U.S. patent application number 13/118369 was filed with the patent office on 2011-12-01 for food compositions comprising tailored oils.
This patent application is currently assigned to Solazyme, Inc.. Invention is credited to Scott Franklin, Jeffrey L. Moseley, Walt Rakitsky, George Rudenko, Aravind Somanchi, Janice Wee.
Application Number | 20110293785 13/118369 |
Document ID | / |
Family ID | 45004441 |
Filed Date | 2011-12-01 |
United States Patent
Application |
20110293785 |
Kind Code |
A1 |
Franklin; Scott ; et
al. |
December 1, 2011 |
FOOD COMPOSITIONS COMPRISING TAILORED OILS
Abstract
Methods and compositions for the production of food
compositions, oils, fuels, oleochemicals, and other compounds in
recombinant microorganisms are provided, including oil-bearing
microorganisms and methods of low cost cultivation of such
microorganisms. Microalgal cells containing exogenous genes
encoding, for example, a lipase, a sucrose transporter, a sucrose
invertase, a fructokinase, a polysaccharide-degrading enzyme, a
keto acyl-ACP synthase enzyme, a fatty acyl-ACP thioesterase, a
fatty acyl-CoA/aldehyde reductase, a fatty acyl-CoA reductase, a
fatty aldehyde reductase, a fatty aldehyde decarbonylase, and/or an
acyl carrier protein are useful in manufacturing food compositions,
and transportation fuels such as renewable diesel, biodiesel, and
renewable jet fuel, as well as oleochemicals such as functional
fluids, surfactants, soaps and lubricants.
Inventors: |
Franklin; Scott; (La Jolla,
CA) ; Somanchi; Aravind; (Redwood City, CA) ;
Wee; Janice; (San Mateo, CA) ; Rudenko; George;
(Mountain View, CA) ; Moseley; Jeffrey L.;
(Redwood City, CA) ; Rakitsky; Walt; (San Diego,
CA) |
Assignee: |
Solazyme, Inc.
South San Francisco
CA
|
Family ID: |
45004441 |
Appl. No.: |
13/118369 |
Filed: |
May 27, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61349774 |
May 28, 2010 |
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61374992 |
Aug 18, 2010 |
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61414393 |
Nov 16, 2010 |
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61428192 |
Dec 29, 2010 |
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Current U.S.
Class: |
426/61 |
Current CPC
Class: |
A23K 20/158 20160501;
Y02T 50/678 20130101; A23D 9/00 20130101; C11B 1/00 20130101; C12N
9/2431 20130101; C12N 15/79 20130101; C12N 9/0071 20130101; C12N
9/16 20130101; C12N 15/67 20130101; C12Y 302/01026 20130101; C11C
3/00 20130101; Y02P 30/20 20151101; C12P 7/64 20130101; C12P 7/6463
20130101; C12N 15/8216 20130101; C12N 9/2465 20130101; Y02E 50/10
20130101; C12Y 301/02 20130101; C12P 7/6445 20130101; C12Y
301/02014 20130101; C12Y 302/01022 20130101; C12Y 114/19001
20130101; A23D 7/00 20130101 |
Class at
Publication: |
426/61 |
International
Class: |
A23D 9/02 20060101
A23D009/02; A23D 7/02 20060101 A23D007/02 |
Claims
1. A food composition comprising at least 0.1% w/w recombinant
algal biomass and one or more other ingredient, wherein the
recombinant algal biomass comprises at least about 10% triglyceride
oil by weight and is cultured under heterotrophic conditions.
2. The food composition of claim 1, wherein the triglyceride oil
comprises a fatty acid profile selected from the group consisting
of at least about 1% C8:0, at least about 1% C10:0, at least about
1% C12:0, at least about 2% C14:0, at least about 30% C16:0, at
least about 5% C18:0, at least about 60% C18:1, less than about 7%
C18:2, and at least about 35% saturated fatty acids.
3. The food composition of claim 1, wherein the fatty acid profile
of algal triglyceride oil is similar to the fatty acid profile of a
naturally occurring oil.
