U.S. patent application number 12/230921 was filed with the patent office on 2009-03-12 for biological oils and production and uses thereof.
This patent application is currently assigned to MARTEK BIOSCIENCES CORPORATION. Invention is credited to Kirk E. Apt, William Robert Barclay, Paul Warren Behrens, Jon Milton Hansen, James Casey Lippmeier, David Christian Martin, Joseph W. Pfeifer, III.
Application Number | 20090064567 12/230921 |
Document ID | / |
Family ID | 40430345 |
Filed Date | 2009-03-12 |
United States Patent
Application |
20090064567 |
Kind Code |
A1 |
Lippmeier; James Casey ; et
al. |
March 12, 2009 |
Biological oils and production and uses Thereof
Abstract
The present invention provides biological oils and methods and
uses thereof. The biological oils are preferably produced by
heterotrophic fermentation of one or more microorganisms using
cellulose-containing feedstock as a main source of carbon. The
present invention also provides methods of producing lipid-based
biofuels and food, nutritional, and pharmaceutical products using
the biological oils.
Inventors: |
Lippmeier; James Casey;
(Columbia, MD) ; Pfeifer, III; Joseph W.;
(Westminster, MD) ; Hansen; Jon Milton;
(Lexington, KY) ; Apt; Kirk E.; (Ellicott City,
MD) ; Barclay; William Robert; (Boulder, CO) ;
Behrens; Paul Warren; (Ellicott City, MD) ; Martin;
David Christian; (Reisterstown, MD) |
Correspondence
Address: |
FINNEGAN, HENDERSON, FARABOW, GARRETT & DUNNER;LLP
901 NEW YORK AVENUE, NW
WASHINGTON
DC
20001-4413
US
|
Assignee: |
MARTEK BIOSCIENCES
CORPORATION
|
Family ID: |
40430345 |
Appl. No.: |
12/230921 |
Filed: |
September 8, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60960037 |
Sep 12, 2007 |
|
|
|
Current U.S.
Class: |
44/308 ;
435/134 |
Current CPC
Class: |
C10L 1/026 20130101;
C10L 2200/0469 20130101; C10L 2290/26 20130101; C10L 2270/04
20130101; C12P 7/6472 20130101; C10L 1/02 20130101; Y02P 30/20
20151101; C10L 2270/026 20130101; C12P 7/649 20130101; Y02E 50/10
20130101 |
Class at
Publication: |
44/308 ;
435/134 |
International
Class: |
C10L 1/18 20060101
C10L001/18; C12P 7/64 20060101 C12P007/64 |
Claims
1. A method for producing a biological oil comprising growing a
microorganism of the kingdom Stramenopile by heterotrophic
fermentation using feedstock comprising cellulose as a carbon
source, wherein about 11% to about 99% of unsaturated fatty acids
in said biological oil are polyunsaturated fatty acids.
2. The method of claim 1, wherein greater than about 50% of
unsaturated fatty acids in said biological oil are polyunsaturated
fatty acids.
3. The method of claim 1, wherein said microorganism is a
Thraustochytrid.
4. The method of claim 1, wherein said microorganism is selected
from the group consisting of microorganisms of the genus
Schizochytrium, microorganism of the genus Thraustochytrium, and
microorganisms of the genus Ulkenia.
5. The method of claim 1, wherein said microorganism saccharifies
said cellulose.
6. The method of claim 1, wherein said microorganism is resistant
to or degrades feedstock components selected from the group
consisting of lignin, hemicellulose, plant oil, plant extracellular
polysaccharides, and combinations thereof.
7. The method of claim 1, wherein said microorganism is a
genetically modified microorganism.
8. The method of claim 1, wherein said microorganism produces oil
in triglyceride form in an amount of from about 25% to about 85% by
weight of its dry biomass.
9. The method of claim 1, further comprising performing autolysis
or induced lysis of said microorganism after said microorganism has
produced oil in an amount of from about 30% to about 90% by weight
of its dry biomass.
10. The method of claim 1, further comprising inducing lysis of
said microorganism by exposing said microorganism to a condition
favorable for lysis selected from the group consisting of a pH, a
temperature, the presence of an enzyme, the presence of a
detergent, physical disruption, and combinations thereof.
11. The method of claim 1, wherein said feedstock comprising
cellulose comprises a source of cellulose selected from the group
consisting of grass, sugar cane, agricultural waste, waste paper,
sewage, wood, an organism of the kingdom viridiplantae, and
combinations thereof.
12. The method of claim 1, wherein said fermentation is performed
in a nonsterile fermentor.
13. The method of claim 1, wherein said fermentation is performed
in a fermentor selected from the group consisting of fiber
reinforced polymer fermentors, metal matrix composite fermentors,
ceramic matrix composite fermentors, thermoplastic composite
fermentors, metal fermentors, epoxy lined carbon steel fermentors,
plastic lined carbon steel fermentors, plastic fermentors,
fiberglass fermenters, and concrete fermentors.
14. The method of claim 1, wherein said fermentation is carried out
in a fermentor that is submerged in water.
15. The method of claim 1, wherein said fermentation is carried out
in fermentors having cooling systems connected in series such that
cooling water effluent from a first fermentor or a set of
fermentors in the series is used as a cooling water supply for a
second fermentor or set of fermentors in the series.
16. The method of claim 1, wherein said fermentation is carried out
in fermentors having gas systems connected in series such that
sparge exhaust from a first fermentor or a set of fermentors in the
series is used as a gas supply for a second fermentor or set of
fermentors in the series.
17. A method for producing biodiesel comprising: (a) growing a
microorganism of the kingdom Stramenopile by heterotrophic
fermentation using feedstock comprising cellulose as a carbon
source to produce a biological oil, wherein about 11% to about 99%
of unsaturated fatty acids in said biological oil are
polyunsaturated fatty acids; and (b) transesterifying said
biological oil to produce biodiesel.
18. The method of claim 17, wherein greater than about 50% of
unsaturated fatty acids in said biological oil are polyunsaturated
fatty acids.
19. The method of claim 17, wherein said transesterifying of said
biological oil is performed using an alcohol derived from an
alcohol production process.
20. The method of claim 17, further comprising using glycerol
resulting from said transesterifying of said biological oil as a
carbon source for a subsequent fermentation process to produce an
alcohol or a biological oil.
21. The method of claim 20, wherein said subsequent fermentation
process grows a microorganism that is capable of using said
glycerol as a carbon source.
22. A method for producing jet biofuel comprising: (a) growing a
microorganism of the kingdom Stramenopile by heterotrophic
fermentation using feedstock comprising cellulose as a carbon
source to produce a biological oil, wherein about 11% to about 99%
of unsaturated fatty acids in said biological oil are
polyunsaturated fatty acids; and (b) cracking said biological oil
to produce jet biofuel.
23. The method of claim 22, wherein said biological oil comprises
about 10% to about 75% by weight of polyunsaturated fatty
acids.
24. A lipid-based biofuel composition comprising from about 1% to
about 75% by weight of alkyl esters of long chain fatty acids
having 20 or more carbons.
25. The lipid-based biofuel composition of claim 24, wherein said
lipid-based biofuel composition has a melting temperature of from
about 30.degree. C. to about -50.degree. C.
26. A method for producing a biological oil comprising growing two
or more microorganisms simultaneously or sequentially by
heterotrophic fermentation, using feedstock comprising cellulose as
a carbon source, wherein one or more of said microorganisms are
capable of saccharifying said cellulose.
27. A method of producing a biological oil comprising growing a
microorganism by heterotrophic fermentation in a nonsterile
fermentor.
28. The method of claim 27, wherein said biological oil is produced
at a rate of about 5 g/L/day to about 70 g/L/day.
29. The method of claim 28, wherein said biological oil is produced
at a rate of about 30 g/L/day to about 70 g/L/day.
30. The method of claim 27, wherein growing said microorganism
achieves a cell density of about 10 g/L to about 300 g/L.
31. The method of claim 30, wherein growing said microorganism
achieves a cell density of about 150 g/L to about 250 g/L.
32. The method of claim 27, wherein growing said microorganism
comprises using cellulose as a carbon source.
33. A method of producing biodiesel comprising: (a) growing a
microorganism in a nonsterile fermentor to produce a biological
oil; and (b) transesterifying said biological oil to produce
biodiesel.
34. A method of producing jet biofuel comprising: (a) growing a
microorganism in a nonsterile fermentor to produce a biological
oil; and (b) cracking said biological oil to produce jet
biofuel.
35. A method of producing biodiesel comprising: (a) growing a
microorganism using nutrients comprising recycled media to produce
a biological oil; and (b) transesterifying said biological oil to
produce biodiesel.
36. The method of claim 35, wherein said recycled media is selected
from the group consisting of de-lipidated biomass, hydrolyzed
biomass, partially hydrolyzed biomass, recycled metals, recycled
salts, recycled amino acids, recycled extracellular carbohydrates,
recycled glycerol, recycled yeast biomass, and combinations
thereof.
37. The method of claim 35, wherein growing said microorganism
comprises using cellulose as a carbon source.
38. A method of producing jet biofuel comprising: (a) growing a
microorganism using nutrients comprising recycled media to produce
a biological oil; and (b) cracking said biological oil to produce
jet biofuel.
39. A method of producing biodiesel comprising: (a) growing a
microorganism using a fermentation system comprising a continuous
seed stage and a lipid-production stage to produce a biological
oil; and (b) transesterifying said biological oil to produce
biodiesel.
40. The method of claim 39, wherein said continuous seed stage
produces biomass of said microorganism such that about 10% to about
95% of the total biomass production of said microorganism is
achieved during said continuous seed stage.
41. The method of claim 39, wherein said lipid-production stage is
carried out as a fed-batch process.
42. The method of claim 39, wherein said lipid-production stage
produces lipids such that about 10% to about 95% of the total lipid
production of said microorganism is achieved during said
lipid-production stage.
43. The method of claim 39, wherein growing said microorganism
comprises using cellulose as a carbon source.
44. A method of producing jet biofuel comprising (a) growing a
microorganism using a fermentation system comprising a continuous
seed stage and a lipid-production stage to produce a biological
oil; and (b) cracking said biological oil to produce jet biofuel.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority under 35
U.S.C. .sctn.119(e) of U.S. Provisional Application No. 60/960,037,
filed Sep. 12, 2007, the disclosure of which is incorporated by
reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to biological oils and uses
and production thereof. The biological oils of the present
invention can be produced by fermentation of a microorganism,
preferably using a cellulose-containing feedstock. The present
invention also relates to methods of producing lipid-based biofuels
and fuel additives, and food, nutritional, and pharmaceutical
products using these biological oils.
BACKGROUND OF THE INVENTION
[0003] The production of biological oils from sources such as
plants (including oilseeds), microorganisms, and animals is
essential for various purposes. For example, the production of
biodiesel requires large quantities of biological oils. Biodiesel
has been proposed as a carbon-neutral liquid fuel alternative to
petroleum-derived diesel. Biodiesel is most commonly formed by the
transesterification of acyl groups of vegetable oil lipids using a
simple alcohol (such as methanol, ethanol, or isopropanol). The
resulting alkyl esters can then be burned directly in most modern
compression ignition engines without any mechanical modifications.
Energy density of biodiesel has been estimated at 95% of that for
petroleum diesel (or "fossil diesel"). However, the higher
lubricity of biodiesel (and thus improved fuel efficiency) results
in approximately equal mileage obtained from equivalent volumes of
either fossil- or biodiesel.
[0004] Since biodiesel is currently made primarily from the seed
oils of CO.sub.2-fixing plants, the fuel is considered
"carbon-neutral" in that all of the CO.sub.2 emitted from burning
biodiesel was already in the atmosphere recently as opposed to
fossil diesel which when burned, releases carbon that has not been
in the atmosphere for millions of years. Therefore, biodiesel and
other carbon-neutral fuels may have much to contribute to
world-wide efforts to reduce the emission of greenhouse gasses
(such as CO.sub.2).
[0005] Several states in the United States have mandated that
biodiesel be mixed with fossil diesel sold in that state and the
federal government has also set goals for the use of renewable
transportation fuel. Current supplies of vegetable oils for
conversion to biodiesel have had trouble meeting these mandate
levels, resulting in higher prices for many oilseed crops,
particularly soybeans. If current trends continue, prices of
important oilseed crops could rise significantly. Ultimately the
goal is to supplant all sources of fossil fuels with competitively
priced bio-based alternatives. Unfortunately, if current sources of
oil for biodiesel do not change significantly, this goal may never
be realized.
[0006] Recognizing this challenge, investigations have been
conducted on alternative sources of oil for biodiesel production,
including the feasibility of making biodiesel from photosynthetic
algae grown in open ponds. Since some algae are oleaginous and grow
very quickly (for some, the duration of time from inoculum to
harvest is less than two weeks), the theoretical yield of oil per
acre per year could be orders of magnitude greater than what could
be derived from higher plants. It should be noted that the small
portions of the seeds of most oil-producing higher plants represent
only a small fraction of the overall mass of the plant, whereas
photosynthetic microalgae might accumulate a higher percentage of
their mass as oil useful for biodiesel production. There are
however, serious problems with the photosynthetic algae technology
that prevent the massive scale-up which are required to compete
effectively with fossil diesel technology.
[0007] The photosynthetic microalgae often had to be supplemented
with CO.sub.2 in order to achieve high yields of oil. From the
perspective of bioremediation, this is actually a benefit as excess
CO.sub.2 released from coal or oil-fired electrical plants, which
would otherwise be released to the atmosphere, could be used as a
feedstock for making biodiesel. This approach obviously does not
produce a truly carbon neutral fuel as the CO.sub.2 from a coal
plant is still released to the atmosphere eventually (after the
biodiesel is burned), but it does delay the rate at which
fossil-derived CO.sub.2 is released and generates more useful
energy per unit mass of fossil fuel. In fact, several companies
have been established to capitalize on this technology, including
Greenfuels Inc. Greenfuels specifically uses closed photobioreactor
systems which dissolve very high levels of CO.sub.2 from
fossil-fuel-fired electrical plants into photosynthetic algal
cultures. Due to the biophysical limitations of self-shading,
accumulation of biomass is dependent upon total illuminated surface
area. Thus, many photobioreactors are required to produce even
limited quantities of biodiesel. Therefore, while this technology
is useful as a bioremediation strategy for sequestering carbon (and
other greenhouse gases) from fossil-fuel burning electrical plants,
it is unlikely scalable to the levels required to meet future
biodiesel demands.
[0008] To address the issues of scalability, other organizations
have opted to further develop open pond technologies for making
phototrophic, algal-derived biodiesel. Open pond systems also rely
on CO.sub.2 supplementation for hypothetically economical levels of
oil accumulation. Therefore these systems also may be better
regarded as systems for bioremediation of waste carbon from fossil
fuels. The yields per acre per year of useful oil from these
systems are orders of magnitude greater than what can be derived
from seed-oil crops. From most perspectives, these systems appear
to be the best answer to limited supplies of biodiesel oil.
