limitation (limiting the amount of gas to the culture), whereas ethanol is
produced when limiting nutrients, and thus excess gas is supplied which can negatively
affect gas conversion. Small amounts of acetate are always present in the product
stream when the dominant product is ethanol. However, when acetic acid is the
dominant product, ethanol is usually not present in measurable concentrations. In
shifting dominant products from ethanol to acetic acid by nutrient manipulation, it was
shown that it was very difficult to remove all traces of ethanol. Complete removal of
ethanol occurred only after several weeks of continued operation on acetic acid
enhancing medium.
EXAMPLE 9. STEADY STATE OPERATION WITH AND WITHOUT CELL
RECYCLE
The ultimate commercial goal of producing ethanol from CO, CO2 and H2 is to
achieve high steady state concentrations of ethanol, while at the same time, obtaining
high ethanol to acetate product ratios and high productivity. Steady state data for the
production of ethanol from CO-rich gas containing 20% H2, 65% CO, 10% CO, and
5% CH4 using C. Ijungdahlii, strain C-01 in a straight through CSTR (no cell recycle)
are shown in Table 4. In the table, GRT refers to the gas retention time (ratio of liquid
volume to inlet gas flow rate), LRT refers to the liquid retention time (ratio of liquid
volume to liquid flow rate), and XRT refers to the cell retention time (average amount
of time cells spend in the reactor). As is noted in. the Table 4, ethanol concentrations
of 17.5 to 33 g/L were obtained, and the ethanol productivity ranged from 14.4 to
21.1 g/L•day.
Similar results are shown for ethanol production from gas that is not as
rich in CO. The gas used in the experiment using C. Ijimgdahlii C-01 without recycle,
for which results are reported in Table 5, contains 16% H2, 27% CO, 6% CO2, and
51% N,. Ethanol concentrations ranging from 11 to 26 g/L were obtained with this
gas, with 2.0 to 5.0 g/L acetate present as a secondary product. The ethanol
productivity ranged from 11.1-20.1 g/L•day. * The cell concentration is based upon
dry cell weight in Table 5.
Finally, steady state data for the conversion of gas containing 50% H2,
45% CO and 5% CH4 in a CSTR with cell recycle using C. Ijungdahlii O-52 (ATCC
Accession No. 559S9) are shown in Table 6 below. Ethanol concentrations of 18 to
23.5 g/L and acetate concentrations of 3.0 to 5.7 g/L were attained. The ethanol
productivity ranged from 21.1 to 39.0 g/L•day.
EXAMPLE 10. HIGH ETHANOL PRODUCTIVITY IN A CSTR WITH CELL
RECYCLE AND PRESSURE
A high pressure AUTOKLAV™ reactor (Buchi) was operated as a CSTR
with culture circulation and cell recycle using C. Ijungdahlii, strain C-01 for the
production of ethanol from CO, CO2 and H2. The reactor was operated at 30 psig and
fed gas containing 62% H2, 31% CO and 5% C2H6. The gas retention time was 1.14
min (atmospheric pressure basis), with an actual gas retention time of 3.5 min. Liquid
medium containing excess salts, vitamins and trace metals was fed to the 600 ml
reactor at a liquid retention time of 3.6 hours. The pH was 4.5 and the agitation rate
was 825 rpm. Under these conditions, the cell concentration was 8 g/L, the CO
conversion was 90% and the H2 conversion was 40%. The product stream contained
20 g/L ethanol and 2.75 g/L acetate. The ethanol productivity was 150 g/L-day.
In another high pressure AUTOKLAV™ reactor (Buchi) operated as a CSTR
with culture circulation and cell recycle using C. Ijungdahlii, strain C-01, the reactor
was operated at 6 atm (75 psig) and fed syngas containing 55% H2, 30% CO, 5% CH4
and 10% CO2. The gas retention time was 1 min (atmospheric pressure basis), with
an actual gas retention time of 6.0 min. Liquid medium containing excess salts,
vitamins and trace metals was fed to the reactor at a liquid retention time of 1.62 hi.
The cell retention time was 24 hr, the pH was 4.5 and the agitation rate was 800 rpm.
Under these conditions, the cell concentration was 2.0 g/L, the CO conversion was
95% and the H2 conversion was 60%. The product stream contained 25 g/L ethanol
and 3 g/L acetate. The ethanol productivity was 369 g/L•d.
EXAMPLE 11: START-UP FROM STOCK CULTURE WITH EXCESS H2
PRESENT
Start-up using a batch inoculum from stock culture ensures a healthy inoculum
free from contaminants, but is not always successful as an inoculation procedure
because of the rather low cell density employed, especially if the method parameters
such as gas rate and agitation rate are pushed upward too rapidly just after
inoculation.
Start-up using batch inoculum from stock culture is discussed in this example.
To prepare the stock cultures for inoculation of the reactor, cultures of C. Ijiungdahlii,
strain C-01 (ATCC Accession No. 55988) were grown up in 150 ml serum bottles on
CO, CO, and H2 in a rich medium containing 1 g/L yeast extract and 1 g/L trypticase,
in salts and vitamins. The vitamin concentration employed was 0.4 ml/L medium of
an aqueous solution containing 50.5 mg/L calcium pantothenate, 20.6 mg/L d-biotin
and 50.6 mg/L thiamine HCl. Bottles were incubated at 37°C in a shaker incubator.
The cultures were grown to the exponential growth phase, as determined by visual
inspection. With each inoculation, approximately 90 ml of stock culture were
transferred from serum bottles to 1 liter of medium, representing 9% by volume
inoculation. A successful inoculation is described below. The outlined procedure can
be repeated several times to obtain a successful inoculation.
In obtaining a successful inoculation, 90 ml/L of inoculum were added to a 1