4. The food composition of claim 3, wherein the naturally occurring
oil is selected from the group consisting of cocoa butter, coconut
oil, palm oil, beef tallow, and lard.
5. The food composition of claim 1, wherein the fatty acid profile
of the algal triglyceride oil is at least 60% C18:1.
6. The food composition of claim 5, wherein the fatty acid profile
of the algal triglyceride oil is at least 80% C18:1.
7. The food composition of claim 1, wherein the recombinant algal
biomass is predominantly intact cells.
8. The food composition of claim 1, wherein the recombinant algal
biomass is predominantly lysed cells.
9. The food composition of claim 8, wherein the recombinant algal
biomass is a homogenate.
10. The food composition of claim 8, wherein the recombinant algal
biomass is a powder.
11. The food composition of claim 8, wherein the recombinant algal
biomass is in the form of a powder, and wherein the recombinant
algal biomass comprises at least about 40% triglyceride oil by dry
weight.
12. The food composition of claim 1, that is a salad dressing, egg
product, baked good, bread, bar, snack chip, pasta, sauce, soup,
beverage, frozen dessert, butter or spread.
13. The food composition of claim 10, wherein average particle size
of the powder is from about 0.2 to about 20 microns.
14. The food composition of claim 1, wherein the recombinant algal
biomass is a species of the genus Chlorella or Prototheca.
15. The food composition of claim 14, wherein the recombinant algal
biomass is selected from the group consisting of Chlorella
protothecoides and Prototheca moriformis.
16. A method of making a food composition comprising combining
heterotrophically cultivated recombinant algal biomass comprising
at least 10% triglyceride oil by weight with at least one other
ingredient.
17. The method of claim 16, wherein said triglyceride oil comprises
a fatty acid profile selected from the group consisting of at least
about 1% C8:0, at least about 1% C10:0, at least about 1% C12:0, at
least about 2% C14:0, at least about 30% C16:0, at least about 5%
C18:0, at least about 60% C18:1, less than about 7% C18:2, and at
least about 35% saturated fatty acids.
18. The method of claim 16 comprising the steps of: a. determining
the amount non-algal oil, non-algal fat or egg in a conventional
food product; and b. replacing a portion of the non-algal oil,
non-algal fat or egg or supplementing the non-algal oil, non-algal
fat or egg with a specified amount of recombinant algal
biomass.
19. The method of claim 18, wherein non-algal oil, non-algal fat or
egg is not added to the food composition.
20. The method of claim 18, wherein the amount of recombinant algal
biomass is from about 0.25 times to about 4 times the mass or
volume of the non-algal oil, non-algal fat or egg in the
conventional food product.
21. The method of claim 18, wherein the recombinant algal biomass
is predominantly lysed and is in the form of a powder or a
homogenate.
22. The method of claim 16, wherein the recombinant algal biomass
is a species of the genus Chlorella or Prototheca.
23. The method of claim 22, wherein the recombinant algal biomass
is selected from the group consisting of Chlorella protothecoides
and Prototheca moriformis.
24. A food composition comprising at least about 0.1% w/w
recombinant algal biomass and one or more other ingredient, wherein
the recombinant algal biomass is a color mutant and comprises at
least about 10% triglyceride oil by dry weight.
25. The food composition of claim 24, wherein the triglyceride oil
comprises a fatty acid profile selected from the group consisting
of at least about 1% C8:0, at least about 1% C10:0, at least about
1% C12:0, at least about 2% C14:0, at least about 30% C16:0, at
least about 5% C18:0, at least about 60% C18:1, less than about 7%
C18:2, and at least about 35% saturated fatty acids.
26. The food composition of claim 24, wherein the recombinant algal
biomass is a species of the genus Chlorella or Prototheca.
27. The food composition of claim 26, wherein the recombinant algal
biomass is selected from the group consisting of Chlorella
protothecoides and Prototheca moriformis.
28. The food composition of claim 24, wherein the recombinant algal
biomass is cultured under GMP conditions.