However, there is a significant problem which has not yet been
addressed. While the absolute theoretical yields of oil per acre
per year are quite high, the actual density of biomass accumulated
in open pond systems is relatively dilute. Because of this, massive
volumes of culture media need to be processed to extract the oil
from the biomass, which could significantly increase the costs of
the final oil.
[0009] A path to the replacement of gasoline with renewable
alternatives such as ethanol is less complex. It should be noted,
however, that the markets for compression combustion engines (which
burn fossil diesel or biodiesel) and for ignition combustion
engines (which burn gasoline or ethanol) generally serve different
needs. Compression ignition engines offer superior torque, which
make them more useful in industrial applications over ignition
combustion engines, which offer greater acceleration (thus making
the latter more popular for general commuting). Hence, there is no
reason to expect that the ignition combustion engine could fully
replace the compression combustion engine should a renewable
replacement for gasoline ever be fully adopted.
[0010] Despite certain disadvantages, much has been made of the
potential for ethanol to supplant gasoline as a liquid
transportation fuel. The Brazilian model, which relies on sugarcane
as a feedstock for ethanol fermentation, has been often cited as a
pioneering example for bio-fuel viability. Unfortunately, the
United States does not have a climate that could support the kind
of sugarcane productivity needed for massive ethanol production.
Initial efforts at scaling up American ethanol fermentation have
used corn syrup and corn starch as a feedstock, but there is
controversy surrounding the sustainability and scalability of this
arrangement as well. Because of this, more recent efforts have
focused on "cellulosic" sources of sugars to use as feedstocks in
ethanol fermentation. Cellulosic feedstock can be any feedstock
containing cellulose.
[0011] Because most plants are primarily composed of structural
polysaccharides (cellulose and hemicellulose) and lignan, acreage
can be used more efficiently if the sugar monomers of cellulose and
other structural polysaccharides are mobilized as a feedstock for
ethanol fermentation. This is in contrast to using corn starch,
which is found only in the corn plant kernels and constitute a
relatively low percentage of the crop's dry weight. Additionally,
since all plants contain cellulose, much faster-growing and more
climate-tolerant plants can be used as the primary source of
cellulose-based sugar. Examples of such plants include Switchgrass,
Miscanthus gigantus, and Poplar.
[0012] Today's primary biodiesel crops use land in a similarly
inefficient way (as corn for ethanol) since only the oil from the
seeds of biodiesel crops is used to make biodiesel. Cellulosic
ethanol processes have yet to be adopted on a broad scale but thus
far cellulosic ethanol is widely accepted as a possible sustainable
and economically competitive alternative to gasoline. Cellulosic
feedstocks are already being considered for the manufacture of
other petroleum-derived products (like plastics).
[0013] Patent application publication nos. WO 2005/035693, U.S.
2005/0112735, WO 2007/027633, WO 2006/127512, U.S. 2007/0099278,
U.S. 2007/0089356, and WO 2008/067605, the contents of which are
incorporated herein by reference in their entirety, all relate to
biodiesel or biofuel production systems.
[0014] Recently, heterotrophic growth of the microalga Chlorella
protothecoides by fermentation has been investigated for purposes
of biodiesel production. Researchers at Tsinghua University in
Beijing, China have performed studies on biodiesel production using
oil from the heterotrophic microalga Chlorella protothecoides. In
these studies, microalgae are grown in fermentors using glucose or
corn powder hydrolysate as sources of carbon. Microalgal oil is
then extracted and transesterified to produce biodiesel. See Miao,
X. and Wu, Q., Bioresource Technology 97: 841-846 (2006); Xu, H. et
al., Journal of Biotechnology 126: 499-507 (2006). Although these
researchers have suggested that starch and cellulose hydrolyzed
solutions can be a low cost substitute for glucose as a carbon
source in the fermentation process, they have also suggested that
cellulose hydrolyzation is difficult and costly. See Li, X. et al.,
"Large-scale biodiesel production from microalga Chlorella
protothecoids through heterotrophic cultivation in bioreactors,"
Biotechnology and Bioengineering, Accepted Preprint, Accepted Apr.
20, 2007.
[0015] In addition to diesel, another oil-based fuel that is in
need of a renewable and sustainable source is jet fuel. Aircrafts
depend on the use of various types of jet fuels, including
kerosene-type jet fuels and naphtha-type jet fuels. The heavy
reliance of the aviation industry on the limited supply of
petroleum-based jet fuels creates an urgent need for the discovery
of renewable jet biofuels.
[0016] Therefore, there exists a need for a low-cost and efficient
method for producing lipid-based biofuels that can be easily scaled
up to replace fossil diesel and jet fuels. As used herein,
"lipid-based biofuel" refers to any fuel that is produced from a
biological oil of the present invention, including, but not limited
to, biodiesel, jet biofuels, and specialty fuels. In order to
satisfy this need, an inexpensive and simple method must be
developed for producing biological oils which can be converted to
lipid-based biofuels. To reduce the costs of lipid-based biofuels
production, there exists a need for a low-cost method of producing
biological oils through the use of abundant and inexpensive raw
materials, such as cellulose-containing feedstock as a main carbon
source. In addition to a need to use inexpensive raw materials,
there exists a need for improved processes that also target cost
reduction in the production of biological oils. The improved
methods of producing these biological oils will not only lower the
cost of lipid-based biofuels production, but will also reduce the
costs associated with the use of these biological oils in many
other applications, including food, nutritional, and pharmaceutical
products.
[0017] For example, it is desirable to increase the dietary intake
of many beneficial nutrients found in biological oils. Particularly
beneficial nutrients include fatty acids such as omega-3 and
omega-6 long chain polyunsaturated fatty acids (LC-PUFAs) and
esters thereof. Omega-3 PUFAs are recognized as important dietary
compounds for preventing arteriosclerosis and coronary heart
disease, for alleviating inflammatory conditions and for retarding
the growth of tumor cells. Omega-6 PUFAs serve not only as
structural lipids in the human body, but also as precursors for a
number of factors in inflammation, such as prostaglandins,
leukotrienes, and oxylipins. Long chain omega-3 and the omega-6
PUFAs represent important classes of PUFAs.
[0018] There are two main series or families of LC-PUFAs, depending
on the position of the double bond closest to the methyl end of the
fatty acid: the omega-3 series contains a double bond at the third
carbon, while the omega-6 series has no double bond until the sixth
carbon. Thus, docosahexaenoic acid ("DHA") has a chain length of 22
carbons with 6 double bonds beginning with the third carbon from
the methyl end and is designated "22:6 n-3". Other important
omega-3 LC-PUFAs include eicosapentaenoic acid ("EPA"), which is
designated "20:5 n-3," and omega-3 docosapentaenoic acid ("DPA
n-3"), which is designated "22:5 n-3." Important omega-6 LC-PUFAs
include arachidonic acid ("ARA"), which is designated "20:4 n-6,"
and omega-6 docosapentaenoic acid ("DPA n-6"), which is designated
"22:5 n-6."
[0019] Because humans and many other animals cannot directly
synthesize omega-3 and omega-6 essential fatty acids, they must be
obtained in the diet. Traditional dietary sources of PUFAs include
vegetable oils, marine animal oils, fish oils and oilseeds. In
addition, oils produced by certain microorganisms have been found
to be rich in LC-PUFAs. In order to reduce the costs associated
with the production of dietary sources of PUFAs, there exists a
need for a low-cost and efficient method of producing biological
oils containing PUFAs. To lower the costs of PUFA containing
biological oils, there exists a need to develop a method of
producing these biological oils using inexpensive raw materials
(such as cellulose-containing feedstock) and improved processes
that are designed to lower the costs of production.
SUMMARY OF THE INVENTION
[0020] The present invention provides a method for producing a
biological oil comprising growing a microorganism of the kingdom
Stramenopile by heterotrophic fermentation using feedstock
comprising cellulose as a carbon source, wherein about 11% to about
99% of unsaturated fatty acids in the biological oil are
polyunsaturated fatty acids. In some embodiments of the present
invention, greater than about 50% of unsaturated fatty acids in the
biological oil are polyunsaturated fatty acids.
[0021] The microorganism used in the present invention can be, but
is not limited to, a Thraustochytrid, preferably selected from the
group consisting of microorganisms of the genus Schizochytrium,
microorganism of the genus Thraustochytrium, and microorganisms of
the genus Ulkenia.
[0022] In some embodiments of the present invention, the
microorganism used saccharifies the cellulose. Preferably, a
microorganism of the present invention degrades or is resistant to
feedstock components selected from the group consisting of lignin,
hemicellulose, plant oil, plant extracellular polysaccharides, and
combinations thereof. In some embodiments of the present invention,
the microorganism is a genetically modified microorganism.
[0023] A microorganism of the present invention can produce oil in
triglyceride form in an amount of from about 25% to about 85% by
weight of its dry biomass. In some embodiments of the present
invention, the growing of the microorganism biomass is performed at
a dissolved oxygen concentration of from about 10% to about 100%.
The production of biological oil by the microorganism may be
performed at a dissolved oxygen concentration of, for example, from
0% to about 10%. The microorganisms can grow at a temperature of
from about 15.degree. C. to about 45.degree. C.
[0024] In some embodiments of the present invention, the method of
producing biological oil further comprises performing autolysis or
induced lysis of the microorganism after the microorganism has
produced oil in an amount of from about 30% to about 90% by weight
of its dry biomass. Inducing lysis of the microorganism may be
achieved by exposing the microorganism to a condition favorable for
lysis selected from the group consisting of a pH, a temperature,
the presence of an enzyme, the presence of a detergent, physical
disruption, and combinations thereof.
[0025] In some embodiments of the present invention, the
fermentation feedstock containing cellulose comprises a source of
cellulose selected from the group consisting of grass, sugar cane,
agricultural waste, waste paper, sewage, wood, an organism of the
kingdom viridiplantae, and combinations thereof.
[0026] In preferred embodiments of the present invention, the
fermentation is performed in a nonsterile fermentor. In some
embodiments of the invention, the fermentation is performed in a
fermentor selected from the group consisting of fiber reinforced
polymer fermentors, metal matrix composite fermentors, ceramic
matrix composite fermentors, thermoplastic composite fermentors,
metal fermentors, epoxy lined carbon steel fermentors, plastic
lined carbon steel fermentors, plastic fermentors, fiberglass
fermentors, and concrete fermentors.
[0027] In some embodiments of the present invention, the
fermentation is carried out in a fermentor that is submerged in
water. The fermentation can be carried out in fermentors having
cooling systems connected in series such that cooling water
effluent from a first fermentor or a set of fermentors in the
series is used as a cooling water supply for a second fermentor or
set of fermentors in the series. Similarly, the fermentation can be
carried out in fermentors having gas systems connected in series
such that sparge exhaust from a first fermentor or a set of
fermentors in the series is used as a gas supply for a second
fermentor or set of fermentors in the series.
[0028] The present invention further provides a method for
producing biodiesel comprising (a) growing a microorganism of the
kingdom Stramenopile by heterotrophic fermentation using feedstock
comprising cellulose as a carbon source to produce a biological
oil, wherein about 11% to about 99% of unsaturated fatty acids in
the biological oil are polyunsaturated fatty acids; and (b)
transesterifying the biological oil to produce biodiesel. In some
embodiments of the present invention, greater than about 50% of
unsaturated fatty acids in the biological oil are polyunsaturated
fatty acids.
[0029] The transesterifying of the biological oil may be performed
using an alcohol derived from an alcohol production process. In
some embodiments of the present invention, glycerol resulting from
the transesterifying of the biological oil can be used as a carbon
source for a subsequent fermentation process to produce an alcohol
or a biological oil. In some embodiments of the present invention,
a subsequent fermentation process grows a microorganism that is
capable of using the glycerol as a carbon source.
[0030] The present invention also provides a method for producing
jet biofuel comprising (a) growing a microorganism of the kingdom
Stramenopile by heterotrophic fermentation using feedstock
comprising cellulose as a carbon source to produce a biological
oil, wherein about 11% to about 99% of unsaturated fatty acids in
the biological oil are polyunsaturated fatty acids; and (b)
cracking the biological oil to produce jet biofuel. In some
embodiments of the present invention, the biological oil used to
produce jet biofuel comprises about 10% to about 75% by weight of
polyunsaturated fatty acids.
[0031] The present invention provides a lipid-based biofuel
composition comprising from about 1% to about 75% by weight of
alkyl esters of long chain fatty acids having 20 or more carbons.
In some embodiments of the present invention, the lipid-based
biofuel composition has a melting temperature of from about
30.degree. C. to about -50.degree. C.
[0032] The present invention also provides a method for producing a
biological oil comprising: (a) growing two or more microorganisms
simultaneously or sequentially by heterotrophic fermentation, using
feedstock comprising cellulose as a carbon source, wherein one or
more of the microorganisms are capable of saccharifying said
cellulose.
[0033] The present invention further provides a method for
producing biodiesel comprising transesterifying a biological oil
produced by two or more microorganisms that have undergone
heterotrophic fermentation using feedstock comprising cellulose as
a carbon source, wherein one or more of the microorganisms are
capable of saccharifying the cellulose. To produce jet biofuel,
cracking may be performed on a biological oil produced by two or
more microorganisms that have undergone heterotrophic fermentation
using feedstock comprising cellulose as a carbon source, wherein
one or more of the microorganisms are capable of saccharifying the
cellulose.
[0034] The present invention provides a method of producing a
biological oil comprising growing a microorganism by heterotrophic
fermentation in a nonsterile fermentor. In some embodiments of the
present invention, the biological oil is produced at a rate of
about 5 g/L/day to about 70 g/L/day, preferably at a rate of about
30 g/L/day to about 70 g/L/day in the nonsterile fermentor.
[0035] In some embodiments of the present invention, growing the
microorganisms in the nonsterile fermentor achieves a cell density
of about 10 g/L to about 300 g/L, preferably about 150 g/L to about
250 g/L. Preferably, the growing of the microorganism comprises
using cellulose as a carbon source.
[0036] The present invention also provides a method of producing
biodiesel comprising: (a) growing a microorganism in a nonsterile
fermentor to produce a biological oil; and (b) transesterifying the
biological oil to produce biodiesel. The present invention further
provides a method of producing jet biofuel comprising: (a) growing
a microorganism in a nonsterile fermentor to produce a biological
oil; and (b) cracking the biological oil to produce jet
biofuel.
[0037] The present invention provides a method of producing
biodiesel comprising: (a) growing a microorganism using nutrients
comprising recycled media to produce a biological oil; and (b)
transesterifying the biological oil to produce biodiesel. The
recycled media can be, but is not limited to, de-lipidated biomass,
hydrolyzed biomass, partially hydrolyzed biomass, recycled metals,
recycled salts, recycled amino acids, recycled extracellular
carbohydrates, recycled glycerol, recycled yeast biomass, and
combinations thereof. Preferably, growing the microorganism
comprises using cellulose as a carbon source.