liter batch of basal medium (shown in Table 1) containing 0.4 ml/L vitamins and salts
(t=0). The agitation rate was 240 rpm, the pH was 5.3, the temperature was 38.5°C
and the gas retention time (continuous gas flow) was 110 minutes. The gas feed
contained 62% H2, 31% CO and 7% C2H6. After 13 hr (t=13 hr) some CO
conversion was noted, and at t=23 hr the agitation rate was increased from 240 rpm
to 300 rpm. The gas retention time was decreased to 100 minutes at t = 27 hr, and a
further decrease in gas retention time was made at t = 46 hr. The agitation rate was
also increased in 100 rpm increments at t = 28 hr, 59 hr, 72 hr and 85 hr.
By t= 110 hr, the system was operating with a gas retention time of 80
minutes and an agitation rate of 600 rpm. The cell concentration was 0.5 g/L and the
CO conversion was 35%. There was still no H2 conversion, but small amounts of
ethanol and acetate (~ 1g/L each) had accumulated in the batch culture broth. The
efforts up until this time emphasized cell growth in the reactor.
Medium flow using the same concentrations as in basal medium was started at
a rate of 0.4 ml/min at t = 120 hr. A program of nominal increases in gas rate,
agitation rate and medium rate was then initiated while carefully maintaining the
system under excess H2. By t = 210 hr, the ethanol concentration was 17 g/L, the
acetate concentration was 1 g/L, the cell concentration was 1.6 g/L, the CO
conversion was nearly 100% and the H, conversion was 90%. The ethanol
productivity reached 11.4 g/L•day.
A program of gradual gas rate increases was again started. Concurrent
vitamin (see Table 1) increases were made to bring the vitamin addition rate to 0.7
ml/L medium. By t = 610 hr, the reactor was producing 20 g/L ethanol and about 2
g/L acetate. The CO conversion was nearly 100% and the H, conversion was 85%.
The ethanol productivity reached 14 g/L•day.
EXAMPLE 12. START-UP USING INOCULUM FROM EXISTING CSTR
The start-up of a CSTR using continuous inoculum from an existing CSTR is
much faster and is more dependable than a start-up from batch bottles of stock
culture. A CSTR containing Isolate C. Ijungdahlii, strain C-01 (ATCC Accession
No. 559S8), that had nearly ceased ethanol production and was producing 2-3 g/L
ethanol, 7-8 g/L acetate and about 0.3 g/L butanol as the liquid phase products, was
restarted using a continuous inoculum from an existing CSTR.
The CSTR from which the inoculum was taken was producing about 17 g/L
ethanol and 1-2 g/L acetate, while operating at a gas retention time of 25 minutes, a
liquid retention time of 32 hours, an agitation rate of 650 rpm, a temperature of
38.5°C and pH 4.66. The cell concentration was 1.7 g/L, the CO conversion was
essentially 100% and the H2 conversion was S5%.
Continuous inoculum addition was started (t=0), and at this time, the agitation
rate was reduced to 500 rpm and the gas retention time was set at 38 minutes.
Effluent from the productive reactor (0.5 ml/min) served as the continuous inoculum
for the CSTR being inoculated, with continuous inoculation occurring over a period
of several hours. By t = 5 hr (5 hr after the onset of continuous inoculation), gas
conversion was noted, and the agitation rate was increased to 700 rpm. The
continuous inoculum was turned off at t = 28 hr. The gas conversions improved
steadily, allowing steady increases in gas rate (lowered gas retention times) and an
agitation rate increase to 750 rpm. By t = 30 hr, the CO conversion was 95% and the
H2 conversion was 80%. The ethanol concentration was 13 g/L and acetate
concentration was 1.5 g/L, and it steadied at 1.4 g/L for well over 100 hours. During
this time period, the ethanol productivity was 10 to 15 g/L•day.
EXAMPLE 13. RECOVERY FROM SEVERE METHOD UPSET
A CSTR with cell recycle containing C. ljungdahlii, strain C-01 being
continuously fed gas and liquid nutrients and producing 15-35 g/L ethanol and 0-5 g/L
acetate at a steady state (e.g., Example 1) is upset due to unforeseen changes in
method conditions, e.g., mechanical problems in the reactor. Upset to the reactor
system can either be minor, such as a brief increase in the gas rate which causes short-
term substrate inhibition, or major, such as a longer term increase in the gas rate
which eventually leads to increased acetic acid production and more severe molecular
acetic acid product inhibition.
Short-term upsets are easily corrected by merely readjusting the upset
parameter (for example, lowering the gas rate to its original level) and monitoring the
progress of the reactor to assure that the upset has not led to a longer-term problem.
However, acetic acid product inhibition is a more severe problem. If excess
molecular acetic acid is produced by the culture as a result of long term substrate
inhibition, excess nutrient addition, CO2 accumulation or mechanical problems of
many types, the problem that led to the excess acetic acid must first be corrected. The
excess acetic acid, which quickly leads to product inhibition, is then cleared from the
system by increasing the liquid rate to wash the acetic acid (and unfortunately ethanol)
from the system. Once the acetate level is below 3-5 g/L, the liquid rate is reset and
the reactor is placed back under either excess H2 feed, or vitamin or cobalt limitation
(with or without cell recycle). Bringing the reactor back involves reducing the gas
rate to avoid substrate inhibition and/or agitation rate before cell washout and lysis
takes place. The agitation rate or gas rate is then increased, as described in
Example 1.