29. A food composition comprising at least 0.1% w/w algal
triglyceride oil and one or more other ingredient, wherein the
algal triglyceride oil is isolated from recombinant algal biomass
that is cultured under heterotrophic conditions.
30. The food composition of claim 29, wherein said triglyceride oil
comprises a fatty acid profile selected from the group consisting
of at least about 1% C8:0, at least about 1% C10:0, at least about
1% C12:0, at least about 2% C14:0, at least about 30% C16:0, at
least about 5% C18:0, at least about 60% C18:1, less than about 7%
C18:2, and at least about 35% saturated fatty acids.
31. The food composition of claim 29, wherein the profile of the
recombinant algal triglyceride oil is similar to the triglyceride
profile of a naturally occurring oil.
32. The food composition of claim 31, wherein the naturally
occurring oil is selected from the group consisting of cocoa
butter, coconut oil, palm oil, beef tallow, and lard.
33. The food composition of claim 29, wherein the profile of the
algal triglyceride oil is at least 60% C18:1.
34. The food composition of claim 33, wherein the profile of the
algal triglyceride oil is at least 80% C18:1.
35. The food composition of claim 29, wherein the recombinant algal
biomass is a species of the genus Chlorella or Prototheca.
36. The food composition of claim 35, wherein the recombinant algal
biomass is selected from the group consisting of Chlorella
protothecoides and Prototheca moriformis.
37. The food composition of claim 29 that is a salad dressing, egg
product, baked good, bread, bar, snack chip, pasta, sauce, soup,
beverage, frozen dessert, butter or spread.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. 119(e)
of U.S. Provisional Patent Application No. 61/349,774, filed May
28, 2010, U.S. Provisional Patent Application No. 61/374,992, filed
Aug. 18, 2010, U.S. Provisional Patent Application No. 61/414,393,
filed Nov. 16, 2010, and U.S. Provisional Patent Application No.
61/428,192, filed Dec. 29, 2010. Each of these applications is
incorporated herein by reference in its entirety for all
purposes.
REFERENCE TO A SEQUENCE LISTING
[0002] This application includes a sequence listing as shown in
pages 1-195, appended hereto.
FIELD OF THE INVENTION
[0003] The present invention relates to the production of food
compositions, oils, fuels, and oleochemicals made from
microorganisms. In particular, the disclosure relates to
oil-bearing microalgae, methods of cultivating them for the
production of biomass and useful compounds, including lipids, fatty
acid esters, fatty acids, aldehydes, alcohols, and alkanes, and
methods and reagents for genetically altering them to improve
production efficiency and alter the type and composition of the
oils produced by them.
BACKGROUND OF THE INVENTION
[0004] As the human population continues to increase, there's a
growing need for additional food sources, particularly food sources
that are inexpensive to produce but nutritious. Moreover, the
current reliance on meat as the staple of many diets, at least in
the most developed countries, contributes significantly to the
release of greenhouse gases, and there's a need for new foodstuffs
that are equally tasty and nutritious yet less harmful to the
environment to produce. There remains a need for methods to produce
foodstuffs from microorganism, including algae, cheaply and
efficiently, at large scale, particularly foodstuffs that are tasty
and nutritious. The present invention meets these and other
needs
SUMMARY OF THE INVENTION
[0005] The present invention provides oleaginous microbial cells,
preferably microalgal cells, having distinct lipid profiles, and
includes recombinant cells expressing exogenous genes encoding
proteins such as fatty acyl-ACP thioesterases. The present
invention also provides methods of making lipids and oil-based
products, including fuels such as biodiesel, renewable diesel and
jet fuel, from such cells.
