Enhanced microbial lipid production by Cryptococcus albidus in the high-cell-density continuous cultivation with membrane cell recycling and two-stage nutrient limitation.

As a potential feedstock for biofuel production, a high-cell-density continuous culture for the lipid production by Cryptococcus albidus was investigated in this study. The influences of dilution rates in the single-stage continuous cultures were explored first. To reach a high-cell-density culture, a single-stage continuous culture coupled with a membrane cell recycling system was carried out at a constant dilution rate of 0.36/h with varied bleeding ratios. The maximum lipid productivity of 0.69 g/L/h was achieved with the highest bleeding ratio of 0.4. To reach a better lipid yield and content, a two-stage continuous cultivation was performed by adjusting the C/N ratio in two different stages. Finally, a lipid yield of 0.32 g/g and lipid content of 56.4% were obtained. This two-stage continuous cultivation, which provided a higher lipid production performance, shows a great potential for an industrial-scale biotechnological production of microbial lipids and biofuel production.

Lipid production by microalgae Chlorella protothecoides with volatile fatty acids (VFAs) as carbon sources in heterotrophic cultivation and its economic assessment.

Volatile fatty acids (VFAs) that can be derived from food wastes were used for microbial lipid production by Chlorella protothecoides in heterotrophic cultures. The usage of VFAs as carbon sources for lipid accumulation was investigated in batch cultures. Culture medium, culture temperature, and nitrogen sources were explored for lipid production in the heterotrophic cultivation. The concentration and the ratio of VFAs exhibited significant influence on cell growth and lipid accumulation. The highest lipid yield coefficient and lipid content of C. protothecoides grown on VFAs were 0.187 g/g and 48.7%, respectively. The lipid content and fatty acids produced using VFAs as carbon sources were similar to those seen on growth and production using glucose. The techno-economic analysis indicates that the biodiesel derived from the lipids produced by heterotrophic C. protothecoides with VFAs as carbon sources is very promising and competitive with other biofuels and fossil fuels.

The effect of volatile fatty acids as a sole carbon source on lipid accumulation by Cryptococcus albidus for biodiesel production.

The use of volatile fatty acids (VFAs) for microbial lipid accumulation was investigated in flask cultures of Cryptococcus albidus. The optimum culture temperature and pH were 25°C and pH 6.0, respectively, and the highest lipid content (27.8%) was obtained with ammonia chloride as a nitrogen source. The lipid yield coefficient on VFAs was 0.167 g/g of C. albidus with a VFAs (acetic, propionic, butyric acids) ratio of 8:1:1, which was in good agreement with a theoretically predicted lipid yield coefficient of the VFAs as a carbon source. The major fatty acids of the lipids accumulated by C. albidus were similar to those of soybean oil and jatropha oil. A preliminary cost analysis shows that VFAs-based biodiesel production is competitive with current palm and soybean based biodiesels. Further process development for lower aeration cost and higher lipid yield will make this process more economical.

Enhanced production of human serum albumin by fed-batch culture of Hansenula polymorpha with high-purity oxygen.

Fed-batch cultures of Hansenula polymorpha were studied to develop an efficient biosystem to produce recombinant human serum albumin (HSA). To comply with this purpose, we used high purity oxygen supplying strategy to increase viable cell density in a bioreactor and enhance the production of target protein. A mutant strain, H. polymorpha GOT7 was utilized in this study as a host strain in both 5-L and 30-L scale fermentors. To supply high purity oxygen into a bioreactor, nearly 100 % high purity oxygen from commercial bomb or higher than 93 % oxygen available in-situ from a pressure swing adsorption oxygen generator (PSA) was employed. Under the optimal fermentation of H. polymorpha with high purity oxygen, the final cell densities and produced HSA concentrations were 24.6 g/L and 5.1 g/L in the 5-L fermentor, and 24.8 g/L and 4.5 g/L in the 30-L fermentor, respectively. These were about 2-10 times higher than those obtained in air-based fed-batch fermentations. The discrepancies between the 5-L and 30-L fermentors with air supply were presumably due to the higher contribution of surface aeration over submerged aeration in the 5-L fermentor. This study, therefore, proved the positive effect of high purity oxygen to enhance viable cell density as well as target recombinant protein production in microbial fermentations.

Effect of redox potential regulation on succinic acid production by Actinobacillus succinogenes.