In one specific example, a CSTR with cell recycle containing C. ljungdahlii,
strain C-01 that was producing ethanol and acetic acid from CO, CO2 and H2 began
producing acetic acid in response to a mechanical, problem. The 2100 ml reactor was
fed gas containing 62% H2, 31% CO and 7% C2H6 at a gas retention time of 15
minutes, and was operating with an agitation rate of 600 rpm and a pH of 4.86. The
liquid retention time was 23 hours and the cell retention time was 68 hours. B-
vitamin solution (an aqueous mixture of 50.5 mg/1 calcium pantothenate, 20.6 mg/L d-
biotin and 50.6 mg/L thiamine HCl) was present in the liquid nutrient medium
containing salts and vitamins at a concentration of 0.4 ml vitamin solution per liter of
medium (see Table 2). The ethanol concentration fell to 7 g/L, while the acetate
concentration rose to 7 g/L, conditions that are neither stable for operating the reactor
nor economical for ethanol production. The cell concentration was 2.4 g/L, the CO
conversion was 85% and the H2 conversion was 25%.
The strategy used in recovering the reactor consisted of first dramatically
reducing the gas feed rate to the reactor, followed by gradual recovery of the reactor
in the presence of excess H2 . The liquid rate to the reactor was not reduced to clear
product inhibition in this example because the acetate concentration was not
exceedingly high. Instead, the acetate concentration was allowed to more gradually
drop to non-inhibiting levels with the reduction in gas flow rate and subsequent
operation in the presence of excess H2. The specific procedure in recovering the
reactor is discussed below.
Cell recycle was turned off and the gas rate was dramatically reduced by 70%
to a gas retention time of 62 minutes, while only slightly adjusting the liquid retention
time from 23 to 30 hours (t=0). The vitamin concentration in the medium was not
changed. With this change in gas rate the CO conversion increased to 98% and the H2
conversion increased to 80%. More importantly the system had excess H2 present, as
evidenced by the decrease in CO2 in the outlet gas from 19 to 5%. With the onset of
excess H2, the acetate concentration fell while the ethanol concentration increased. At
t = 66 hr (66 hr after turning off cell recycle), for example, the acetate concentration
had fallen to 4 g/L and the ethanol concentration had risen slightly to 7.5 g/L.
The presence of excess H2 (and the lowered acetate concentration) permitted
subsequent increases in gas rate, first slowly and then at a faster rate. By t = 215 hr
the gas retention was 29 minutes, the ethanol concentration was 12 g/L and the
acetate concentration was 3 g/L. The ethanol productivity was S g/L-day. CO2 was
present in the outlet gas at 6%, the CO conversion was 98% and the H2 conversion
was 80%. By t = 315 hr, the ethanol concentration was 16 g/L and the acetate
concentration was 4 g/L, again with good gas conversions, and a gas retention time of
20 minutes. The ethanol productivity was 11 g/L•day. By t = 465 hr, the ethanol
concentration had reached 20 g/L, with 3.5-4 g/L acetate also present. The ethanol
productivity was 16 g/L•day. The gas retention time had been dropped to 16 minutes,
with CO and H2 conversions of 95 and 73%, respectively. These conditions were
maintained for nearly 200 hours of continuous operation, demonstrating that the
reactor system had recovered its ability to produce ethanol and had essentially
retained the previous operating conditions.
EXAMPLE 14. ETHANOL PRODUCTION METHOD WITH OVERSUPPLY OF
CO
A simple experiment was performed in a continuous high pressure stirred tank
reactor with cell recycle to demonstrate the shift from acetic acid production to
ethanol production due to the presence of high CO concentrations. Prior to this
experiment the reactor containing C. Ijungdahlii, strain C-01 was operated at a
pressure of 20-25 psig and fed gas containing 57% H2, 36% CO and 7% C2H6. The
gas retention time was less than 2 minutes, the liquid retention time was 38 hours, the
cell retention time was 28 hours, the agitation rate was 600 rpm and the temperature
was 38°C. Under these conditions the CO conversion was variable and averaged
85%, and the H2 conversion was variable and averaged 20%. The cell concentration
was about 2.5 g/L, and the product stream contained 9 g/L ethanol and 3 g/L acetate.
As a first step in preparing for the test, the gas retention time was increased in
order to ensure that excess CO was not present. The pressure was maintained at 23-
24 psig. The pH was followed long enough to ensure that it was stable in the normal
operating range of 4.5 - 4.6. Pure CO was then blended with the regular feed gas to
yield a gas feed of 47% H2, 47% CO and 6% C2H6 at a gas retention time of 2.3
minutes The reactor pH, exit gas composition, and product stream were then
monitored with time.
Table 7 shows the pH changes and product compositions with time after the
addition of extra CO to the system. Thirty minutes after the CO addition, the reactor
pH had increased to 5.25 and the culture had shifted 1.54 g/L (0.0257 mole/L) acetate
to 1.12 g/L (0.0243 mole/L) ethanol. The pH increase occurred as a result of the
free acetic acid being converted to ethanol. Accompanying this change was a
decrease in CO conversion from 91% to 71%. In decreasing the culture circulation
rate from 0.4 gpm to 0.15 gpm, the reactor pH fell, but the ethanol and acetate
concentrations held.
Fifty minutes after CO introduction the ethanol concentration was 11.29 g/L
and the acetate concentration was 1.75 g/L. At this time, the excess CO was turned