[0006] In a first aspect, the present invention provides oleaginous
microbial cells, preferably microalgal cells, having a lipid
profile that is at least 1% or at least 5%, preferably at least 3%,
C8:0. In some cases, the lipid profile is at least 10% or at least
15%, preferably at least 12%, C8:0. In some embodiments, the cell
is a recombinant cell. In some cases, the recombinant cell
comprises an exogenous gene encoding an acyl-ACP thioesterase
protein that has hydrolysis activity towards fatty acyl-ACP
substrates of chain length C8. In some embodiments, the exogenous
gene encodes a Cuphea palustris acyl-ACP thioesterase. In some
cases, the cell is a Prototheca cell. In some cases, the cell is of
a microalgal genus or species selected from microalgae identified
in Table 1.
[0007] In a second aspect, the present invention provides
oleaginous microbial cells, preferably microalgal cells, having a
lipid profile that is at least 4% C10:0. In some cases, the lipid
profile is at least 20%, at least 25% or at least 30%, preferably
at least 24%, C10:0. In some cases, the ratio of C10:0 to C12:0 is
at least 6:1. In some embodiments, the cell is a recombinant cell.
In some cases, the recombinant cell comprises an exogenous gene
encoding an acyl-ACP thioesterase protein that has hydrolysis
activity towards fatty acyl-ACP substrates of chain length C10. In
some embodiments, the exogenous gene encodes an acyl-ACP
thioesterase protein from a species selected from the group
consisting of Cuphea hookeriana and Ulmus americana. In some cases,
the cell is a Prototheca cell. In some embodiments, the cell is of
a microalgal genus or species selected from microalgae identified
in Table 1.
[0008] In a third aspect, the present invention provides oleaginous
microbial cells, preferably microalgal cells, having a lipid
profile that is at least 10% or at least 15%, preferably at least
13%, C12:0. In some cases, the lipid profile is at least 30%, at
least 35% or at least 40%, preferably at least 34%, C12:0. In some
cases, the ratio of C12 to C14 is at least 5:1. In some cases, the
cell is a recombinant cell. In some embodiments, the recombinant
cell comprises an exogenous gene encoding an acyl-ACP thioesterase
protein that has hydrolysis activity towards fatty acyl-ACP
substrates of chain length C12. In some cases, the recombinant cell
comprises at least two exogenous genes encoding acyl-ACP
thioesterase proteins from Umbellularia californica and Cinnamomum
camphora that have hydrolysis activity towards fatty acyl-ACP
substrates of chain length C12. In some embodiments, the cell is a
Prototheca cell.
[0009] In a fourth aspect, the present invention provides
oleaginous microbial cells, preferably microalgal cells, having a
lipid profile that is at least 5% or at least 15%, preferably at
least 10%, C14:0. In some cases, the lipid profile is at least 40%,
at least 45%, or at least 50%, preferably at least 43%, C14:0. In
some cases, the ratio of C14:0 to C12:0 is at least 7:1. In some
cases, the cell is a recombinant cell. In some embodiments, the
recombinant cell comprises an exogenous gene encoding an acyl-ACP
thioesterase protein that has hydrolysis activity towards fatty
acyl-ACP substrates of chain length C14. In some embodiments, the
acyl-ACP thioesterase protein is from a species selected from the
group consisting of Cinnamomum camphora and Ulmus americana. In
some cases, the cell is a Prototheca cell. In some embodiments, the
cell is of a microalgal genus or species selected from microalgae
identified in Table 1.
[0010] In a fifth aspect, the present invention provides oleaginous
microbial cells, preferably microalgal cells, having a lipid
profile that is at least 10% or at least 20%, preferably at least
15%, C16:0. In some cases, the lipid profile is at least 30%, at
least 35% or at least 40%, preferably at least 37%, C16:0. In some
cases, the cell is a recombinant cell. In some embodiments, the
recombinant cell comprises an exogenous gene encoding an acyl-ACP
thioesterase protein that has hydrolysis activity towards fatty
acyl-ACP substrates of chain length C16. In some embodiments, the
recombinant cell comprises at least two exogenous genes encoding
acyl-ACP thioesterase proteins from Umbellularia californica and
Cinnamomum camphora that have hydrolysis activity towards fatty
acyl-ACP substrates of chain length C16. In some cases, the cell is
a Prototheca cell.