[0038] The present invention further provides a method of producing
jet biofuel comprising: (a) growing a microorganism using nutrients
comprising recycled media to produce a biological oil; and (b)
cracking the biological oil to produce jet biofuel.
[0039] Some embodiments of the present invention provide a method
of producing biodiesel comprising: (a) growing a microorganism
using a fermentation system comprising a continuous seed stage and
a lipid-production stage to produce a biological oil; and (b)
transesterifying the biological oil to produce biodiesel.
Preferably, the continuous seed stage produces biomass of the
microorganism such that about 10% to about 95% of the total biomass
production of the microorganism is achieved during the continuous
seed stage. In some embodiments of the present invention, the
lipid-production stage is carried out as a fed-batch process.
Preferably, the lipid-production stage produces lipids such that
about 10% to about 95% of the total lipid production of the
microorganism is achieved during the lipid-production stage. In
some embodiments of the present invention, growing the
microorganism comprises using cellulose as a carbon source.
[0040] The present invention further provides a method of producing
jet biofuel comprising: (a) growing a microorganism using a
fermentation system comprising a continuous seed stage and a
lipid-production stage to produce a biological oil; and (b)
cracking the biological oil to produce jet biofuel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 shows various embodiments of a method of producing
biological oils and biodiesel in accordance with the present
invention.
[0042] FIG. 2 shows an example of a fermentation system design in
accordance with the present invention.
[0043] FIG. 3 shows graphs of the dry cell weight, percent by
weight of lipids, percentage by weight of DHA, and amount of lipid
produced per liter of fermentation broth over time for the growth
of a microorganism (ATCC 20888) under sterile and nonsterile
conditions described in Example 4.
[0044] FIG. 4 shows graphs of the sugar consumption rate, oil
production rate (as grams per liter of fermentation broth per day),
biomass productivity rate (in grams per liter per day), and the
amount of lipid-free biomass over time for the growth of a
microorganism (ATCC 20888) under sterile and nonsterile conditions
described in Example 4.
[0045] FIG. 5 shows a diagram of a two-stage fermentation process
comprising a continuous seed stage and a fed-batch lipid
accumulation stage.
DETAILED DESCRIPTION OF THE INVENTION
[0046] The present invention provides biological oils and uses and
production thereof. Some embodiments of the present invention
provide oleaginous, heterotrophic organisms and processes suitable
for converting carbon, via fermentation, from directly
cellulose-based or ligno-cellulose based saccharides into vegetable
oil for biodiesel manufacturing. The processes of the present
invention would be more scalable, sustainable, and would generate a
more cost-competitive biodiesel than currently used or researched
processes (such as seed-oil biodiesel or photosynthetic algal
biodiesel).
[0047] Some aspects of the present invention involve high density
growth of two, oleaginous microorganisms using saccharified
cellulosic feedstocks. For example, the protist Schizochytrium sp.
and the oleaginous yeast Yarrowia lipolytica are suitable for such
processes because both have well-developed transformation systems
for modifying the microorganisms and are capable of producing high
levels of lipid by fermentation. Some aspects of the present
invention provide oleaginous thraustochytrids and fungi capable of
growing on a variety of cellulosic and ligno-cellulosic substrates,
and organisms that may be naturally amenable to combined
saccharification and fermentation, as well as lignin degradation or
resistance.
[0048] The present invention is also directed to improved strains
of organisms and processes for utilizing cellulose-based substrates
for oil production via molecular, biological, classical genetic,
and physiological means. Some embodiments of the present invention
provide an economical scale-up of a fermentation process for
converting cellular acylglycerides into biodiesel. The present
invention also provides biological and chemical reactor designs and
constructions, as well as commercial production strategies for the
implementation of the methods of the invention.
[0049] Various organisms can be used for the production of
biological oil in accordance with the present invention, including
microorganisms. The microorganisms can be algae, bacteria, fungi or
protists. Microbial sources and methods for growing microorganisms
are known in the art (Industrial Microbiology and Biotechnology,
2nd edition, 1999, American Society for Microbiology). For example,
the microorganisms can be cultured in a fermentation medium in a
fermentor. Oils produced by microorganisms can be used in the
methods and compositions of the present invention. In some
embodiments, organisms include those selected from the group
consisting of golden algae (such as microorganisms of the kingdom
Stramenopiles), green algae, diatoms, dinoflagellates (such as
microorganisms of the order Dinophyceae including members of the
genus Crypthecodinium such as, for example, Crypthecodinium
cohnii), yeast (such as a member of the genera Yarrowia (such as
Yarrowia lipolytica), Cryptococcus (such as Cryptococcus albidus),
Trichosporon, Candida, Lipomyces, Rhodosporidium, and Rhodotorula),
and fungi of the genera Mucor and Mortierella, including but not
limited to Mortierella alpina and Mortierella sect. schmuckeri.
Members of the microbial group Stramenopiles include microalgae and
algae-like microorganisms, including the following groups of
microorganisms: Hamatores, Proteromonads, Opalines, Develpayella,
Diplophrys, Labrinthulids, Thraustochytrids, Biosecids, Oomycetes,
Hypochytridiomycetes, Commation, Reticulosphaera, Pelagomonas,
Pelagococcus, Ollicola, Aureococcus, Parmales, Diatoms,
Xanthophytes, Phaeophytes (brown algae), Eustigmatophytes,
Raphidophytes, Synurids, Axodines (including Rhizochromulinaales,
Pedinellales, Dictyochales), Chrysomeridales, Sarcinochrysidales,
Hydrurales, Hibberdiales, and Chromulinales. The Thraustochytrids
include the genera Schizochytrium (species include aggregatum,
limnaceum, mangrovei, minutum, octosporum), Thraustochytrium
(species include arudimentale, aureum, benthicola, globosum,
kinnei, motivum, multirudimentale, pachydermum, proliferum, roseum,
striatum), Ulkenia (species include amoeboidea, kerguelensis,
minuta, profunda, radiate, sailens, sarkariana, schizochytrops,
visurgensis, yorkensis), Aplanochytrium (species include
haliotidis, kerguelensis, profunda, stocchinoi), Japonochytrium
(species include marinum), Althornia (species include crouchii),
and Elina (species include marisalba, sinorifica). The
Labrinthulids include the genera Labyrinthula (species include
algeriensis, coenocystis, chattonii, macrocystis, macrocystis
atlantica, macrocystis macrocystis, marina, minuta, roscoffensis,
valkanovii, vitellina, vitellina pacifica, vitellina vitellina,
zopfi), Labyrinthomyxa (species include marina), Labyrinthuloides
(species include haliotidis, yorkensis), Diplophrys (species
include archeri), Pyrrhosorus* (species include marinus),
Sorodiplophrys* (species include stercorea), Chlamydomyxa* (species
include labyrinthuloides, montana). (*=there is no current general
consensus on the exact taxonomic placement of these genera).
[0050] Some embodiments of the present invention provide a method
for producing a biological oil comprising growing a microorganism
of the kingdom Stramenopile by heterotrophic fermentation using
feedstock comprising cellulose as a carbon source. In some
embodiments of present invention, the biological oil contains
unsaturated fatty acids of which a significant portion is
polyunsaturated fatty acids. As described previously, certain
polyunsaturated fatty acids such as omega-3 and omega-6 long chain
polyunsaturated fatty acids are particularly important dietary
compounds. Therefore, it is desirable to produce a biological oil
with a significant amount of polyunsaturated fatty acids. In some
embodiments of the present invention, the biological oils are
converted to lipid-based biofuels. For such applications, it may be
desirable to produce hydrocarbons of various chain lengths,
particularly for jet biofuel applications. The presence of
significant amounts of polyunsaturated fatty acids in the
biological oils used to produce lipid-based biofuels will provide
greater flexibility and variety for the production of hydrocarbons
since the multiple sites of unsaturation in a polyunsaturated fatty
acid provide multiple sites for cleavage to make hydrocarbons. For
example, certain jet fuels require hydrocarbons with two to eight
carbons. The polyunsaturated fatty acids may be cleaved through
known processes in the art, such as cracking, to produce shorter
hydrocarbons of various chain lengths.
[0051] In some embodiments, the biological oils produced through
the methods of the present invention has unsaturated fatty acids
wherein about 11% to about 99% of the unsaturated fatty acids in
the biological oil are polyunsaturated fatty acids. The biological
oils of the present invention may contain unsaturated fatty acids
wherein about 20% to about 99%, about 26% to about 99%, about 30%
to about 99%, about 40% to about 99%, about 51% to about 99%, about
60% to about 99%, about 70% to about 99%, about 80% to about 99%,
or about 90% to about 99% of the unsaturated fatty acids in the
biological oil are polyunsaturated fatty acids. In some embodiments
of the present invention, greater than about 10%, greater than
about 20%, greater than about 25%, greater than about 30%, greater
than about 40%, greater than about 50%, greater than about 60%,
greater than about 70%, greater than about 80%, or greater than
about 90% of the unsaturated fatty acids in the biological oil are
polyunsaturated fatty acids.
[0052] In some embodiments of the present invention, the biological
oil comprises about 10% to about 75% by weight of polyunsaturated
fatty acids. For certain uses, the biological oil preferably
comprises about 20% to about 75%, about 30% to about 75%, about 40%
to about 75%, about 50% to about 75%, or about 60% to about 75% by
weight of polyunsaturated fatty acids. In some embodiments of the
present invention, the biological oil comprises at least about 10%,
at least about 20%, at least about 30%, at least about 40%, at
least about 50%, at least about 60%, or at least about 70% by
weight of polyunsaturated fatty acids. The methods of producing a
biological oil in accordance with the present invention may
optionally further comprise collecting the biological oil from the
microorganism.
[0053] As used herein, "cellulose" includes unsaccharified or
unhydrolyzed cellulose, as well as saccharified or hydrolyzed
cellulose. In some embodiments of the present invention, the
microorganism used is a Thraustochytrid. Preferably, the
microorganism is of the genus Schizochytrium, Thraustochytrium, or
Ulkenia. In some embodiments of the present invention, the
microorganism used is a yeast of the genus Yarrowia (such as
Yarrowia lipolytica), Cryptococcus (such as Cryptococcus albidus),
Trichosporon, Candida, Lipomyces, Rhodosporidium, or Rhodotorula.
Patent application publication no. WO 2004/101757, the contents of
which are incorporated herein by reference in its entirety,
discloses examples of these yeasts.
[0054] The present invention further contemplates the use of a
combination of two or more microorganisms for producing a
biological oil or a blend of biological oils. To reduce the costs
of fermentation, two or more microorganisms are preferably grown
under the same fermentation conditions. When two or more different
microorganisms are combined to produce the biological oil, one or
more microorganisms may accumulate oil during fermentation. One or
more microorganisms may facilitate the growth and accumulation of
oil by another microorganism through activity such as, but not
limited to, the breakdown of feedstock components into usable sugar
monomers (such as the saccharification of cellulose), the breakdown
of feedstock components that inhibit growth of another
microorganism (such as metabolizing or degrading feedstock
components such as lignin, hemicellulose (such as xylan,
glucuronoxylan, arabinoxylan, glucomannan, and xyloglucan), plant
oils, plant extracellular polysaccharides, etc.), and the synthesis
of components that promote growth of another microorganism (such as
through synthesis of certain enzymes that facilitate growth of the
microorganism).
[0055] Organisms suitable for the metabolization of hemicellulose
include, but are not limited to, Fibrobacter succinogenes, and
yeasts of the genera Cryptococcus (such as Cryptococcus albidus,
Cryptococcus curvatus), Trichosporon, Candida, Lipomyces,
Rhodosporidium, and Rhodotorula. Other organisms suitable for
metabolization of hemicellulose include species of Pichia (such as
Pichia stipitis), Aeromonas, Aspergillus, Streptomyces,
Rhodococcus, Bacillus (such as Bacillus subtilis, Bacillus brevis,
and Bacillus lentis), Echerichia, Kluyveromyces, Saccharomyces and
organisms of the genera Trichoderma, Organisms suitable for the
metabolization of lignin include, but are not limited to,
Phanerochaete chrysosporium and other "white rot" fungi. Patent
application publication no. WO 91/018974, the contents of which are
incorporated herein by reference in its entirety, discloses
examples of organisms that have hemicellulase activity.
[0056] Methods suitable for use in the present invention for
generating free sugars and oligosaccharides from lignocellulosic
biomass are disclosed, for example, in patent application
publication no. U.S. 2004/0005674, the content of which is
incorporated herein by reference in its entirety. These methods
involve converting lignocellulosic biomass to free sugars and small
oligosaccharides with enzymes (such as cellulases, xylanases,
ligninases, amylases, proteases, lipidases and glucuronidases) that
break down lignocellulose. These enzymes may be bought from a
commercial source or produced recombinantly, such as by expression
either in microorganisms, fungi, i.e., yeast, or plants.
[0057] Oleaginous microorganisms are preferred for use in the
present invention. As used herein, "oleaginous microorganisms" are
defined as microorganisms capable of accumulating greater than 20%
of the dry weight of their cells in the form of lipids. In some
embodiments of the present invention, a microorganism produces from
about 30% to about 95% by weight of its dry biomass as lipids.
Preferably, a microorganism of the present invention produces from
about 35% to about 93%, from about 40% to about 90%, from about 45%
to about 88%, from about 50% to about 85%, from about 55% to about
83%, from about 60% to about 80%, from about 65% to about 78%, or
from about 70% to about 75% by weight of its dry biomass as lipids.
In some embodiments of the present invention, the microorganism
produces at least about 30%, at least about 35%, at least about
40%, at least about 45%, at least about 50%, at least about 55%, at
least about 60%, at least about 65%, or at least about 70% by
weight of its dry biomass as lipids.
[0058] When two or more microorganisms are used to produce the
biological oils of the present invention, one or more
microorganisms may produce biological oils. In some embodiments of
the present invention, when two or more microorganisms are combined
to produce biological oils, the ratio of the amount of oil produced
by a first microorganism to the amount of oil produced by a second
microorganism, as measured by weight, is from about 1:9 to about
1:1, from about 1:9 to about 2:3, from about 1:9 to about 3:7, or
from about 1:9 to about 1:4.
[0059] Preferably, a microorganism of the present invention
produces oil in triglyceride form in an amount of from about 25% to
about 85% by weight of its dry biomass, from about 30% to about 85%
by weight of its dry biomass, from about 35% to about 85% by weight
of its dry biomass, from about 40% to about 85% by weight of its
dry biomass, from about 45% to about 85% by weight of its dry
biomass, from about 50% to about 85% by weight of its dry biomass,
from about 55% to about 85% by weight of its dry biomass, from
about 60% to about 85% by weight of its dry biomass, from about 60%
to about 80% by weight of its dry biomass, from about 65% to about
80% by weight of its dry biomass, from about 65% to about 75% by
weight of its dry biomass, or from about 70% to about 75% by weight
of its dry biomass. In some embodiments of the present invention,
the microorganism produces oil in triglyceride form in an amount of
at least about 25%, at least about 30%, at least about 35%, at
least about 40%, at least about 45%, at least about 50%, at least
about 55%, at least about 60%, at least about 65%, or at least
about 70% by weight of its dry biomass.