off and the ethanol concentration and pH began to fall, and the acetate concentration
began to rise. The decrease in pH was due to the conversion of ethanol to molecular
acetic acid. The ethanol-acetic acid shift through oversupply of CO is thus reversible.
EXAMPLE 15. WATER RECYCLE TO MINIMIZE Acetate PRODUCTION
The recycle of method water back to the fermentation bioreactor after
distillation to recover ethanol is essential to minimize effluent production, and to
maximize the yield of ethanol from the reactor, and to limit the acetic acid production.
Distillation has been found to be the most economical method for concentrating 15-35
g/L ethanol obtained from the reactor to 95% ethanol. Adsorption with molecular
sieves is then used to further concentrate the ethanol to the desired concentration. In
performing the distillation, 95% ethanol in water is produced as the overhead product.
Water is generated as the bottoms product during distillation. The bottoms product
contains acetic acid from the reactor produced during fermentation (3-5 g/L acetate)
and any nutrients not used up during fermentation or destroyed by the heat of
distillation, such as trace metals and other minerals. The recycle of nutrients
minimizes the quantity of effluent, that must be treated as well as the quantity of
nutrients that must be subsequently added to the fermentation bioreactor. The recycle
of acetate prevents the formation of further acetic acid by establishing equilibrium
between the ethanol and acetic acid. Thus, no net acetic acid is produced with water
recycle. Recycle of more than 3-5 g/L acetate can result in acetic acid inhibition in the
reactor. Thus, as a result of water containing acetate recycle, the substrate CO, CO2
and H2 can be converted to ethanol as the only product.
Table 8 shows results for the fermentation of gas containing 50% CO, 45% H2
and 5% CH4; using C. Ijungdahlii, strain O-52 with water recycle. In these
experiments, the permeate from hollow fiber filtration used for cell recycle was sent to
distillation. After removing ethanol, the water was filtered with a 0.2 micron filter to
remove any precipitated by-products. The fraction of water recycled compared to the
total water (as medium) fed to the reactor in these experiments ranged from 25-100%.
The experiment with 100% water recycle lasted for nearly 500 hours or about 20
liquid retention times. As is noted in the results with 100% water recycle, no net
acetic acid was produced. In fact, a small amount of acetic acid was eventually
consumed. The ethanol productivity ranged from 12 to 27 g/L•day.
EXAMPLE 16. TWO-STAGE CSTR SYSTEM WITH PANTOTHENATE FEED
TO THE GROWTH STAGE
The proper pantothenate feed to the growth stage is a variable that must be
optimized. Typical results from a Growth Stage Reactor using C. Ijungdahlii C-01
were described in Examples 11 and 12, with the exception that a bit more acetic acid
would be produced in this reactor since additional pantothenate or cobalt is fed to the
Growth Stage to ensure a healthy and stable culture. The vitamin concentration
employed was 0.7-0.8 ml/L medium of an aqueous solution containing 50.5 mg/L
calcium pantothenate, 20.6 mg/L d-biotin and 50.6 mg/L thiamine HCl. The
Production Stage CSTR with cell recycle is fed effluent from the growth stage reactor
and produces ethanol as the predominant product. The pantothenate concentration
fed to this reactor is much lower than in the Growth Stage, only 0.1-0.2 ml total
vitamins/L medium of the aqueous solution containing 50.5 mg/L calcium
pantothenate, 20.6 mg/L d-biotin and 50.6 mg/L thiamine HCl. The gas retention
time in this Production Stage was 11-30 minutes, the liquid retention time was about
20 hours, the cell retention time was 30-50 hours, and the agitation rate was 800-900
rpm. The pH was 5.0 and the temperature was 38°C. Once the reactor reached
steady state, the gas retention time was held constant at 11 minutes, the liquid
retention time was set at 19 hours, the cell retention time was constant at 37 hours
and the agitation rate was 900 rpm. The CO conversion averaged 96% and the H2
conversion averaged 60%. The ethanol concentration steadied at 25-30 g/L, with
about 3 g/L acetate also present. The ethanol productivity was 31.6-37.9 g/L•day.
EXAMPLE 17. REGULATING THE FERMENTATION PARAMETERS TO
AVOID ACCLIMATION TO LOW LIMITING CALCIUM PANTOTHENATE
The acclimation of the culture in the fermentation bioreactor to low limiting
calcium pantothenate concentration is avoided by regulating the fermentation
parameters (gas rate, liquid rate, agitation rate, H2 partial pressure) while avoiding
major changes in nutrients, but instead maintaining a relatively constant nutrient feed
concentration, as follows.
During start-up of a laboratory New Brunswick Scientific Bioflo® CSTR, C.
Ijungdahlii, strain C-01 was fed a liquid nutrient stream containing vitamins, trace
minerals and salts necessary to provide nutrition to the culture. The pantothenate
concentration in the nutrient medium was 20 pg/L, a concentration that when coupled
with the slow rate of medium feed ensures that there is more than 100 µg calcium
pantothenate fed per gram of cells produced (excess pantothenate) because of low cell
production in the bioreactor. Similarly the cobalt concentration in the medium was 1
ppm, a concentration that ensures cobalt is also present in excess. Instead, the H2
partial pressure in the exit gas was kept in excess of than 0.55 atmospheres by feeding
a gas containing no CO2, 63.3% H2, 31.4% CO and 5.3% C2H6, thus yielding a ratio