[0011] In a sixth aspect, the present invention provides oleaginous
microbial cells, preferably microalgal cells, having a lipid
profile that is at least 55% or at least 65%, preferably at least
60%, saturated fatty acids. In some cases the cells have a lipid
profile that is at least 80%, at least 85%, or at least 90%,
preferably at least 86%, saturated fatty acids. In some cases, the
cell is a recombinant cell. In some embodiments, the recombinant
cell comprises an exogenous gene encoding an acyl-ACP thioesterase
protein that has hydrolysis activity towards fatty acyl-ACP
substrates of chain lengths C10-C16. In some embodiments, the cell
comprises an exogenous gene encoding a ketoacyl synthase protein.
In some cases, the cell is a Prototheca cell.
[0012] In a seventh aspect, the present invention provides
oleaginous microbial cells, preferably microalgal cells, comprising
a mutated endogenous desaturase gene, wherein the mutation renders
the gene or desaturase inactive. In some cases, the cell has a
lipid profile that is at least 40% or at least 50%, preferably at
least 45%, saturated fatty acids. In some cases, the cell has a
lipid profile that is at least 15%, at least 20% or at least 25%,
preferably at least 19%, C18:0. In some embodiments, the cell
comprises a mutated endogenous desaturase gene that results in at
least a 2-fold increase in C18:0 fatty acid, as compared to a
wild-type cell. In some cases, the microalgal cell has a lipid
profile that is no more than 1% or no more than 5%, preferably no
more than 2%, C18:2. In some embodiments, the microalgal cell has a
lipid profile that is no more than 5% or no more than 10%,
preferably no more than 7%, 18:1.
[0013] In some embodiments of the recombinant cells discussed
herein, the cell comprises a mutated endogenous desaturase gene,
wherein the mutation renders the gene or desaturase inactive.
[0014] In a eighth aspect, the present invention provides a method
of making lipid. In one embodiment, the method comprises (a)
cultivating a cell as discussed above until the cell is at least
15% or at least 25%, preferably at least 20%, lipid by dry weight,
and (b) separating the lipid from water-soluble biomass
components.
[0015] In a ninth aspect, the present invention provides another
method of making lipid. In one embodiment, the method comprises (a)
cultivating an oleaginous microbial, preferably a microalgae cell,
containing exogenous genes encoding two distinct acyl-ACP
thioesterases, wherein the lipid profile of the cell is distinct
from (i) the profile of the cell without the exogenous genes and
(ii) the profile of the cell with only one of the exogenous genes,
and (b) separating the lipid from water-soluble biomass components.
In some cases, at least one of the exogenous genes encodes a fatty
acyl-ACP thioesterase selected from the group consisting of the
thioesterases identified in Table 4.
[0016] In a tenth aspect, the present invention provides a method
of making an oil-based product. In one embodiment, the method
comprises (a) cultivating a cell as discussed above until the cell
is at least 5% or at least 15%, preferably at least 10%, lipid by
dry weight, (b) separating the lipid from water-soluble biomass
components, and (c) subjecting the lipid to at least one chemical
reaction selected from the group consisting of: saponification;
metathesis; acid hydrolysis; alkaline hydrolysis; enzymatic
hydrolysis; catalytic hydrolysis; hot-compressed water hydrolysis;
a catalytic hydrolysis reaction wherein the lipid is split into
glycerol and fatty acids; an amination reaction to produce fatty
nitrogen compounds; an ozonolysis reaction to produce mono- and
dibasic-acids; a triglyceride splitting reaction selected from the
group consisting of enzymatic splitting and pressure splitting; a
condensation reaction that follows a hydrolysis reaction; a
hydroprocessing reaction; a hydroprocessing reaction and a
deoxygenation reaction or a condensation reaction prior to or
simultaneous with the hydroprocessing reaction; a gas removal
reaction; a deoxygenation reaction selected from the group
consisting of a hydrogenolysis reaction, hydrogenation, a
consecutive hydrogenation-hydrogenolysis reaction, a consecutive
hydrogenolysis-hydrogenation reaction, and a combined
hydrogenation-hydrogenolysis reaction; a condensation reaction
following a deoxygenation reaction; an esterification reaction; an
interestification reaction; a transesterification reaction; a
hydroxylation reaction; and a condensation reaction following a
hydroxylation reaction, whereby an oil-based product is
produced.