[0060] As used herein, a "triglyceride" is an ester of three fatty
acid residues and glycerol having a general chemical formula of
CH.sub.2(OOCR.sup.1)CH(OOCR.sup.2)CH.sub.2(OOCR.sup.3), wherein
each of OOCR.sup.1, OOCR.sup.2, and OOCR.sup.3 represents a fatty
acid residue. In some embodiments of the present invention,
suitable triglycerides may contain at least one PUFA. In some
embodiments, the PUFA has a chain length of at least 18 carbons.
Such PUFAs are referred to herein as long chain PUFAs or LC PUFAs.
In some embodiments, the PUFA can be docosahexaenoic acid C22:6 n-3
(DHA), omega-3 docosapentaenoic acid C22:5 n-3 (DPA(n-3)), omega-6
docosapentaenoic acid C22:5 n-6 (DPA(n-6)), arachidonic acid C20:4
n-6 (ARA), eicosapentaennoic acid C20:5 n-3 (EPA), stearidonic acid
(SDA), linolenic acid (LLA), alpha linolenic acid (ALA), gamma
linolenic acid (GLA), conjugated linolenic acid (CLA),
eicosatetraenoic acid (C20:4 n-3), homo-alpha and -gamma linolenic
acid (C20:3 n-6 and 20:3 n-3), adrenic acid (C22:4 n-6),
octacosaoctaenoic acid (C28:8), or mixtures thereof. The PUFAs can
also be present in any of the common forms found in natural lipids
including but not limited to triacylglycerols, diacylglycerols,
monoacylglycerols, phospholipids, free fatty acids, or in natural
or synthetic derivative forms of these fatty acids (e.g. calcium
salts of fatty acids, and the like). Reference to an oil or other
composition comprising triglycerides having PUFA residues, as used
in the present invention, can refer to either a composition
comprising triglycerides having only a single type of PUFA residue
such as DHA or a composition comprising triglycerides having a
mixture of more than one type of PUFA residues such as DHA, EPA and
ARA.
[0061] In preferred embodiments of the present invention, the
microorganisms are capable of high density cell growth. In some
embodiments of the present invention, the microorganisms are
capable of achieving a cell density of at least about 10 g/L, at
least about 15 g/L, at least about 20 g/L, at least about 25 g/L,
at least about 30 g/L, at least about 50 g/L, at least about 75
g/L, at least about 100 g/L, at least about 125 g/L, at least about
135 g/L, at least about 140 g/L, at least about 145 g/L, or at
least about 150 g/L. In some embodiments of the present invention,
the microorganisms are capable of achieving a cell density of from
about 10 g/L to about 300 g/L, from about 15 g/L to about 300 g/L,
from about 20 g/L to about 300 g/L, from about 25 g/L to about 300
g/L, from about 30 g/L to about 300 g/L, from about 50 g/L to about
300 g/L, from about 75 g/L to about 300 g/L, from about 100 g/L to
about 300 g/L, from about 125 g/L to about 300 g/L, from about 130
g/L to about 290 g/L, from about 135 g/L to about 280 g/L, from
about 140 g/L to about 270 g/L, from about 145 g/L to about 260
g/L, or from about 150 g/L to about 250 g/L. The high density
growth of the microorganisms of the present invention can be
increased by adjusting the fermentation conditions (such as
temperature, pH, concentration of ions, and gas
concentrations).
[0062] The present invention provides highly efficient production
of the biological oils. In some embodiments of the present
invention, the amount of biological oil produced is at least about
5 g/L/day, at least about 10 g/L/day, at least about 20 g/L/day, at
least about 30 g/L/day, at least about 40 g/L/day, at least about
50 g/L/day, at least about 60 g/L/day, or at least about 70
g/L/day. In some embodiments of the present invention, the amount
of biological oil produced is from about 5 g/L/day to about 70
g/L/day, from about 10 g/L/day to about 70 g/L/day, from about 20
g/L/day to about 70 g/L/day, or from about 30 g/L/day to about 70
g/L/day.
[0063] In some embodiments of the present invention, the
microorganism used for the production of the biological oil is a
cellulolytic microorganism and therefore is capable of
saccharifying cellulose from cellulosic or ligno-cellulosic
feedstocks. Cellulosic or ligno-cellulosic feedstocks include any
sources comprising cellulose. These include, but are not limited
to, grasses, sugar cane, agricultural waste, waste paper, sewage,
wood, and any organism in the viridiplantae kingdom or products
thereof. Preferably, the cellulose used is from a source other than
tree-based cellulose sources. The types of grasses useful as a
source of cellulose include, but are not limited to, saw grass,
wheat grass, rice grass, switch grasses, and Miscanthus type
grasses.
[0064] In order for a microorganism to use cellulose as a carbon
source, the cellulose must be broken down to its constituent sugar
monomers. Cellulose is a polymer of glucose linked by
beta-glucoside bonds which provide a highly stable linear
structure. The breakdown of cellulose into sugar monomers (also
referred to as saccharifying the cellulose) is a difficult
challenge and many attempts have been made to accomplish this.
Enzymatic hydrolysis of cellulose by cellulases is one approach to
degrade cellulose. A complete hydrolysis of cellulose generally
requires: an endoglucanase, which cleaves interior regions of
cellulose polymers; an exoglucanase, which cleaves cellobiose units
from the ends of cellulose polymers; and a beta-glucosidase, which
cleaves cellobiose into its glucose subunits. Cellulases may have
multiple complexes that accomplish the activities of an
endoglucanase, an exoglucanase, and a beta-glucosidase. Trichoderma
reesei is an important organism used for the production of
cellulases. Other methods of breaking down cellulose into sugar
monomers include thermochemical disruptions (with or without
mechanical disruptions), including hot water, steam explosion, acid
treatments, and/or ammonia fiber explosion.
[0065] In some embodiments of the present invention, the
microorganism that is grown to produce the biological oil is the
same microorganism that saccharifies the cellulose. In some
embodiments of the present invention, two or more microorganisms
can be grown, either simultaneously or sequentially, to produce
biological oils using cellulose-containing feedstock as a main
carbon source. In accordance with the present invention, when two
or more microorganisms are fermented simultaneously or
sequentially, one or more of the microorganisms are capable of
saccharifying cellulose. In some embodiments of the present
invention, a microorganism can undergo heterotrophic fermentation
in the presence of a cellulase to enhance the saccharification of
cellulose during fermentation. In some embodiments, at least one of
the microorganisms is from the Stramenopile kingdom, and preferably
is a member of the group commonly called thraustochytrids.
[0066] The microorganisms suitable for use in the present invention
may also be tolerant of high temperatures and/or highly acidic or
basic environments such that their growth is not inhibited and, in
some cases, is even enhanced by high temperatures and/or acidic
mediums. In some embodiments of the present invention, a
microorganism is grown by heterotrophic fermentation using
cellulose-containing feedstock at a temperature and/or a pH that
facilitates the degradation of cellulose. In some embodiments of
the present invention, the fermentation is performed at a
temperature of from about 15.degree. C. to about 70.degree. C.,
from about 20.degree. C. to about 40.degree. C., or from about
25.degree. C. to about 35.degree. C. In further embodiments of the
present invention, the fermentation is performed at a pH of from
about 3 to about 11, from about 3 to about 10, from about 4 to
about 9.5, from about 4 to about 9, from about 5 to about 7, or
from about 6 to about 9. Pretreatment of cellulose-containing
feedstocks using, for example, cellulases, chemical and/or
mechanical disruptions, and ammonia fiber explosions can also be
performed prior to using the feedstocks in the production of the
biological oils of the present invention. Alternatively, no such
pretreatment is necessary.
[0067] Some examples of methods of pretreating feedstock are
disclosed in patent application publication nos. U.S. 2007/0161095,
WO 05/053812, WO 06/086757, U.S. 2006/0182857, U.S. 2006/177551,
U.S. 2007/0110862, WO 06/096834, WO 07/055735, U.S. 2007/0099278,
WO 06/119318, U.S. 2006/0172405, and U.S. 2005/0026262, the
contents of which are incorporated herein by reference in their
entirety.
[0068] Examples of enzymes suitable for digestion of cellulose are
disclosed in patent or patent application publication nos. U.S.
2003/0096342, WO 03/012109, U.S. 7059993, WO 03/012095, WO
03/012090, U.S. 2003/0108988, U.S. 2004/0038334, U.S. 2003/0104522,
EP 1 612 267, and WO 06/003175, the contents of which are
incorporated herein by reference in their entirety.
[0069] In some embodiments of the present invention, the cellulosic
feedstock that is used to grow a microorganism comprises cellulose
in an amount of from about 5% to about 100%, from about 10% to
about 95%, from about 20% to about 90%, from about 30% to about
85%, from about 40% to about 80%, from about 50% to about 75%, or
from about 60% to about 70% by dry weight of the carbon feedstock.
In some embodiments of the present invention, the cellulosic
feedstock comprises cellulose in an amount of at least about 5%, at
least about 10%, at least about 20%, at least about 30%, at least
about 40%, at least about 50%, at least about 60%, or at least
about 70% of the dry weight of the carbon feedstock.
[0070] Preferably, the microorganism used in the present invention
is resistant to or degrades feedstock components such as lignin,
xylan, hemicellulose, plant oil, plant extracellular
polysaccharides, and combinations thereof. The degradation of or
resistance to these feedstock components ensures that the
fermentation performance of the microorganism will not be inhibited
by the presence of these components.
[0071] In some embodiments of the present invention, the cellulosic
feedstock used to grow a microorganism comprises from about 1% to
about 50%, from about 5% to about 40%, or from about 10% to about
30% by weight of a component selected from lignin, hemicellulose,
or a combination thereof. In some embodiments of the present
invention, the cellulosic feedstock used to grow a microorganism
comprises at least about 1%, at least about 5%, at least about 10%,
at least about 20%, or at least about 30% by weight of a component
selected from lignin, hemicellulose, or a combination thereof.
[0072] Suitable organisms can be obtained from a number of
available sources, including by collection from the natural
environment. As used herein, any organism, or any specific type of
organism, includes wild strains, mutants, or recombinant types.
Growth conditions in which to culture or grow these organisms are
known in the art, and appropriate growth conditions for at least
some of these organisms are disclosed in, for example, U.S. Pat.
No. 5,130,242, U.S. Pat. No. 5,407,957, U.S. Pat. No. 5,397,591,
U.S. Pat. No. 5,492,938, U.S. Pat. No. 5,711,983 and U.S. Pat. No.
6,607,900, all of which are incorporated herein by reference in
their entirety. When microbial oils are used, the microorganisms
are cultured in an effective medium, herein defined as any medium
capable of promoting oil production. Preferably, the effective
medium also promotes rapid microbial growth. The microorganisms can
be cultured in conventional fermentation modes, which include, but
are not limited to, batch, fed-batch, semi-continuous, and
continuous. As used herein, a "semi-continuous" mode refers to a
mode of fermentation in which a portion of the fermentation culture
containing microorganisms is not harvested from the fermentor after
the completion of a fermentation process. The portion of the
fermentation culture remaining in the fermentor can serve to
inoculate a subsequent fermentation process. In some embodiments of
the present invention, from about 1% to about 50%, from about 1% to
about 25%, from about 1% to about 15%, from about 1% to about 10%,
or from about 2% to about 8% by volume of the fermentation culture
is not harvested after completion of the fermentation process, and
is allowed to remain in the fermentor to inoculate a subsequent
fermentation process.
[0073] In some embodiments of the present invention, the
fermentation process comprises a first stage that targets
accumulation of biomass of the microorganism and a second stage
that targets lipid accumulation by the microorganism. Preferably,
there is no nutrient limitation during the biomass accumulation
stage. The lipid accumulation stage is preferably carried out with
nitrogen limitation with a carbon feed.
[0074] The methods of the present invention for producing biodiesel
can comprise (a) growing a microorganism using a fermentation
system comprising a continuous seed stage and a lipid-production
stage to produce a biological oil, and (b) converting the
biological oil into biodiesel through known means in the art, such
as through transesterifying the biological oil to produce
biodiesel. The continuous seed stage targets biomass accumulation
and is performed by providing continuous nutrient feed to the seed
vessel (the vessel with the initial inoculation). The fermentation
broth from the seed vessel is withdrawn and transferred to a
lipid-production stage vessel, which may run as a fed-batch process
where a carbon source is fed to the batch to maintain a target
sugar concentration throughout the run.
[0075] A similar two-stage fermentation process can be used to
produce biological oil for the production of jet biofuel. In some
embodiments of the present invention, the methods of producing jet
biofuel comprises converting the biological oil produced using this
fermentation system into jet biofuel by methods known in the art,
utilizing processes such as cracking to assist in transforming the
biological oil into a jet biofuel.
[0076] The two-stage fermentation process increases the efficiency
of the biological oil production process and therefore contributes
to lowering the cost of lipid-based biofuel production. This
improved fermentation system for the production of lipid-based
biofuel is particularly advantageous in maximizing efficient,
large-scale production of biological oils and therefore makes a
significant contribution to making lipid-based biofuel production
from biological oils more commercially feasible. The two-stage
fermentation process may be used to produce biological oil with
high or low polyunsaturated fatty acid content, depending on the
requirements of a specific application.
[0077] In some embodiments of the present invention, the biomass
accumulation stage (such as the continuous seed stage) produces
biomass of the microorganism such that about 10% to about 95%,
about 20% to about 95%, about 30% to about 95%, about 40% to about
95%, or about 50% to about 95% of the total biomass production of
the microorganism is achieved during the biomass accumulation
stage. In further embodiments of the present invention, about 60%
to about 95%, about 70% to about 95%, or about 80% to about 95% of
the total biomass production of the microorganism is achieved
during the biomass accumulation stage. In some embodiments of the
present invention, the biomass accumulation stage produces biomass
of the microorganism such that at least about 10%, at least about
20%, at least about 30%, at least about 40%, at least about 50%, at
least about 60%, at least about 70%, at least about 80%, at least
about 90%, or at least about 95% of the total biomass production of
the microorganism is achieved during the biomass accumulation
stage. Preferably, about 50% to about 95% of the total biomass
production of the microorganism is achieved during the biomass
accumulation stage.
[0078] In some embodiments of the present invention, the lipid
accumulation stage produces lipids such that about 10% to about
95%, about 20% to about 95%, about 30% to about 95%, about 40% to
about 95%, or about-50% to about 95% of the total lipid production
of the microorganism is achieved during the lipid accumulation
stage. In further embodiments of the present invention, about 60%
to about 95%, about 70% to about 95%, or about 80% to about 95% of
the total lipid production of the microorganism is achieved during
the lipid accumulation stage. In some embodiments of the present
invention, the lipid accumulation stage produces lipids such that
at least about 10%, at least about 20%, at least about 30%, at
least about 40%, at least about 50%, at least about 60%, at least
about 70%, at least about 80%, at least about 90%, or at least
about 95% of the total lipid production of the microorganism is
achieved during the lipid accumulation stage. Preferably, about 50%
to about 95% of the total lipid production of the microorganism is
achieved during the lipid accumulation stage.