The effects of redox potential used as a control parameter on the process of succinic acid production in batch cultures of Actinobacillus succinogenes NJ113 have been investigated. In batch fermentation, cell growth and metabolite distribution were changed with redox potential levels in the range of -100 to -450 mV. From the results, the ORP level of -350 mV was preferable, which resulted in high succinic acid yield (1.28 mol mol(-1)), high succinic acid productivity (1.18 g L(-1) h(-1)) and high mole ratio of succinic acid to acetic acid (2.02). The mechanism of redox potential regulation was discussed by metabolic flux analysis and the ratio of NADH/NAD+. We expected that redox potential can be used as a valuable parameter to monitor and control much more anaerobic fermentation production.

Oxygen transfer rate control in the production of human-like collagen by recombinant Escherichia coli.

The effects of different methods for elevating the OTR (oxygen transfer rate) during foreign gene expression and the cell growth of recombinant Escherichia coli BL21 were investigated. Two strategies were introduced to control DO (dissolved oxygen) levels in the fermentation broth: (i) increasing fermentor pressure and (ii) supplying oxygen-enriched air. These two methods were compared with the glucose feedback model, which acted as the control. By adopting a fed-batch method of cultivation, the cell yield coefficient (YX/S), accumulation of acetic acid and volumetric product yield (Yp) were measured or estimated. Adoption of these two methods led to an improvement in the OTR. The cell density and volumetric product yield in the cultivation controlled by increasing the fermentor pressure reached 77 g x l(-1) (dry cell weight) and 14 g x l(-1) respectively, which were much higher than those obtained with the strategy of supplying oxygen-enriched air (48 and 6 g x l(-1) respectively) and in the control (46 and 7 g x l(-1) respectively). The results indicate that increasing fermentor pressure is an effective way to enhance the OTR and recombinant protein (human-like collagen) productivity.

Effects of acetic acid and its assimilation in fed-batch cultures of recombinant Escherichia coli containing human-like collagen cDNA.

The primary processing problem in recombinant Escherichia coli fermentation is the production of acetic acid, which can inhibit both cell growth and recombinant protein production. The ability of E. coli to assimilate acetate permits it to solve this problem in a rather creative manner. In this study, the effects of acetic acid assimilation through a glucose starvation period at different cell growth phases were investigated in fed-batch cultures of recombinant E. coli. Experimental results showed that the human-like collagen (HLC) production could be improved by introducing glucose starvation at the end of batch culture and pre-induction phase, while the glucose starvation at the induction phase resulted in a poor HLC productivity. The acetic acid assimilation was observed during all the glucose starvation periods. In addition, a systematic study for evaluating the effects of acetic acid was carried out by adding acetate into culture media at different cell growth phases and then employing a glucose starvation after several hours. It was found that obvious acetate inhibition on cell growth occurred in the batch culture phases while its inhibitory effect on HLC expression occurred only in the post-induction phase. The longer the elevated acetic acid concentration maintained, the stronger the inhibitory effects were. These results are of significance for optimizing and scaling-up fermentation processes.

Continuous production of succinic acid using an external membrane cell recycle system.

Succinic acid was produced by continuous fermentation of Actinobacillus succinogenes sp. 130Z in an external membrane cell recycle reactor to improve viable cell concentration and productivity. Using this system, cell concentration increased to 16.4 g/l at the dilution rate 0.2 h-1, up to 3 times higher than that of batch culture, and the volumetric productivity of succinic acid increased up to 6.63 g/l/h at the dilution rate 0.5 h-1, 5 times higher than that of batch fermentation. However, in the continuous culture using a high dilution rate, operational problems including severe membrane fouling and contamination by lactic acid producer were observed. Another succinic acid producer, Mannheimia succiniciproducens MBEL55E, was also utilized in this system, and the cell concentration and productivity of succinic acid at the dilution rate of 0.3 h-1 were found to be above 3 and 2.3 times higher, respectively, compared with those obtained at the dilution rate of 0.1 h-1. These observations give a deep insight into the process design for a continuous succinic acid production by microorganisms.

Initial investigation of novel human-like collagen/chitosan scaffold for vascular tissue engineering.