of H2 fed / (2 COconwrted and 3CO2 converted) of more than 1 and by carefully regulating the
gas feed rate and agitation rates to achieve greater than 95% CO conversion and
greater than 80% H, conversion. As these high conversions are attained with time,
the cell concentration builds from an initial level of near 0 g/L to about 1.5 g/L.
Since the pantothenate concentration is held constant during this start-up, the
µg pantothenate per gram of cells produced gradually decreases until it is less than 15
µg pantothenate/g cell produced, a condition which is then pantothenate limited. The
system thus grows into pantothenate limitation. High ethanol:acetate product ratios
are attained throughout the start-up by excess H2. Alternatively the reactor is allowed
to produce acetic acid during the early stages of start-up, with the product ratio later
brought under control through pantothenate limitation.
EXAMPLE 18. LIMITING COBALT TO THE REACTOR
C. Ijungdahlii, strain ERI2 was fed 62 to 3500 µg cobalt/g cell produced
during acetic acid production from CO, CO2 and H2, a condition where the reactor
was not limited on cobalt (or any other limitation except for the ability to transfer gas
to the culture), and no ethanol was found in the product stream. During limitation on
cobalt for ethanol production from CO, CO2 and H2, C. Ijungdahlii strain C-01 was
fed 33 to 48 µg cobalt/g cells produced, while maintaining all other nutrients in
excess. Under these conditions, strain C-01 produced 18 to 26 g/L ethanol and about
4 g/L acetate.
EXAMPLE 19. AVOIDING ACCLIMATION TO LOW LIMITING COBALT
CONCENTRATION
Acclimation to low limiting cobalt concentration is avoided by regulating the
fermentation parameters (gas rate, liquid rate, agitation rate, CO2 content) while
avoiding major changes in nutrients, but instead maintaining a relatively constant
nutrient feed concentration, as follows.
During start-up of a laboratory New Brunswick Scientific Bioflo® CSTR, C.
Ijungdahlii, strain C-01 was fed a liquid nutrient stream containing vitamins, trace
minerals and salts necessary to provide nutrition to the culture. The cobalt
concentration in the nutrient medium was 75 ppb, a concentration that when coupled
with the slow rate of medium feed ensures that there is more than 50 µg cobalt fed per
g of cells produced (excess cobalt) because of low cell production in the bioreactor
Similarly the pantothenate concentration in the medium was 20 µg/L, a concentration
that ensures pantothenate is also present in excess. Instead, the H2 partial pressure in
the exit gas was kept in excess of 0.55 atmospheres by feeding a gas containing large
quantities of H2 and no CO2, and by carefully regulating the gas feed rate and agitation
rates to achieve greater than 95% CO conversion and greater than 80% H2
conversion. As these high conversions are attained with time, the cell concentration
builds from an initial level of near 0 g/L to about 1.5 g/L. Since the cobalt
concentration is held constant during this start-up, the µg cobalt per g cells produced
gradually decreases until it is less than 50 µg cobalt/g cell produced, a condition which
is then cobalt limited. The system thus grows into cobalt limitation. High ethanol
yields are attained throughout the start-up by employing excess H2 in the feed.
Alternatively the reactor is allowed to produce acetic acid during the early stages of
start-up, with the product ratio later brought under control through cobalt limitation.
EXAMPLE 20. OVERSUPPLYING HYDROGEN
During operation of a laboratory AUTOKJLAV™ reactor (Buchi)
operated as a CSTR with liquid recirculation and cell recycle, C. Ijungdahlii was
operated with excess vitamins, trace minerals and salts necessary to provide nutrition
to the culture. The reactor was operated with excess H2 present in the feed gas such
that the ratio of the moles of H2 fed to the sum of two times the moles of CO
converted and three times the moles of CO2 converted was 5.67. If this ratio were not
greater than 1.0, excess H2 cannot be present in the reactor and ethanol production
due to the presence of excess H2 cannot occur. Furthermore, the H2 partial pressure
in the exit gas was 2.61 atm, a level that exceeds the requirement of 0.4 atm for
ethanol production due to excess H2. Finally, the ratio of H2 partial pressure to CO2
partial pressure in the exit gas was 10.88, a level which is greater than 3.0 and assures
that enough H2 is present to utilize all of the available carbon. Under these conditions
the reactor produced nearly 26 g/L ethanol and less than 3 g/L acetate. The ethanol
productivity was more than 200 g/L•day. If any of these above criteria are not met,
the reactor cannot produce ethanol due to excess H2 being present. Another aspect of
H2 abundance is that it results in additional reduced ferredoxin by oxidation through
hydrogenase.
EXAMPLE 21. ALLEVIATING CO SUBSTRATE INHIBITION
A laboratory New Brunswick Scientific Bioflo® CSTR operating at an
agitation rate of 800 rpm shows an outlet CO concentration of 10% when it had been
previously operating with only 5% CO in the gas outlet. By decreasing the agitation
rate to 600 rpm, CO inhibition was removed and the outlet CO concentration returned
to 5%. This results in increased H2 uptake, a necessary condition to efficiently utilize
all of the gas fed to the reactor.
EXAMPLE 22. MASS TRANSFER
As an example of excess mass transfer leading to ethanol production,
consider a laboratory CSTR with cell recycle containing C. ljungdahlii, strain ERI2