[0079] Genetically modified microorganisms are also suitable for
the present invention. Microorganisms of the present invention may
be genetically modified to enhance their ability to produce
biological oils at reduced costs (for example, through an enhanced
ability to use cellulose-based feedstock as a main carbon source).
These genetically modified microorganism can include, but are not
limited to, microorganisms that have been genetically modified to
have an enhanced ability to saccharify cellulose or cellulosic
feedstock, to have increased oil production, to have the ability to
degrade lignin or be resistant to lignin, or to grow in culture
conditions that are not optimal for the corresponding wild-type
organism (such as high temperatures or highly acidic mediums). For
example, a microorganism can be genetically modified to introduce
or enhance the activities of an endoglucanase, an exoglucanase,
and/or a beta-glucosidase.
[0080] Genes from organisms used to develop cellulases can be
introduced into a microorganism to enhance its ability to
saccharify cellulose. For example, genes encoding components of
cellulases from organisms of the genera Trichoderma, Clostridium,
Cellulomonas, Thermobifida, Acidothermus, Schizochytrium, or
Thraustochytrium can be introduced into a microorganism of the
present invention through recombinant genetic techniques to produce
a microorganism that is capable of directly saccharifying
cellulose. Preferably, genes encoding cellulase components from the
species Trichoderma reesei, Clostridium thermocellum, Acidothermus
cellulolyticus, or Schizochytrium aggregatum are introduced and
expressed in microorganisms of the present invention. In some.
embodiments of the present invention, a cellulase from one organism
is cloned into a different organism.
[0081] Genetic transformation techniques for microorganisms are
well-known in the art and are discussed, for example, in Sambrook
et al., 1989, Molecular Cloning: A Laboratory Manual, Cold Spring
Harbor Labs Press. A general technique for transformation of
dinoflagellates, which can be adapted for use with Crypthecodinium
cohnii, is described in detail in Lohuis and Miller, The Plant
Journal (1998)13(3): 427-435. A general technique for genetic
transformation of Thraustochytrids is described in detail in U.S.
Patent Application Publication No. 20030166207, published Sep. 4,
2003.
[0082] In some embodiments of the present invention, fermentation
of the microorganisms to produce biological oils is performed under
low dissolved oxygen concentrations. The ability of the
microorganisms to grow and produce oil at low dissolved oxygen
concentrations reduces energy input into fermentation, and
therefore would also reduce the cost of fermentation. In some
embodiments of the present invention, the growing of the
microorganism biomass (biomass accumulation stage) is performed at
a dissolved oxygen concentration of from about 4% to about 100%,
from about 10% to about 100%, from about 10% to about 80%, from
about 10% to about 70%, from about 10% to about 60%, from about 15%
to about 50%, or from about 20% to about 40%. The production of
biological oil by the microorganism (the lipid accumulation stage)
may be performed at a dissolved oxygen concentration of, for
example, from 0% to about 10%, from 0% to about 8%, from about 1%
to about 5%, or from about 1% to about 3%.
[0083] To reduce energy costs associated with the cooling of the
fermentors, the microorganisms used in the present invention are
preferably temperature tolerant over a wide range of temperatures.
In some embodiments of the present invention, the microorganisms
can grow and produce oil at a temperature of from about 15.degree.
C. to about 45.degree. C., from about 20.degree. C. to about
45.degree. C., from about 25.degree. C. to about 45.degree. C.,
from about 30.degree. C. to about 45.degree. C., or from about
35.degree. C. to about 45.degree. C.
[0084] Conventionally, the fermentation of a microorganism is
usually carried out in a sterile environment to avoid contaminants
that may interfere with the biomass growth and/or lipid
accumulation of the microorganism. Performing the fermentation
under sterile conditions adds to the cost of the biological oil
production from the microorganisms. In order to minimize the cost
of fermentation, the present invention provides the unexpected
solution of producing the biological oils by fermentation in
nonsterile fermentors. The use of nonsterile fermentors to produce
oil from a microorganism is especially suitable for production of
oils for lipid-based biofuel purposes since it significantly
reduces the costs of oil production and makes lipid-based biofuel
production more commercially viable. Nonsterile fermentors may be
used to produce biological oils with high or low polyunsaturated
fatty acid content, depending on the requirements for a specific
application.
[0085] Preferably, low-cost fermentors could be employed in the
fermentations, including fiber reinforced polymer fermentors, metal
matrix composite fermentors, ceramic matrix composite fermentors,
thermoplastic composite fermentors, metal fermentors, epoxy lined
carbon steel fermentors, plastic lined carbon steel fermentors,
plastic fermentors, fiberglass fermentors, concrete fermentors, and
fermentors made of polymers (such as polypropylene (PP), high
density polyethelene (HDPE), polycarbonate (PC), polystyrene (PS),
polyvinyl chloride (PVC), kynar, and nylon). The low-cost fermentor
can also be made of a combination of the above materials. Low-cost
tank cleaning can also be employed in accordance with the present
invention to further reduce costs of fermentation. Low-cost tank
cleaning include, but is not limited to, using methoxide or
ethoxide to chemically scrub the fermentation tanks.
[0086] In some embodiments of the present invention, the biological
oil is produced at a rate of about 5 g/L/day to about 70 g/L/day in
a nonsterile fermentor. Preferably, the amount of biological oil
produced in a nonsterile fermentor is at least about 5 g/L/day, at
least about 10 g/L/day, at least about 20 g/L/day, at least about
30 g/L/day, at least about 40 g/L/day, at least about 50 g/L/day,
at least about 60 g/L/day, or at least about 70 g/L/day. In some
embodiments of the present invention, the amount of biological oil
produced in a nonsterile fermentor is from about 10 g/L/day to
about 70 g/L/day, from about 20 g/L/day to about 70 g/L/day, or
from about 30 g/L/day to about 70 g/L/day.
[0087] The growing of the microorganism in a nonsterile fermentor
preferably achieves a high cell density of at least about 10 g/L,
at least about 15 g/L, at least about 20 g/L, at least about 25
g/L, at least about 30 g/L, at least about 50 g/L, at least about
75 g/L, at least about 100 g/L, at least about 125 g/L, at least
about 135 g/L, at least about 140 g/L, at least about 145 g/L, at
least about 150 g/L, or at least about 200 g/L. In some embodiments
of the present invention, the microorganisms undergoing
fermentation in a nonsterile fermentor are capable of achieving a
cell density of from about 10 g/L to about 300 g/L, from about 15
g/L to about 300 g/L, from about 20 g/L to about 300 g/L, from
about 25 g/L to about 300 g/L, from about 30 g/L to about 300 g/L,
from about 50 g/L to about 300 g/L, from about 75 g/L to about 300
g/L, from about 100 g/L to about 300 g/L, from about 125 g/L to
about 300 g/L, from about 130 g/L to about 290 g/L, from about 135
g/L to about 280 g/L, from about 140 g/L to about 270 g/L, from
about 145 g/L to about 260 g/L, or from about 150 g/L to about 250
g/L.
[0088] In some embodiments of the present invention, changes in the
fermentation conditions of the microorganism (such as pH,
temperature, dissolved oxygen concentration, ion ratios, etc.) can
be utilized to alter the fatty acid profile of the resulting oil
depending on the intended use of the biological oil. In accordance
with the intended use of the biological oils of the present
invention, fermentation conditions can be adjusted, for example, to
promote or impede the production of lipids in the triglyceride form
by the microorganisms, to promote or impede the production of
specific fatty acids or blends of fatty acids by the microorganisms
(such as fatty acids of a specific chain length or degree of
unsaturation), to promote or impede the production of oils that
provide a high or low level of energy per unit volume of the oil,
or to promote or impede the accumulation of certain byproducts in
the oils produced by the microorganisms. Different uses of the
biological oils of the present invention for lipid-based biofuel
purposes include, but are not limited to, uses as heating oil,
transportation biodiesel, jet fuel, and fuel additives. In some
embodiments of the present invention, deuterium can be utilized in
the fermentation medium to facilitate production of ultra-low
volume, very high value, specialty fuels or lubricants. In some
embodiments of the present invention, the conversion of biological
oils into lipid-based biofuels involves chemical processes and
refining techniques known in the art which may also produce or be
used to produce specialty chemical compounds similar to petroleum
distillates (such as plastics components). The profit from the sale
of these specialty chemicals could also offset the costs of
lipid-based biofuels production. Various other uses of the
biological oils are contemplated within the scope of the present
invention. For example, the biological oils of the present
invention can be used in any suitable food, nutritional, or
pharmaceutical products.
[0089] The present invention also provides methods for fermenting
the microorganisms in fermentation tanks that are submerged in a
liquid such as water for cooling. In some embodiments of the
present invention, the fermentation utilities can be set up in
series to minimize energy use. For example, cooling effluent and
sparge exhaust from one series of fermentors could be used as a
supply (or partial supply) of cooling water and gas, respectively,
for fermentors that are next in line in the series or upstream in
the series. The fermentation system can be set up such that the
cooling water could come from a natural body of water such as a
lake, pond, or ocean. The fermentation system can be designed such
that the cooling systems for the fermentors are connected in series
such that the cooling water effluent from a first fermentor or a
set of fermentors that are in the series can be used as a cooling
water supply for a second fermentor or set of fermentors in the
series. Similarly, the fermentation system can be designed such
that the gas supply for the fermentors are connected in series such
that the sparge exhaust from a first fermentor or a set of
fermentors that are in the series can be used as a gas supply for a
second fermentor or set of fermentors in the series. The first
fermentor or set of fermentors can be earlier or later in the
series in relation to the second fermentor or set of fermentors.
The fermentations of the present invention are preferably conducted
in batch, fed-batch, semi-continuous, or continuous modes.
[0090] While in some embodiments of the invention, the biological
oils comprising triglycerides can be a crude oil (discussed in more
detail below), other such oils useful in the present invention can
be recovered from their sources by any suitable means known to
those in the art. For example, oils can be recovered by extraction
with solvents such as chloroform, hexane, methylene chloride,
methanol and the like, by supercritical fluid extraction, or by
solventless extraction methods. In some embodiments of the present
invention, the biological oils are recovered by extraction with
hexane. Alternatively, the oils can be extracted using extraction
techniques, such as are described in U.S. Pat. No. 6,750,048 and
PCT Patent Application Serial No. U.S.01/01806, both filed Jan. 19,
2001, and entitled "Solventless Extraction Process," both of which
are incorporated herein by reference in their entirety. Additional
extraction and/or purification techniques are taught in PCT Patent
Application Serial No. PCT/IB01/00841 entitled "Method for the
Fractionation of Oil and Polar Lipid-Containing Native Raw
Materials" filed Apr. 12, 2001; PCT Patent Application Serial No.
PCT/IB01/00963 entitled "Method for the Fractionation of Oil and
Polar Lipid-Containing Native Raw Materials Using Water-Soluble
Organic Solvent and Centrifugation" filed Apr. 12, 2001; U.S.
Provisional Patent Application Ser. No. 60/291,484 entitled
"Production and Use of a Polar Lipid-Rich Fraction Containing
Stearidonic Acid and Gamma Linolenic Acid from Plant Seeds and
Microbes filed May 14, 2001; U.S. Provisional Patent Application
Ser. No. 60/290,899 entitled "Production and Use of a Polar-Lipid
Fraction Containing Omega-3 and/or Omega-6 Highly Unsaturated Fatty
Acids from Microbes, Genetically Modified Plant Seeds and Marine
Organisms" filed May 14, 2001; U.S. Pat. No. 6,399,803 entitled
"Process for Separating a Triglyceride Comprising a Docosahexaenoic
Acid Residue from a Mixture of Triglycerides" issued Jun. 4, 2002
filed February 17, 2000; and PCT Patent Application Ser. No.
U.S.01/01010 entitled "Process for Making an Enriched Mixture of
Polyunsaturated Fatty Acid Esters" filed Jan. 11, 2001; all of
which are incorporated herein by reference in their entirety. The
extracted oils can be evaporated under reduced pressure to produce
a sample of concentrated oil material. Processes for the enzyme
treatment of biomass for the recovery of lipids are disclosed in
U.S. Provisional Patent Application No. 60/377,550, entitled
"HIGH-QUALITY LIPIDS AND METHODS FOR PRODUCING BY ENZYMATIC
LIBERATION FROM BIOMASS," filed on May 3, 2002; PCT Patent
Application Serial No. PCT/U.S.03/14177 entitled "HIGH-QUALITY
LIPIDS AND METHODS FOR PRODUCING BY ENZYMATIC LIBERATION FROM
BIOMASS," filed on May 5, 2003; copending U.S. patent application
Ser. No. 10/971,723, entitled "HIGH-QUALITY LIPIDS AND METHODS FOR
PRODUCING BY LIBERATION FROM BIOMASS," filed on Oct. 22, 2004; EP
Patent Publication 0 776 356 and U.S. Pat. No. 5,928,696, both
entitled "Process for extracting native products which are not
water-soluble from native substance mixtures by centrifugal force,"
the disclosures of which are hereby incorporated herein by
reference in their entirety. The oils may be extracted by
pressing.
[0091] In some embodiments, an oil obtained from a source described
above can serve as the starting material for further modifications
(such as transesterification or cracking) in accordance with the
methods of the present invention even when it has not been
subjected to conventional processing. Examples of such conventional
processes that may be avoided include refining (e.g., physical
refining, silica refining or caustic refining), desolventization,
deodorization, winterization, chill filtration, and/or bleaching.
Thus, in certain embodiments, the oils containing triglycerides
have not been subjected to one or more treatments selected from
refining, desolventization, deodorization, winterization, chill
filtration, and bleaching and in further embodiments, the oils have
not been subjected to any one of refining, desolventization,
deodorization, winterization, chill filtration, and bleaching.
[0092] In some embodiments, the crude oil may be isolated from a
microorganism using standard techniques, without being subjected to
further refinement or purification. For example, the oil can be a
microbial oil that has only been subjected to solvent extraction,
such as hexane extraction, isopropanol extraction, or the like. In
some embodiments of the present invention, the crude oil may be
isolated from a microorganism using physical and/or mechanical
extraction methods (such as through the use of a homogenizer, or by
pressing), without being subjected to further refinement or
purification.
[0093] In other embodiments, compositions comprising triglycerides
having polyunsaturated fatty acid residues, such as oils described
above, may be subjected to further processing steps, such as
refining, desolventization, deodorization, winterization, chill
filtration, and/or bleaching. Such "processed" oils include
microbial oils that have been subjected to solvent extraction and
one or more of these additional processing steps. In some
embodiments, oils are minimally processed. "Minimally processed"
oils include microbial oils that have been subjected to solvent
extraction and filtration. In certain embodiments, minimally
processed oils are further subjected to winterization.