With the increasing occurrence of vascular diseases and poor long-term patency rates of current small diameter vascular grafts, it becomes urgent to pursuit biomaterial as scaffold to mimic blood vessel morphologically and mechanically. In this study, novel human-like collagen (HLC, produced by recombinant E. coli)/chitosan tubular scaffolds were fabricated by cross-linking and freeze-drying process. The scaffolds were characterized by scanning electron microscope (SEM), X-ray photoelectron spectroscopy (XPS), and tensile test, respectively. Human venous fibroblasts were expanded and seeded onto the scaffolds in the density of 1 x 10(5) cells/cm(2). After a 15-day culture under static conditions, the cell-polymer constructs were observed using SEM, confocal laser scanning microscopy (CLSM), histological examination, and biochemical assays for cell proliferation and extracellular matrix production (collagen and glycosaminoglycans). Furthermore, the scaffolds were implanted into rabbits' livers to evaluate their biocompatibility. The results indicated that HLC/chitosan tubular scaffolds (1) exhibited interconnected porous structure; (2) achieved the desirable levels of pliability (elastic up to 30% strain) and stress of 300 +/- 16 kPa; (3) were capable of enhancing cell adhesion and proliferation and ECM secretion; (4) showed superior biocompatibility. This study suggested the feasibility of HLC/chitosan composite as a promising candidate scaffold for blood vessel tissue engineering.

Production of biomass and recombinant human-like collagen in Escherichia coli processes with different CO2 pulses.

The evolution of CO(2) in a fed-batch culture of recombinant Escherichia coli containing human-like collagen (HLC) cDNA was determined with an O(2)-enriched air supply (40%, v/v) in a 12.8 l fermentor; a maximum CO(2) concentration of 12.7% in the effluent gas was detected. The CO(2) pulse injection experiments showed that: (1) a 20% CO(2) pulse introduced in the batch cultivation phases inhibited cell growth but if introduced in the fed-batch cultivation phases slightly stimulated growth; and (2) CO(2) inhibited HLC expression only in the expression phase, where the final HLC concentration decreased by 34% under a 3 h 20% CO(2) pulse. The higher the CO(2) concentration and/or the longer the duration of the CO(2) pulse, the stronger the stimulatory or inhibitory effects.

Optimal production of poly-gamma-glutamic acid by metabolically engineered Escherichia coli.

Metabolically-engineered Escherichia coli strains were developed by cloning poly-gamma-glutamic acid (gamma-PGA) biosynthesis genes, consisting of pgsB, pgsC and pgsA, from Bacillus subtilis The metabolic and regulatory pathways of gamma-PGA biosynthesis in E. coli were analyzed by DNA microarray. The inducible trc promoter and a constitutive promoter (P(HCE)) derived from the D-amino acid aminotransferase (D-AAT) gene of Geobacillus toebii were employed. The constitutive HCE promoter was more efficient than inducible trc promoter for the expression of gamma-PGA biosynthesis genes. DNA microarray analysis showed that the expression levels of several NtrC family genes, glnA, glnK, glnG, yhdX, yhdY, yhdZ, amtB, nac, argT and cbl were up-regulated and sucA, B, C, D genes were down-regulated. When (NH(4))(2)SO(4 )was added at 40 g/l into the feeding solution, the final gamma-PGA concentration reached 3.7 g/l in the fed-batch culture of recombinant E. coli/pCOpgs.

Characteristics of fed-batch cultures of recombinant Escherichia coli containing human-like collagen cDNA at different specific growth rates.

Fed-batch cultures of recombinant Escherichia coli BL21 for producing human-like collagen were performed at different specific growth rates (0.1 approximately 0.25 h(-1)) before induction and at a constant value of 0.05 h(-1) after induction by the method of pseudo-exponential feeding. Although the final biomass (around 69 g l(-1)) was almost the same in all fed-batch cultures, the highest product concentration (13.6 g l(-1)) was achieved at the specific growth rate of 0.15 h(-1) and the lowest (9.6 g l(-1)) at 0.25 h(-1). The mean productivity of human-like collagen was the highest at 0.15 h(-1) (0.57 g l(-1)h(-1)) and the lowest at 0.1 h(-1) (0.35 g l(-1 )h(-1)). In the phase before induction, the cell yield coefficient (Y(X/S)) decreased when the specific growth rate increased, while the formation of acetic acid increased upto 2.5 g l(-1) at 0.25 h(-1). The mean product yield coefficient (Y(P/S)) also decreased with specific growth rate increasing. The respiration quotient (RQ) increased slightly with specific growth rate increasing before induction, and the mean value of RQ was around 72%. The optimum growth rate for human-like collagen production was 0.15 approximately 0.2 h(-1).