operating without nutrient limitation or excess H2 or CO in the feed gas. That is,
pantothenate is fed at a rate of more than 100 µg calcium pantothenate per gram of
cells produced and cobalt is fed at a rate of more than 100 µg per gram of cells
produced. H2 is present in the exit gas at about 0.2 atm and the specific CO uptake
rate is less than 0.3 mmol CO/g cells•min. The agitation rate is 800 rpm. Under these
conditions the culture produces only acetic acid (no ethanol present in the product
stream). If the agitation rate is increased quickly to 900 rpm or the gas rate is
increased by about 10%, ethanol is observed in the product stream, until the cell
concentration increases in order to uptake the gas or until the culture dies due to
substrate inhibition.
EXAMPLE 23. CONTROLLING ACETIC ACID PRODUCT INHIBITION
In a laboratory CSTR which is producing 8 g/L acetic acid and 10 g/L
ethanol, the liquid retention time is reduced from 24 hours to 12 hours for a period of
36 hours in an attempt to wash out the excess acetic acid from the reactor which is
limiting the ability of the culture to produce more ethanol. All other reactor operating
and nutrient conditions are held constant. After this period of time, the liquid
retention time is returned to 24 hours and a product stream containing 3 g/L acetate
and 15 to 25 g/L ethanol results. Several attempts in reducing the liquid retention
time are required to clear the product inhibition. Alternatively, H2 is added to the gas
feed to allow excess H2 control, since excess CO2 can also lead to acetic acid
production in favor of ethanol. These modifications prevent excess acetic acid
production, and thus prevent a poor product ratio, and a low ethanol productivity.
Thereafter, the use of excess H2 in the feed gas or limiting liquid phase nutrient
concentration is resumed.
EXAMPLE 24. OVERSUPPLYING CARBON MONOXIDE
C. ljungdahlii, strain ERI2 when fed excess nutrients (pantothenate
and cobalt in excess) and without an abundance of H2 in the feed gas had a specific
CO uptake rate of 0.23 to 0.48 mmol/g•min., and no ethanol was found in the product
stream. However, when C. ljungdahlii, strain C-01 was similarly fed excess nutrients
without an abundance of H2, in the feed gas, but was under a condition where ah
oversupply of CO was causing ethanol production, the specific CO uptake rate was
0.67 to 1.34 mmol/g•rnin. Under these conditions the culture produced 9.9 to 12.0
g/L ethanol and 2.6 to 2.7 g/L acetate.
EXAMPLE 25: CONTROLLING PRODUCT RATIOS WITH CELL PURGE
A gaseous substrate (30% CO, 15% H2, 10% CO2, 45% N2)
fermentation takes place in a CSTR (pH= 5.0, Temperature= 38ºC, Pressure = 20
psig) utilizing C. ljungdahlii, strain C-01, with cell recycle (cell retention time = 40
hours and the liquid retention time = 6 hours) and the culture is not limited in growth
by cobalt, calcium pantothenate, or any other nutrient. As the culture grows, a cell
density is attained such that the specific uptake (mmol CO per gram of dry cells per
minute) is below 0.5 and acetic acid is produced preferentially to ethanol. To prevent
this occurrence, the cell purge rate is increased to prevent an increase in cell density,
such that the steady concentration of cells is kept low enough to maintain a specific
uptake higher than 0.5 mmol CO per gram dry cells per minute. In doing so, the cell
retention time is reduced to between 6 and 25 hours.
a MPFN Trace Metals contains (per liter of solution): 10 ml of 85% H3PO4,
0.10 g of ZnSO4 • 7H20, 0.03 g of MnCl2•4H2O 0.3 g of H3BO3, 0.20 g of CoCl2 •
6H2O, 0.02 g of CuCl2 • H2O, 0.04 g of NiCl2 • 6H2O, 0.03 g of NaMoO4 • 2H2O,
2.00 g of FeCl2•4H2O, 0.01 g of Na2SeO3, and 0.10 g of Na2WO4• 2H2O
b Vitamins solution contains 20.6 mg/L d-biotin, 50.6 mg/L thiamine HCl
and 50.5 mg/L d-pantothenic acid, calcium salt
c Varies considerably from 0.3 - 0.5 ml at inoculation to as much as 0.7-0.8
ml at high gas rates
All published documents are incorporated by reference herein. Numerous
modifications and variations of the present invention are included in the
above-identified specification and are expected to be obvious to one of skill in the art.
Such modifications and alterations to the compositions and methods of the present
invention are believed to be encompassed in the scope of the claims appended hereto.
We claim:
1. A stable continuous method for producing ethanol from the anaerobic
bacterial fermentation of a gaseous substrate, the method comprising:
culturing in a bioreactor an anaerobic, acetogenic bacterium which is
capable of producing ethanol in a liquid nutrient medium;
supplying to said bioreactor said gaseous substrate comprising carbon
monoxide;
feeding calcium pantothenate into said bioreactor at an amount of 2 to
50µg/grams of dry cell of bacteria produced in said bioreactor; and
maintaining the specific rate of CO uptake in said bioreactor at an amount
of at least 0.3mmol CO/gram cell dry weight of bacteria/minute;
wherein free acetic acid is produced in said bioreactor at a concentration
of less than 5g/L free acid, said ethanol is produced at a productivity
greater than 10g/L per day and wherein both ethanol and acetate are
produced in said fermentation broth in said bioreactor at a ratio of ethanol
to acetate ranging from 1:1 to 20:1.
2 The method according to claim 1, wherein said bioreactor comprises a
growth reactor which feeds said fermentation broth to a second bioreactor
in which most of said ethanol is produced.
3 The method according to claim 1, further comprising the steps of removing