[0094] In some embodiments of the present invention, a method
similar to the FRIOLEX.RTM. (Westfalia Separator Industry GmbH,
Germany) process is used to extract the biological oils produced by
the microorganisms. FRIOLEX.RTM. is a water-based physical oil
extraction process, whereby raw material containing oil can be used
directly for extracting oil without using any conventional solvent
extraction methods. In this process, a water-soluble organic
solvent can be used as a process aid and the oil is separated from
the raw material broth by density separation using gravity or
centrifugal forces. Patent application publication nos. WO 01/76715
and WO 01/76385, the contents of which are incorporated herein by
reference in their entirety, disclose such extraction methods.
[0095] After the oil has been extracted, the oil can be recovered
or separated from non-lipid components by any suitable means known
in the art. In preferred embodiments of the present invention,
low-cost physical and/or mechanical techniques are used to separate
the lipid-containing compositions from non-lipid compositions. For
example, if multiple phases or fractions are created by the
extraction method used to extract the oil, where one or more phases
or fractions contain lipids, a method for recovering the
lipid-containing phases or fractions can involve physically
removing the lipid-containing phases or fractions from the
non-lipid phases or fractions, or vice versa. In some embodiments
of the present invention, a FRIOLEX.RTM. type method is used to
extract the lipids produced by the microorganisms and the
lipid-rich light phase is then physically separated from the
protein-rich heavy phase (such as by skimming off the lipid-rich
phase that is on top of the protein-rich heavy phase after density
separation).
[0096] The biological oils produced by the microorganisms of the
present invention can be recovered from autolysis or induced lysis
of the microorganisms by exposing the microorganisms to a condition
including, but not limited to, a certain pH, a certain temperature,
the presence of an enzyme, the presence of a detergent, physical
disruptions, or combinations thereof. In some embodiments of the
present invention, a microorganism is exposed to such conditions
that promote autolysis or induced lysis after producing oil in an
amount of from about 30% to about 90% by weight of its dry biomass,
from about 40% to about 90% by weight of its dry biomass, from
about 50% to about 90% by weight of its dry biomass, from about 60%
to about 90% by weight of its dry biomass, from about 65% to about
85% by weight of its dry biomass, from about 70% to about 85% by
weight of its dry biomass, or from about 75% to about 80% by weight
of its dry biomass. In further embodiments of the present
invention, a microorganism is exposed to such conditions that
promote autolysis or induced lysis after producing oil in an amount
of at least about 30%, at least about 40%, at least about 50%, at
least about 60%, at least about 70%, or at least about 75% by
weight of its dry biomass. In some embodiments of the present
invention, lysis or autolysis of the microorganisms is performed by
the use of mechanical forces. In further embodiments of the present
invention, the lysis or autolysis of the microorganisms is followed
by mechanical separation of the lipids from the non-lipid
compositions.
[0097] Suitable enzymes that can be used to induce lysis of the
oil-producing microorganisms include, but are not limited to,
commercially available enzymes or enzyme mixtures such as
Proteinase K or Alcalase. The genetic modification of a
microorganism to introduce activities of an enzyme that induces
lysis of another microorganism or that induces autolysis is
contemplated within the scope of the present invention. In some
embodiments of the present invention, the oil-producing
microorganisms undergo induced lysis in the presence of a detergent
such as ionic (cationic or anionic) detergents, nonionic
detergents, zwitterionic detergents, or combinations thereof. In
further embodiments of the present invention, physical disruption
methods such as mechanical grinding, liquid homogenization, use of
high frequency sound waves in sonication, freeze/thaw cycles
methods, pressing, extruding, or milling can be used to induce
lysis of the oil-producing microorganisms. Preferably, the
extraction of the oils will take place in the fermentors at the end
of the fermentation by in-tank lysis of the oil-producing
microorganisms.
[0098] Once the biological oils are produced in accordance with the
present invention, various methods known in the art can be used to
transform the biological oils into esters of fatty acids for use as
biodiesel, jet biofuel, or as ingredients for food or
pharmaceutical products. In some embodiments of the present
invention, the production of esters of fatty acids comprises
transesterifying the biological oils produced by the microorganism.
In some embodiments of the present invention, the extraction of the
oil from the microorganisms and the transesterification of the oil
can be performed simultaneously, in a one step method. For example,
the culture containing the oil-producing microorganisms can be
exposed to conditions or treatments (or a combination of conditions
or treatments) that promote both extraction of the oil and the
transesterification of the oil. Such conditions or treatments could
include, but are not limited to, pH, temperature, pressure, the
presence of solvents, the presence of water, the presence of
catalysts or enzymes, the presence of detergents, and
physical/mechanical forces. Two sets of conditions or treatments
could be combined to produce a one step method of extracting and
transesterifying the oil, where one set of conditions or treatments
favorably promotes extraction of the oil and the other set of
conditions or treatments favorably promotes transesterification of
the oil, so long as the two sets of conditions or treatments can be
combined without causing significant reduction in the efficiency of
either the extraction or the transesterification of the oil. In
some embodiments of the present invention, hydrolysis and
transesterification can be performed directly of whole-cell
biomass. In other embodiments of the present invention, the
extraction of the oil is performed as a step that is separate from
the step of transesterification of the oil.
[0099] Preferably, such transesterification reactions are performed
using acid or base catalysts. In some embodiments of the present
invention, methods for transesterifying the biological oils into
esters of fatty acids for use as biodiesel or as ingredients for
food or pharmaceutical products involve reacting the biological
oils containing triglycerides in the presence of an alcohol and a
base to produce esters of the fatty acid residues from the
triglycerides.
[0100] Alcohols suitable for use in the present invention include
any lower alkyl alcohol containing from 1 to 6 carbon atoms (i.e.,
a C.sub.1-6 alkyl alcohol, such as methyl, ethyl, isopropyl, butyl,
pentyl, hexyl alcohols and isomers thereof). Without being bound by
theory, it is believed that in some embodiments of the present
invention, the use of lower alkyl alcohols in the methods of the
present invention produces lower alkyl esters of the fatty acid
residues. For example, the use of ethanol produces ethyl esters. In
certain embodiments, the alcohol is methanol or ethanol. In these
embodiments, the fatty acid esters produced are a methyl ester and
an ethyl ester of the fatty acid residue, respectively. In
processes of the present invention, the alcohol typically comprises
from about 5 wt. % to about 70 wt.%, from about 5 wt.% to about 60
wt. %, from about 5% to about 50 wt. %, from about 7 wt. % to about
40 wt. %, from about 9 wt. % to about 30 wt. %, or from about 10
wt. % to about 25 wt. % of the mixture of the oil composition, the
alcohol and the base. In certain embodiments, the composition and
the base can be added to either pure ethanol or pure methanol. In
general, the amount of alcohol used may vary with the solubility of
the oil or composition containing triglycerides in the alcohol.
[0101] Any base known in the art to be suitable for use as a
reactant may be used in the present invention. Bases of the formula
RO-M, wherein M is a monovalent cation and RO is an alkoxide of a
C.sub.1-6 alkyl alcohol are particularly suited for the present
invention. Examples of suitable bases include elemental sodium,
sodium methoxide, sodium ethoxide, potassium methoxide, and
potassium ethoxide. In some embodiments, the base is sodium
ethoxide. In processes of the present invention, the base is
typically added in an amount of from about 0.05 to about 2.0 molar
equivalents of triglycerides, from about 0.05 to about 1.5 molar
equivalents of triglycerides, from about 0.1 to about 1.4 molar
equivalents of triglycerides, from about 0.2 to about 1.3 molar
equivalents of triglycerides, or from about 0.25 to about 1.2 molar
equivalents of triglycerides to the reaction step with the
composition and the alcohol.
[0102] The composition comprising triglycerides, the alcohol and
the base are reacted together at a temperature and for an amount of
time that allows the production of an ester from the fatty acid
residues and the alcohol. Suitable reaction times and temperatures
may be determined by one of skill in the art to produce an ester.
Without intending to be bound by theory, the fatty acid residues
are believed to be cleaved from the glycerol backbone of the
triglyceride and esters of each fatty acid residue are formed
during the step of reacting. In certain embodiments, the step of
reacting the composition in the presence of an alcohol and a base
is performed at a temperature from about 20.degree. C. to about
140.degree. C., from about 20.degree. C. to about 120.degree. C.,
from about 20.degree. C. to about 110.degree. C., from about
20.degree. C. to about 100.degree. C., or from about 20.degree. C.
to about 90.degree. C. In further embodiments, the step of reacting
the composition in the presence of an alcohol and a base is
performed at a temperature of at least about 20.degree. C.,
75.degree. C., 80.degree. C., 85.degree. C., 90.degree. C.
95.degree. C., 105.degree. C., or 120.degree. C. In some
embodiments of the present invention, the step of reacting the
composition in the presence of an alcohol and a base is performed
at a temperature of about 20.degree. C., 75.degree. C., 80.degree.
C., 85.degree. C., 90.degree. C., 95.degree. C., 105.degree. C., or
120.degree. C. In some embodiments, the step of reacting the
composition in the presence of an alcohol and a base is performed
for a time from about 2 hours to about 36 hours, from about 3 hours
to about 36 hours, from about 4 hours to about 36 hours, from about
5 hours to about 36 hours, or from about 6 hours to about 36 hours.
In certain embodiments, the step of reacting the composition in the
presence of an alcohol and a base is performed for about 0.25, 0.5,
1.0, 2.0, 4.0, 5.0, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 10, 12, 16, 20,
24, 28, 32, or 36 hours
[0103] In one embodiment, the step of reacting the oil composition,
alcohol and base may be conducted by refluxing the components to
produce the fatty acid esters, such as PUFA esters. In additional
embodiments, the step of reacting the oil composition may be
carried out at a temperature that does not result in the refluxing
of the reaction components. For example, carrying out the step of
reacting the oil composition under pressures greater than
atmospheric pressure can increase the boiling point of the solvents
present in the reaction mixture. Under such conditions, the
reaction can occur at a temperature at which the solvents would
boil at atmospheric pressure, but would not result in the refluxing
of the reaction components. In some embodiments, the reaction is
conducted at a pressure from about 5 to about 20 pounds per square
inch (psi); from about 7 to about 15 psi; or from about 9 to about
12 psi. In certain embodiments, the reaction is conducted at a
pressure of 7, 8, 9, 10, 11, or 12 psi. Reactions conducted under
pressure may be carried out at the reaction temperatures listed
above. In some embodiments, reactions conducted under pressure may
be carried out at at least about 70.degree. C., 75.degree. C.,
80.degree. C., 85.degree. C., or 90.degree. C. In some embodiments,
reactions conducted under pressure may be carried out at 70.degree.
C., 75.degree. C., 80.degree. C., 85.degree. C., or 90.degree.
C.
[0104] The reaction mixture comprising fatty acid esters can be
further processed to obtain the fatty acid esters from the mixture.
For example, the mixture may be cooled, diluted with water, and the
aqueous solution extracted with a solvent such as hexane to produce
a composition comprising fatty acid esters. Techniques for washing
and/or extracting crude reaction mixtures are known in the art.
[0105] In some embodiments of the present invention, microorganisms
that produce low levels of PUFAs are used to produce the biological
oils, especially for use in biodiesel production. This method could
reduce the costs of biodiesel production. In some embodiments of
the present invention, less than about 50% of unsaturated fatty
acids in the biological oil are PUFAs. For certain biofuel
applications, the unsaturated fatty acids in the biological oil
preferably contains less than about 40%, less than about 30%, less
than about 20%, less than about 10%, or less than about 5% PUFAs.
In some embodiments of the present invention, the biological oil
comprises less than about 50%, less than about 40%, less than about
30%, less than about 20%, less than about 10%, or less than about
5% by weight of PUFAs.
[0106] The more valuable PUFA esters can be recovered by
distillation to yield high potency PUFA esters which can then be
sold to reduce the overall cost of production of a biodiesel
product.
[0107] Examples of modified lipid production systems are disclosed
in patent application publication nos. WO 06/031699, U.S.
2006/0053515, U.S. 2006/0107348, and WO 06/039449, the contents of
which are incorporated herein by reference in their entirety.
[0108] In one embodiment of the present invention, fatty acid
esters are separated from the reaction mixture by distilling the
composition to recover a fraction comprising the ester of the fatty
acid. In this manner, a targeted fraction of the reaction mixture
including the fatty acid esters of interest can be separated from
the reaction mixture and recovered.
[0109] In certain embodiments, the distillation is performed under
vacuum. Without being bound by theory, distillation under vacuum
allows the distillation to be accomplished at a lower temperature
than in the absence of a vacuum and thus may prevent the
degradation of the esters. Typical distillation temperatures range
from about 120.degree. C. to about 170.degree. C. In some
embodiments, the step of distilling is performed at a temperature
of less than about 180.degree. C., less than about 175.degree. C.,
less than about 170.degree. C., less than about 165.degree. C.,
less than about 160.degree. C., less than about 155.degree. C.,
less than about 150.degree. C., less than about 145.degree. C.,
less than about 140.degree. C., less than about 135.degree. C., or
less than about 130.degree. C. Typical pressures for vacuum
distillation range from about 0.1 mm Hg to about 10 mm Hg. In some
embodiments, the pressure for vacuum distillation is at least about
0.1, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, or 4 mm Hg. In some embodiments
of the present invention, the pressure for vacuum distillation is
about 0.1, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, or 4 mmHg.
[0110] In some embodiments of the present invention, the fatty acid
esters produced through transesterification of the biological oils
are further isolated through urea adduction. Urea can be dissolved
in a medium comprising the fatty acid esters to form a medium
comprising fatty acid esters and dissolved urea. This medium is
then cooled or concentrated to form a precipitate comprising urea
and at least a portion of the saturated fatty acid esters, and a
liquid fraction comprising at least most of the polyunsaturated
fatty acid esters. The precipitate and liquid fraction can then be
separated to isolate the saturated or polyunsaturated fatty acid
esters. In some embodiments of the present invention, the medium
comprising fatty acid esters and dissolved urea is cooled to a
temperature of from about 20.degree. C. to about -50.degree. C.,
from about 10.degree. C. to about -40.degree. C., or from about
0.degree. C. to about -30.degree. C. U.S. Pat. No. 6,395,778, the
content of which is incorporated herein by reference in its
entirety, discloses methods of transesterification followed by urea
adduction.
[0111] In addition to transesterification methods described above,
other techniques of reducing the viscosity of the biological oils
of the present invention can also be incorporated into the methods
of the invention to produce lipid-based biofuels. These techniques
include, but are not limited to, the use of lipases, supercritical
methanol catalysis, and the use of whole-cell systems involving
cytoplasmic overexpression of lipases in a host cell followed by
permeabilization of the host to allow catalysis of
transesterification of triglycerides within the cytoplasm. Patent
or patent application publication nos. U.S. Pat. No. 7,226,771,
U.S. 2004/0005604, WO 03/089620, WO 05/086900, U.S. 2005/0108789,
WO 05/032496, WO 05/108533, U.S. 6982155, WO 06/009676, WO
06/133698, WO 06/037334, WO 07/076163, WO 07/056786, and WO
06/124818, the contents of which are incorporated herein by
reference in their entirety, disclose examples of processes for
converting lipids into biodiesel.