Sequential feeding of glucose and valerate in a fed-batch culture of Ralstonia eutropha for production of poly(hydroxybutyrate-co-hydroxyvalerate) with high 3-hydroxyvalerate fraction.

Several important properties of poly(3-hydroxybutyric-co-3-hydroxyvaleric acids) (P(3HB-co-3HV) depend mainly on the HV unit fraction of the copolymer. Sequential and simultaneous feeding of glucose and valerate were employed to produce P(3HB-co-3HV) in a fed-batch culture of Ralstonia eutropha, and the effects of feeding models on the cell growth, 3HV unit fraction, and copolymer productivity have been investigated. The sequential feeding of glucose and then valerate resulted in a cell density of 110.2 g/L, 3HV unit fraction of 62.7 mol %, and copolymer productivity of 0.56 g/(L.h), while the latter simultaneous feeding strategy never achieved the 3HV fraction of P(3HB-co-3HV) higher than 50%. A nuclear magnetic resonance study confirmed that the production of random copolymer P(3HB-co-3HV) with high 3HV unit fraction was possible even with sequential feeding of glucose and valerate.

Poly(3-hydroxybutyrate) synthesis in fed-batch culture of Ralstonia eutropha with phosphate limitation under different glucose concentrations.

Poly(3-hydroxybutyrate) (PHB) was produced by fed-batch cultures of Ralstonia eutropha with phosphate limitation under different glucose concentrations. When glucose was kept at 2.5 g l(-1), cell growth and PHB synthesis were limited due to the shortage of carbon source but a higher PHB content occurred in the cell-growth stage. This shows that a low glucose concentration is favorable for PHB accumulation in R. eutropha. PHB obtained with glucose at 9 g l(-1) is 1.6 times that obtained with 40 g l(-1). When glucose was in the range of 9 to 40 g l(-1), PHB concentration and productivity decreased significantly with the increase of glucose concentration. The highest PHB productivity was obtained with glucose at 9 g l(-1).

Inhibitory effect of carbon dioxide on the fed-batch culture of Ralstonia eutropha: evaluation by CO2 pulse injection and autogenous CO2 methods.

In order to see the effect of CO(2) inhibition resulting from the use of pure oxygen, we carried out a comparative fed-batch culture study of polyhydroxybutyric acid (PHB) production by Ralstonia eutropha using air and pure oxygen in 5-L, 30-L, and 300-L fermentors. The final PHB concentrations obtained with pure O(2) were 138.7 g/L in the 5-L fermentor and 131.3 g/L in the 30-L fermentor, which increased 2.9 and 6.2 times, respectively, as compared to those obtained with air. In the 300-L fermentor, the fed-batch culture with air yielded only 8.4 g/L PHB. However, the maximal CO(2) concentrations in the 5-L fermentor increased significantly from 4.1% (air) to 15.0% (pure O(2)), while it was only 1.6% in the 30-L fermentor with air, but reached 14.2% in the case of pure O(2). We used two different experimental methods for evaluating CO(2) inhibition: CO(2) pulse injection and autogenous CO(2) methods. A 10 or 22% (v/v) CO(2) pulse with a duration of 3 or 6 h was introduced in a pure-oxygen culture of R. eutropha to investigate how CO(2) affects the synthesis of biomass and PHB. CO(2) inhibited the cell growth and PHB synthesis significantly. The inhibitory effect became stronger with the increase of the CO(2) concentration and pulse duration. The new proposed autogenous CO(2) method makes it possible to place microbial cells under different CO(2) level environments by varying the gas flow rate. Introduction of O(2) gas at a low flow rate of 0.42 vvm resulted in an increase of CO(2) concentration to 30.2% in the exit gas. The final PHB of 97.2 g/L was obtained, which corresponded to 70% of the PHB production at 1.0 vvm O(2) flow rate. This new method measures the inhibitory effect of CO(2) produced autogenously by cells through the entire fermentation process and can avoid the overestimation of CO(2) inhibition without introducing artificial CO(2) into the fermentor.