said fermentation broth from said bioreactor, distilling ethanol from said
broth and recovering said ethanol
4. The method according to claim 3, further comprising the steps of recycling
water containing acetate from said distilling step back to said bioreactor.
5. The method according to claim 1, wherein said bacteria is selected from
the group consisting of: Acetobacterium woodii, Butyribacterium
methylotrophicum, Clostridium aceticum, C. acetobutylicium, C.
thermoaceticum, Eubacterium limosum and Peptostreptococcus products.
6. The method according to claim 1, wherein said bacteria is Clostridium
ljungdahlii.
7. The method according to claim 6, wherein said Clostridium ljungdahlii is
selected from the strains consisting of PETC ATCC No. 55383, ERI-2
ATCC No. 55380, O-52 ATCC No. 55989 and C-01 ATCC No. 55988.
8. The method according to claim 1, wherein said gaseous substrate is
selected from the group consisting of (a) carbon monoxide, (b) carbon
monoxide and hydrogen, and (c) carbon monoxide, carbon dioxide and
hydrogen.
9. The method according to claim 1, wherein said gaseous substrate
additionally comprises nitrogen or methane.
10. The method according to claim 1, further comprising altering at least one
parameter selected from the group consisting of nutrient medium contents,
nutrient feed rate, aqueous feed rate, operating pressure, operating pH,
gaseous substrate contents, gas feed rate, fermentation broth agitation
rate, product inhibition step, cell density, substrate inhibition and
combinations thereof.
11 The method according to claim 10. comprising raising the pH above 4 5
12. The method according to claim 11, wherein the pH is less than about 5.5
13. The method according to claim 11, wherein the pH is 4.5 to 5.5:
14. The method according to claim 10, comprising periodically purging
bacterial cells from said bioreactor.
15. The method according to claim 10, comprising increasing the aqueous
feed rate when the free acetic acid portion of the acetate present in said
fermentation broth exceeds 2g/L, thereby reducing any unwanted increase
in the concentration of said free acetic acid.
16. The method according to claim 10, comprising reducing said gaseous
substrate feed rate to relieve substrate inhibition and maintain said
productivity.
17.The method according to claim 10, wherein said agitation rate is reduced
to relieve substrate inhibition and maintain said productivity.
18. The method according to claim 1, wherein said specific rate of CO uptake
is greater than 0.5mmol CO/gram of dry cell of bacteria in said
bioreactor/minute.
19. The method according to claim 1, wherein said specific rate of CO uptake
is 0.3 to 2 mmol CO/gram of dry cell of bacteria in said bioreactor/minute.
20.The method according to claim 1, wherein said specific rate of CO uptake
is 0 5 to 1 5 mmol CO/gram of dry cell bacteria in said bioreactor/minute
21. The method according to claim 8, wherein said gaseous substrate
comprises carbon monoxide, carbon dioxide, and hydrogen wherein
excess hydrogen relative to said carbon monoxide and carbon dioxide is
present and wherein said excess hydrogen causes said bacteria to
produce a high ethanol to acetate ratio in said fermentation broth.
22. The method according to claim 1, wherein said amount of said calcium
pantothenate is from 2 to 25pg calcium pantothenate/grams of dry cell of
bacteria produced.
23. The method according to claim 1, wherein said amount of said calcium
pantothenate is from 10 to 30µg calcium pantothenate/grams of dry cell of
bacteria produced.
24. The method according to claim 1, further comprising the step of preventing
acclimation of said bacteria in said bioreactor to said calcium pantothenate
amount by adjusting the parameters selected from the group consisting of
gas rate, liquid rate, and agitation rate.
25. The method according to claim 1, wherein said nutrient medium further
comprises cobalt at an amount of 5 to 100µg cobalt/grams of dry cell of
bacteria produced in said bioreactor.
26. The method according to claim 25, wherein said amount of cobalt is 20 to
50µg cobalt/grams of dry cell of bacteria produced.
27. The method according to claim 26, further comprising the step of
preventing acclimation of said bacteria in said bioreactor to said amount of
cobalt by maintaining a constant cobalt concentration and adjusting a
parameter selected from the group consisting of gas rate, liquid rate,
agitation rate and hydrogen gas partial pressure.
28. The method according to claim 3, further comprising separating said
bacteria from said fermentation broth and returning said separated
bacteria to said bioreactor.
A stable continuous method for producing ethanoi from the anaerobic
bacterial fermentation of a gaseous substrate, the method
comprising: culturlng In a bioreactor an anaerobic, acetogenic
bacterium which is capable of producing ethanoi in a liquid nutrient
medium; supplying to said bioreactor said gaseous sustrate
comprising carbon monoxide; feeding calcium pantothenate into said
bioreactor at an amount of 2 to 50 µg/grams of dry cell of bacteria
produced in said bioreactor; and maintaining the specific rate of CO
uptake in said bioreactor at an amount of at least 0.3 mmol CO/gram
cell dry weight of bacteria/minute; wherein free acetic acid is
produced in said bioreactor at a concentration of less than 5 g/L free
acid, said ethanoi is produced at a productivity greater than 10 g/L
per day and wherein both ethanoi and acetate are produced in said
fermentation broth in said bioreactor at a ratio of ethanoi to acetate
ranging from 1:1 to 20:1.