[0112] Thraustochytrids in general and Schizochytrium in particular
are similar to many marine and estuarine microalgae and protists in
that they accumulate a certain amount of polyunsaturated fatty
acids (PUFA) in their cellular lipids. Low levels of PUFA may be
useful as they should lower the gelling point of the fuel making it
more suitable for cold climates. Potential consumer complaints
about odors generated from burning PUFA-containing biodiesel in
inefficient engines (that pass partially-oxidized fuel into the
exhaust) may be somewhat offset by the fact that microalgal
biodiesel fuel can be blended with fossil diesel at ratios of 1-99%
to minimize this problem. To ensure that 100% microalgal
oil-derived biodiesel could be burned without significant consumer
issues, partial or total oil hydrogenation, as is routine in the
manufacture of margarines, may be used. In some embodiments of the
present invention, cracking technology (such as cracking methods
known in the oil industry) can be used to reduce fatty acid chain
length. Once the biological oil has been produced in accordance
with methods of the present invention, cracking of the biological
oil may be performed to produce the desired lipid-based biofuel.
For certain lipid-based biofuels where a variety of shorter
hydrocarbons are required, such as for jet biofuels, high levels of
PUFAs may be useful so that cleavage of PUFA at multiple sites can
occur to produce the various hydrocarbons.
[0113] The lipid-based biofuel compositions of the present
invention are produced at low costs and are efficient replacements
for petroleum diesel or jet fuel. In some embodiments of the
present invention, the lipid-based biofuel composition comprises
from about 1% to about 75% by weight of alkyl esters of long chain
PUFAs having 20 or more carbons. In further embodiments of the
present invention, the biodiesel composition comprises from about
2% to about 50%, from about 4% to about 25%, or from about 5% to
about 10% by weight of alkyl esters of long chain PUFAs having 20
or more carbons.
[0114] In some embodiments of the present invention, the
lipid-based biofuel compositions (100% lipid-based biofuel, not
blended with petroleum diesel or jet fuel) have a melting
temperature of from about 30.degree. C. to about -60.degree. C. ,
from about 30.degree. C. to about -50.degree. C., from about
25.degree. C. to about -50.degree. C, from about 20.degree. C. to
about <30.degree. C., from about 20.degree. C. to about
-20.degree. C., from about 20.degree. C. to about -10.degree. C.,
from about 10.degree. C. to about -10.degree. C., or from about
0.degree. C. to about -10.degree. C. In further embodiments of the
present invention, the biodiesel compositions releases from about
30 to about 45 megajoules per liter, from about 35 to about 40
megajoules per liter, or from about 38 to about 40 megajoules per
liter. Various forms of biodiesel are disclosed, for example, in
patent or patent application publication nos. WO 07/061903, U.S.
Pat. No. 7,172,635, EP 1 227 143, WO 02/38709, WO 02/38707, and
U.S. 2007/0113467, the contents of which are incorporated herein by
reference in their entirety.
[0115] The present invention also provides a scalable lipid-based
biofuel manufacturing facility which may be co-located with an
ethanol production facility (such as a cellulosic ethanol
facility). Examples of algae systems related to the production of
non-lipid based fuels (such as ethanol) are disclosed in patent or
patent application publication nos. U.S. Pat. No. 7,135,308 and WO
02/05932, the contents of which are incorporated herein by
reference in their entirety.
[0116] In some embodiments of the present invention, feedstock
treatment would be similar or identical for both cellulosic ethanol
and for cellulosic lipid-based biofuels fermentations. For example,
after a cellulosic biodiesel fermentation, oil may be extracted and
transesterified (either simultaneously or sequentially) to make
biodiesel. The alcohol used in the transesterification could come
from an ethanol production process (such as a cellulosic ethanol
production process), and the left-over glycerol from the biodiesel
transesterification could be used as a supplementary carbon source
for the ethanol fermentation process (or for the biodiesel process
itself, since organisms such as Schizochytrium readily metabolize
glycerol). In preferred embodiments of the present invention,
microorganisms used in the invention are capable of using glycerol
as a carbon source. Nitrogenous wastes (such as yeast biomass) may
also serve as nitrogen sources in biodiesel fermentations (most
thraustochytrids can utilize yeast extract as a nitrogen source).
Wastes such as de-lipidated microorganism biomass may be recycled
for use in a subsequent fermentation, burned for heat or
electricity, or used as fertilizer for the crop providing the
cellulosic feedstock. The resulting biodiesel or waste gasses can
be used to fuel the biodiesel or ethanol production facilities,
making them energy independent. Additionally, pumps in the facility
could be driven by recovered exhaust air.
[0117] In some embodiments of the present invention, the method of
producing lipid-based biofuels comprises growing a microorganism
using nutrients comprising recycled media to produce a biological
oil. The recycled media include, but is not limited to,
de-lipidated biomass, hydrolyzed biomass, partially hydrolyzed
biomass, metals, salts, amino acids, extracellular carbohydrates,
glycerol, recycled yeast biomass, or combinations thereof, all of
which were recycled from a previous fermentation run or other
process. For example, residual yeast biomass and hydrolyzed
Stramenopile de-lipidated biomass waste can be recycled into the
steam pre-treatment, ammonia fiber explosion, separation step, or
into the enzyme hydrolysis, separation and evaporation step as
shown in FIG. 1. Partially hydrolyzed biomass can be recycled back
along with media into these steps for further hydrolysis. The use
of recycled media may be employed for the production of biological
oils with high or low polyunsaturated fatty acid content, depending
on the requirements of a specific application.
[0118] The cellulose-based (low cost carbon) technology of the
present invention can be used to lower the cost of production of
any compound that can be produced by fermentation of yeasts or
microorganisms of the kingdom Stramenopile (such as
thraustochytrids), including genetically modified microorganisms.
Examples of compounds that can be produced using the methods of the
present invention include, but are not limited to, PUFAs, PUFA
esters, proteins (including enzymes and therapeutic proteins),
oxylipins, carotenoids, and lipids.
[0119] In some embodiments, the methods of the present invention
may be used to produce compositions that contain a high percentage
of PUFA or PUFA esters. For example, such compositions can contain
from about 50 wt. % to about 100 wt. % of a PUFA or an ester of a
PUFA, and in other embodiments, the composition can comprise at
least about 50 wt. %, at least about 55 wt. %, at least about 60
wt. %, at least about 65 wt. %, at least about 70 wt. %, at least
about 75 wt. %, at least about 80 wt. %, at least about 85 wt. %,
at least about 90 wt. %, at least about 95 wt. %, at least about 99
wt. % of PUFAs or esters of PUFAs.
[0120] Compositions comprising PUFAs or PUFA esters of the present
invention may be used in pharmaceutical products. In some
embodiments, the pharmaceutical products may contain PUFAs or PUFA
esters without an additional pharmaceutically active agent. In
other embodiments, the pharmaceutical product may comprise a
pharmaceutically active agent. Examples of pharmaceutically active
agents include statins, anti-hypertensive agents, anti-diabetic
agents, anti-dementia agents, anti-depressants, anti-obesity
agents, appetite suppressants and agents to enhance memory and/or
cognitive function. The pharmaceutical products may further
comprises any pharmaceutically acceptable excipient, carriers,
binders or other formulation components known in the art.
[0121] PUFAs or PUFA esters produced by the methods of the present
invention are suitable for use as therapeutic and experimental
agents. An embodiment of the present invention comprises the
production of PUFAs or PUFA esters for treatment of PUFA-deficient
infants. The PUFAs or PUFA esters can be included in a parenteral
formulation that can be administered to an infant through
parenteral routes to fortify the infant's supply of a PUFA.
Preferred parenteral routes include, but are not limited to,
subcutaneous, intradermal, intravenous, intramuscular and
intraperitoneal routes. A parenteral formulation can include PUFAs
or PUFA esters of the present invention and a carrier suitable for
parenteral delivery. As used herein, a "carrier" refers to any
substance suitable as a vehicle for delivering a molecule or
composition to a suitable in vivo site of action. Examples of such
carriers include, but are not limited to water, phosphate buffered
saline, Ringer's solution, dextrose solution, serum-containing
solutions, Hank's solution and other aqueous physiologically
balanced solutions. Suitable carriers also include oil-based
carriers, non-aqueous solutions, suspensions, and emulsions.
Examples include propylene glycol, polyethylene glycol, vegetable
oils such as olive oil, injectable organic esters such as ethyl
oleate, polyethoxylated castor oil (cremaphor), and others known in
the art. Acceptable protocols to administer PUFAs or PUFA esters in
an effective manner include individual dose size, number of doses,
frequency of dose administration, and mode of administration.
Determination of such protocols can be accomplished by those
skilled in the art depending upon a variety of variables, including
the weight of the infant and the extent of PUFA deficiency. Another
embodiment of the present invention comprises the production of
PUFAs or PUFA esters for treatment of adults, in particular
pregnant mothers. Acceptable protocols for administration of PUFAs
or PUFA esters to adults includes parenteral feeding techniques or
encapsulating PUFAs or PUFA esters of the present invention in a
capsule, such as gelatin (i.e., digestible) capsule, for oral
administration and/or in a liquid diet formulation. A liquid diet
formulation can comprise a liquid composition containing nutrients
suitable for supplementing a diet or nutrients sufficient as a
complete diet.
[0122] PUFAs or PUFA esters produced by the methods of the present
invention may also be used to treat subjects (e.g., humans or
animals) with high levels of triglycerides, including subjects with
triglyceridemia. For example, subjects with triglyceride levels at
or above 500 mg/dL may benefit from treatment with the PUFAs or
PUFA esters of the present invention. In some embodiments,
individual PUFAs or PUFA esters may be administered to a subject to
treat high levels of triglycerides. In certain embodiments, the
PUFA or PUFA ester may be DHA or ARA. In other embodiments
combinations of PUFAs or PUFA esters may be administered to a
subject to treat high levels of triglycerides. In certain
embodiments, the combination of PUFAs or PUFA esters may comprise
omega-3 and omega-6 PUFAs such as DHA and DPA n-6. In some
embodiments, the PUFAs or PUFA esters may comprise about 90% of a
composition administered to the subject. The PUFAs or PUFA esters
may be administered with other components and excipients, such as
the carriers described above. The PUFAs or PUFA esters may also be
used to treat subjects with diseases that can be associated with
high levels of triglycerides, such as cardiovascular disease or
hypertension.
[0123] The PUFA esters produced by the methods of the present
invention may be used to produce PUFA salts. In some embodiments,
PUFA salts can be produced by reacting the PUFA esters of the
present invention in the presence of an alkaline metal base such as
an alkaline metal hydroxide (e.g., potassium hydroxide). The PUFA
salts formed from the PUFA esters of the present invention can be
used in a variety of applications, such as in foods, beverages, and
pharmaceuticals. In some embodiments, the PUFA salts produced using
the PUFA esters of the present invention are water-soluble and can
be used directly in foods, beverages, and pharmaceuticals.
[0124] PUFAs or PUFA esters produced by the methods of the present
invention can be used in any animal food material, particularly
food materials for humans, to create a food product having enhanced
concentrations of PUFAs. The amount of fatty acids naturally in
food products varies from one food product to another. A food
product of the present invention can have a normal amount of a PUFA
or a modified amount of a PUFA. In the former instance, a portion
of the naturally occurring lipids may be substituted by PUFAs or
PUFA esters of the present invention. In the latter instance,
naturally occurring lipids may be supplemented by PUFAs or PUFA
esters of the present invention.
[0125] PUFAs or PUFA esters may be added to foods for infants, such
as infant formula and baby food. According to the present
invention, an infant refers to infants and children less than about
two years old, including, in particular, premature infants. Certain
PUFAs are particularly important components of infant formula and
baby food because of the rapid growth of infants (i.e., doubling or
tripling in weight during the first year of life). An effective
amount of PUFA or PUFA ester to supplement infant formula is an
amount that approximates the concentration of the PUFAs in human
breast milk. Preferred amounts of PUFAs or PUFA esters to add to
infant formula or baby food range from about 0.1 to about 1.0% of
total fatty acids, more preferably from about 0.1 to about 0.6% of
total fatty acids, and even more preferably about 0.4% of total
fatty acids.
[0126] Another aspect of the present invention includes a food
product comprising a food material combined with PUFAs or PUFA
esters of the present invention. PUFAs or PUFA esters may be added
to a food material to create a food product having enhanced
concentrations of PUFAs. As used herein, the term "food material"
refers to any food type fed to humans or non-human animals. Also
within the scope of the present invention is a method to make a
food product comprising adding PUFAs or PUFA esters produced by
methods of the present invention to a food material.
[0127] A suitable food material useful for the formation of a food
product of the present invention includes animal food. The term
"animal" means any organism belonging to the kingdom Animalia and
includes, without limitation, primates (e.g., humans and monkeys),
livestock and domestic pets. The term "food product" includes any
product to be fed to such animals. Preferred food materials to be
consumed by humans include infant formula and baby food. Preferred
food materials to be consumed by domestic pets include dog
foods.
[0128] PUFAs or PUFA esters produced by methods of the present
invention can be added to a wide range of products such as baked
goods, vitamin supplements, diet supplements, powdered drinks, etc.
at various stages of production. Numerous finished or semi-finished
powdered food products can be produced using the compositions of
the present invention.
[0129] A partial list of food products comprising the products of
the present invention includes doughs, batters, baked food items
including, for example, such items as cakes, cheesecakes, pies,
cupcakes, cookies, bars, breads, rolls, biscuits, muffins,
pastries, scones, and croutons; liquid food products, for example,
beverages, energy drinks, infant formula, liquid meals, fruit
juices, multivitamin syrups, meal replacers, medicinal foods, and
syrups; semi-solid food products such as baby food, yogurt, cheese,
cereal, pancake mixes; food bars including energy bars; processed
meats; ice creams; frozen desserts; frozen yogurts; waffle mixes;
salad dressings; and replacement egg mixes. Also included are baked
goods such as cookies, crackers, sweet goods, snack cakes, pies,
granola/snack bars, and toaster pastries; salted snacks such as
potato chips, corn chips, tortilla chips, extruded snacks, popcorn,
pretzels, potato crisps, and nuts; specialty snacks such as dips,
dried fruit snacks, meat snacks, pork rinds, health food bars and
rice/corn cakes; and confectionary snacks such as candy.
[0130] Another product embodiment of the present invention is a
medical food. A medical food includes a food which is in a
formulation to be consumed or administered externally under the
supervision of a physician and which is intended for the specific
dietary management of a disease or condition for which distinctive
nutritional requirements, based on recognized scientific
principles, are established by medical evaluation.
[0131] The present invention, while disclosed in terms of specific
methods, products, and organisms, is intended to include all such
methods, products, and organisms obtainable and useful according to
the teachings disclosed herein, including all such substitutions,
modifications, and optimizations as would be available to those of
ordinary skill in the art. The following examples and test results
are provided for the purposes of illustration and are not intended
to limit the scope of the invention.
EXAMPLES
Example 1
[0132] Using 2-liter fermentors, under typical fermentation
conditions, cultures of a wild-type Schizochytrium or
Thraustochytrium would be cultivated using a saccharified source of
cellulose. Each fermentor would be batched with a media containing
carbon (saccharfied cellulose), nitrogen, phosphorus, salts, trace
metals, and vitamins. Each fermentor would be inoculated with a
typical seed culture, then cultivated for 72-120 hours, and fed
both a carbon (saccharified cellulose) feed and a nitrogen feed
during cultivation. The nitrogen feed would be fed and consumed
only during the growth phase, while the carbon (saccharified
cellulose) would be fed and consumed throughout the fermentation.
After 72-120 hours, each fermentor would be harvested and autolyzed
or hydrolyzed. The hydrolyzed material would be separated into oil
and biomass fractions. The oil would then be transesterified and
separated from the glycerol. The mono alkyl ester would be water
washed to produce a finished product.
Typical fermentation control conditions: [0133] Temperature: 20-40
degrees Celsius [0134] pH: 3.0-10.0 [0135] agitation: 100-400 cps
[0136] airflow: 0.25-3.0 vvm [0137] Saccharified cellulose: 5-35
g/L (in-tank concentration) [0138] inoculum: 1% -50%
Example 2
[0139] Using 10-liter fermentors, under typical fermentation
conditions, a culture of wild-type or transgenic Schizochytrium or
Thraustochytrium would be cultivated on a liquefied cellulose
source. The organism would produce the necessary enzymes to
simultaneously saccharify the cellulose and metabolize the glucose,
xylose, hemicellulose, and lignin. Each fermentor would be batched
with a media containing carbon (liquefied cellulose), nitrogen,
phosphorus, salts, trace metals, and vitamins. Each fermentor would
be inoculated with a typical seed culture, then cultivated for
72-120 hours, and fed both a carbon feed (liquefied cellulose) and
a nitrogen feed during cultivation. The nitrogen feed would be fed
and consumed only during the growth phase, while the carbon
(liquefied cellulose) would be fed and consumed throughout the
fermentation. After 72-120 hours, each fermentor would be harvested
and autolyzed or hydrolyzed. The hydrolyzed material would be
separated into oil and biomass fractions. The oil would then be
transesterified and separated from the glycerol. The mono alkyl
ester would be water washed to produce a finished product.
Typical fermentation conditions: [0140] Temperature: 20-40 degrees
Celsius [0141] pH: 3.0-10.0 [0142] agitation: 100-400 cps [0143]
airflow: 0.25-3.0 vvm [0144] Liquefied cellulose: 5-35 g/L (in-tank
concentration) [0145] inoculum: 1% -50%
Example 3
[0146] The transgenic Schizochytrium or Thraustochytrium of Example
2 would be developed using an exiting transformation system (such
as that disclosed in published patent application no. WO
2002/083869 A2) to express genes encoding known and appropriate
cellulases, hemicellulases, ligninases, saccharide transporters,
epimerases, and saccharide isomerases. Alternately, previously
uncharacterized cellulases, hemicellulases, ligninases, saccharide
transporters, epimerases, and saccharide isomerases could be
isolated from existing genome databases or via standard gene
discovery strategies with uncharacterized or less characterized
organisms, including PCR with degenerate primers based on conserved
regions of homologous genes, or mass sequencing and mining of
Expressed Sequence Tags (ESTs) or genome sequences, or other
techniques. Appropriate gene expression and gene product activities
would be validated using standard techniques such as gel
electrophoresis, northern and western blots, Enzyme-linked
Immunosorbent Assays (ELISA), and substrate conversion assays.
Example 4
[0147] Using 2-liter fermentors, under typical fermentation
conditions, two cultures of a wild-type Schizochytrium (ATCC 20888)
were cultivated to compare the fatty acid profiles and lipid
production rates under sterile and non-sterile conditions. Each
fermentor was batched with a media containing carbon, nitrogen,
phosphorus, salts, trace metals, and vitamins. The sterile
fermentor was autoclaved for 120 minutes and all media components
were either sterilized in the fermentor or added as sterile
solutions after autoclaving. The non-sterile fermentor was batched
with tap water and all ingredients were added to the fermentor
without sterilization prior to inoculation. Each fermentor was
inoculated with a typical seed culture, then cultivated for 50
hours, and fed both a carbon feed and a nitrogen feed during
cultivation. The nitrogen feed was fed and consumed only during the
growth phase, while the carbon was fed and consumed throughout the
fermentation. After 50 hours, each fermentor was sampled,
centrifuged, lyophilized, converted to fatty acid methyl ester, and
analyzed by gas chromatography.
Typical fermentation conditions: [0148] Temperature: 28-30 degrees
Celsius [0149] pH: 5.0-7.5 [0150] agitation: 100-300 cps [0151]
airflow: 0.25-2.0 vvm [0152] glucose: 5-55 g/L (concentration)
[0153] inoculum: 1% -30% The results were as follows:
TABLE-US-00001 [0153] condition sterile non-sterile strain ATCC
20888 ATCC 20888 log hour 50 50 Sample BN25 8.08, 14 BN26 8.08, 14
% 12:0 0.21 0.12 % 13:0 0.16 0.16 % 14:0 9.73 6.14 % 15:1 0.59 0.79
% 16:0 39.93 36.26 % 16:1 0.13 0.07 % 17:0 0.17 0.28 % 18:0 1.13
1.16 % 18:1 n-9 0.13 0.08 % 18:1 n-7 0.10 0.00 % 18:3 n-6 0.10 0.12
% 18:3 n-3 0.04 0.07 % 18:4 n-3 0.12 0.13 % 20:0 0.10 0.10 % 20:3
n-6 0.27 0.33 % 20:4 ARA 0.37 0.32 % 20:5 EPA 0.45 0.56 % 22:5 n-6
12.61 14.52 % 22:6 DHA 32.67 37.43 % Fat 40.92 35.79 % Unknown 0.98
1.10 % saturates 51.44 44.23 % monounsaturates 0.81 0.87 %
polyunsaturates 46.64 53.48
[0154] FIGS. 3 and 4 show graphs of the results of the
experiment.
Example 5
[0155] Using a 5-liter fermentor, under low-cost fermentation
conditions wild-type Schizochytrium (ATCC 20888) was cultivated to
evaluate the potential to produce algal biomass heterotrophically
using low-cost non-sterile conditions. The non-sterile fermentor
consisted of a mild steel vessel, lined with a polypropylene
membrane, a tube sparger, one exhaust line, and one addition line.
The non-sterile fermentor was batched with tap water and a media
containing carbon, nitrogen, phosphorus, salts, trace metals, and
vitamins. The ingredients were added to the fermentor without
sterilization prior to inoculation. The fermentor was inoculated
with a 50 mL culture from a 250 mL flask. The fermentor was
cultivated for 6 days, nothing was added to the fermentor during
cultivation (post-inoculation). After 6 days, the fermentor was
sampled, lyophilized, converted to fatty acid methyl ester, and
analyzed by gas chromatography.
Typical fermentation conditions: [0156] Temperature: 28-30 degrees
Celsius [0157] pH: no control [0158] agitation: none [0159]
airflow: 2.0-4.0 vvm [0160] glucose: 80 g/L (initial concentration;
no additional feeds) [0161] inoculum: 1% Non-sterile batch
media:
TABLE-US-00002 [0161] Ingredient Final Concentration Na2SO4 8 g/L
KCl 1 g/L MgSO4.cndot.7H2O 2 g/L KH2PO4 12 g/L
(NH.sub.4).sub.2SO.sub.4 15 g/L CaCl.sub.2*2H.sub.2O 0.2 g/L
FeSO.sub.4.cndot.7H.sub.2O 51.5 mg/L MnCl.sub.2.cndot.4H.sub.2O 3.1
mg/L ZnSO.sub.4.cndot.7H.sub.2O 3.1 mg/L CoCl.sub.2.cndot.6H.sub.2O
0.04 mg/L Na.sub.2MoO.sub.4.cndot.2H.sub.2O 0.04 mg/L
CuSO.sub.4.cndot.5H.sub.2O 2.07 mg/L NiSO.sub.4.cndot.6H.sub.2O
2.07 mg/L Thiamine 9.75 mg/L Vitamine B12 0.16 mg/L
Ca.sub.1/2-pantothenate 3.33 mg/L Glucose 80 g/L
The results were as follows:
TABLE-US-00003 % PUFA 5.75 % monounsaturates 55.18 % saturates
37.19 g/L oil 4.64
Example 6
[0162] A two-stage fermentation system could be used in the
heterotrophic fermentation of a microorganism. The first stage
(seed stage) will target accumulation of biomass and the second
stage (lipid-production stage) will target lipid accumulation. An
example of the fermentation system is described below.
[0163] The fermentation system described below includes a
continuous seed vessel and multiple lipid-production vessels
running at fed-batch mode. The seed vessel has a working volume of
xx gallons, an eighth of the lipid-production stage vessels' (xxx
gallons) based on the following assumptions:
[0164] 1) 6 hours of cell doubling time,
[0165] 2) 24 hours fill-time for each lipid-production stage
batch,
[0166] 3) Initial volume (after filling) of each lipid-production
batch being 1/2 of the harvest volume
[0167] Continuous Seed Stage
[0168] After the initial inoculation/growth to reach steady state,
the seed vessel will receive continuous sterile nutrient feed at a
constant rate (xx GPM, .about. 1/48 of harvest volume per hour).
Broth will be withdrawn from the vessel and transferred to a
lipid-production stage vessel at the same rate as the nutrient
feed. After a production vessel reaches the desired starting volume
(.about.1/2 of the harvest volume after .about.24-hour filling),
the seed vessel will then be connected to the next available
lipid-production vessel.
[0169] The nutrient feed will include a carbon source (cellulosic
feedstock and/or simple sugars), a nitrogen source (e.g. NH3),
salts, vitamins and trace metals at concentrations to sustain
appropriate growth (and later to support optimal lipid production).
Recycled de-lipidated biomass and glycerol may be used as part of
the nutrients to reduce raw material cost. At steady state, the
biomass concentration will likely to reach at least about 50-100
g/L.
[0170] Airflow will be supplied to provide sufficient oxygen for
cell growth. The airflow requirement could be in the range
.about.0.5-1.0 vvm to achieve OUR (oxygen uptake rate) of
.about.50-150 mmoles/L/hr. Significant metabolic heat generation is
expected for the process and sufficient heat removal will be
required to maintain the target process temperature (e.g.
.about.25-35.degree. C.). A relationship of 0.113 Kcal/mmole O2
uptake is commonly used to estimate metabolic heat generation by
micro-organisms and an estimated heat generation of .about.6-17
Kcal/L/hr may be produced. Some of the heat may be removed by
airflow but significant heat removal capability will still be
required to maintain the target temperature. pH control by an acid
(e.g. sulfuric acid) and/or a base (caustic) may be required to
maintain the pH target for optimal growth. Due to the nature of the
seed stage, the medium and process conditions will very likely
favor contaminant growth; and therefore, a system design with low
contamination risk will be highly desirable. The two-stage process
may be carried out in non-sterile fermentors through the selection
of conditions that are unfavorable for contaminants. Another option
is to run the continuous seed stage aseptically and the
lipid-production stage (which can be under a nutrient limitation
such as nitrogen limitation) under non-sterile conditions.
[0171] Lipid-Production Stage (Fed-Batch)
[0172] The lipid-production stage vessel will run as a fed-batch
process. Most nutrients will be received from the seed stage
(during the 24 hours fill time) and carbon source will be fed to
the batch to maintain a target sugar concentration throughout the
run.
[0173] Each lipid-production batch will have a total cycle time of
120 hour, 24 hours for filling (receiving broth from the seed
vessel), 72 hours for lipid-production and 24 hours for harvest
& turnaround. Therefore, each seed vessels should be able to
supply inoculum for five lipid-production stage vessels. As
mentioned above, the seed transfer rate is expected to be at
.about.xxx GMP ( 1/48 pf harvest volume per hour). After the 24
hour fill time, the production vessel should have around 1/2 of the
target harvest volume. Carbon source, such as cellulosic feedstock
(at .about.70% sugar concentration), will be added to maintain a
target sugar concentration through most of the run time. Anti-foam
will be added as needed to minimize forming. At harvest, a biomass
concentration of at least about 150 g/L or at least about 300 g/L,
and 60-80% oil in biomass may be achieved.
[0174] A continuous or semi-continuous production strategy may be
used for lipid production. In a continuous method, the biomass is
harvested at the same rate that the lipid production vessel is
filled. In a semi-continuous method, the biomass is harvested at
regular intervals, with the amount of biomass harvested dependent
on the lipid-production cycle. For example, in a 72 hour
lipid-production cycle, half of the production tank containing
biomass may be harvested every 36 hours; similarly, 25% of the
biomass in the production tank may be harvested every 18 hours, 75%
of the biomass in the production tank may be harvested every 54
hours, and so on.
[0175] Oxygen is required for cell maintenance and lipid-production
and airflow will be supplied to provide sufficient oxygen transfer.
The airflow requirement could be in the range .about.0.5-1.0 vvm to
achieve OUR (oxygen uptake rate) of .about.40-150 mmoles/L/hr.
Significant metabolic heat generation is expected for the process.
A relationship of 0.113 Kcal/mmole O2 uptake is commonly used to
estimate metabolic heat generation by micro-organisms and an
estimated heat generation of .about.6-17 Kcal/L/hr may be produced.
Some of the heat may be removed by airflow but significant heat
removal capability will still be required to maintain the target
temperature. pH control by an acid (e.g. sulfuric acid) and/or a
base (caustic) may be required to maintain the pH target for high
lipid productivity.
[0176] Other Information/Considerations
[0177] The cost of fermentation may be lowered if fermentation
waste (such as liquid media or de-lipidated biomass) can be
efficiently recycled.
[0178] The sugar to biomass conversion yield will likely be
.about.45-55% (on molar basis) and the sugar to oil conversion
yield will likely be .about.30-40%.
[0179] To minimize potential downtime due to equipment failure or
batch abnormalities, additional seed and lipid-production vessels
should be considered for plant design.
[0180] The principles, preferred embodiments and modes of operation
of the present invention have been described in the foregoing
specification. The invention which is intended to be protected
herein should not, however, be construed as limited to the
particular forms disclosed, as these are to be regarded as
illustrative rather than restrictive. Variations and changes may be
made by those skilled in the art without departing from the spirit
of the present invention. Accordingly, the foregoing best mode of
carrying out the invention should be considered exemplary in nature
and not as limiting to the scope and spirit of the invention as set
forth in the appended claims.
* * * * *