Documents:

19-KOLNP-2003-(25-06-2012)-FORM-27.pdf

19-KOLNP-2003-FORM-27.pdf

19-kolnp-2003-granted-abstract.pdf

19-kolnp-2003-granted-assignment.pdf

19-kolnp-2003-granted-claims.pdf

19-kolnp-2003-granted-correspondence.pdf

19-kolnp-2003-granted-description (complete).pdf

19-kolnp-2003-granted-drawings.pdf

19-kolnp-2003-granted-examination report.pdf

19-kolnp-2003-granted-form 1.pdf

19-kolnp-2003-granted-form 13.pdf

19-kolnp-2003-granted-form 18.pdf

19-kolnp-2003-granted-form 2.pdf

19-kolnp-2003-granted-form 26.pdf

19-kolnp-2003-granted-form 3.pdf

19-kolnp-2003-granted-form 5.pdf

19-kolnp-2003-granted-form 6.pdf

19-kolnp-2003-granted-letter patent.pdf

19-kolnp-2003-granted-reply to examination report.pdf

19-kolnp-2003-granted-specification.pdf

19-kolnp-2003-granted-translated copy of priority document.pdf


Patent Number 213962
Indian Patent Application Number 19/KOLNP/2003
PG Journal Number 04/2008
Publication Date 25-Jan-2008
Grant Date 23-Jan-2008
Date of Filing 03-Jan-2003
Name of Patentee EMMAUS FOUNDATION INC.
Applicant Address 1650 EMMAUS ROAD, FAYETTEVILLE, ARKANSAS 72701
Inventors:
# Inventor's Name Inventor's Address
1 GADDY , JAMES, L. 2207 TALL OAKS DRIVE FAYETTEVILLE, AR 72703
2 ARORA, DINESH, K. 2725 WAKEFIELD PLACE, FAYETTEVILLE, AR 72703
3 KO, CHING-WHAN 1245 MISSION BOULEVARD FAYETTEVILLE, AR 72701
4 PHILLIPS, JOHN, RANDALL 2425 SHARON, FAYETTEVILLE, AR 72703
5 BASU, RAHUL. 572 DOCKERY LANE, FAYETTEVILLE, AR 72702
6 WIKSTROM, CARL, V. 2832 CENTERWOOD ROAD, FAYETTEVILLE, AR 72703
7 CLAUSEN, EDGAR, C. 5137 WINGFOOT ROAD, FAYETTEVILLE
PCT International Classification Number C12P 7/06
PCT International Application Number PCT/US01/23149
PCT International Filing date 2001-07-23
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 60/220794 2000-07-25 U.S.A.