[0017] In some cases, the oil-based product is selected from soap
or a fuel product. In some embodiments, the oil-based product is a
fuel product selected from the group consisting biodiesel,
renewable diesel, and jet fuel. In some cases, the fuel product is
biodiesel with one or more of the following attributes: (i)
0.01-0.5 mcg/g, 0.025-0.3 mcg/g, preferably 0.05-0.244 mcg/g, total
carotenoids; (ii) less than 0.01 mcg/g, less than 0.005 mcg/g,
preferably less than 0.003 mcg/g, lycopene; (iii) less than 0.01
mcg/g, less than 0.005 mcg/g, preferably less than 0.003 mcg/g,
beta carotene; (iv) 0.01-0.5 mcg/g, 0.025-0.3 mcg/g, preferably
0.045-0.268 mcg/g, chlorophyll A; (v) 1-500 mcg/g, 35-175 mcg/g,
preferably 38.3-164 mcg/g, gamma tocopherol; (vi) less than 1%,
less than 0.5%, preferably less than 0.25%, brassicasterol,
campesterol, stignasterol, or beta-sitosterol; (vii) 100-500 mcg/g,
225-350 mcg/g, preferably 249.6-325.3 mcg/g, total tocotrienols;
(viii) 0.001-0.1 mcg/g, 0.0025-0.05 mcg/g, preferably 0.003-0.039
mcg/g, lutein; or (ix) 10-500 mcg/g, 50-300 mcg/g, preferably
60.8-261.7 mcg/g, tocopherols. In some cases, the fuel product is
renewable diesel that has a T10-T90 of at least 20.degree. C.,
40.degree. C. or 60.degree. C. In some cases, the fuel product is
jet fuel that meets HRJ-5 and/or ASTM specification D1655.
[0018] In an eleventh aspect, the present invention provides a
triglyceride oil comprising (a) a lipid profile of at least 3%
C8:0, at least 4% C10:0, at least 13% C12:0, at least 10% C14:0,
and/or at least 60% saturated fatty acids, and (b) one or more of
the following attributes: (i) 0.01-0.5 mcg/g, 0.025-0.3 mcg/g,
preferably 0.05-0.244 mcg/g, total carotenoids; (ii) less than 0.01
mcg/g, less than 0.005 mcg/g, preferably less than 0.003 mcg/g,
lycopene; (iii) less than 0.01 mcg/g, less than 0.005 mcg/g,
prefereably less than 0.003 mcg/g, beta carotene; (iv) 0.01-0.5
mcg/g, 0.025-0.3 mcg/g, preferably 0.045-0.268 mcg/g, chlorophyll
A; (v) 1-300 mcg/g, 35-175 mcg/g, preferably 38.3-164 mcg/g, gamma
tocopherol; (vi) less than 1%, less than 0.5%, preferably less than
0.25%, brassicasterol, campesterol, stignasterol, or
beta-sitosterol; (vii) 100-500 mcg/g, 225-350 mcg/g, preferably
249.6-325.3 mcg/g, total tocotrienols; (viii) 0.001-0.1 mcg/g,
0.0025-0.05 mcg/g, preferably 0.003-0.039 mcg/g, lutein; or (ix)
10-500 mcg/g, 50-300 mcg/g, preferably 60.8-261.7 mcg/g,
tocopherols.
[0019] In a twelfth aspect, the present invention provides an
isolated oil from microalgae that has a C8:C10 fatty acid ratio of
at least 5:1. In a related aspect, the present invention provides
an isolated oil from microalgae with at least 50% to 75%,
preferably at least 60%, saturated fatty acids. In another related
aspect, the present invention provides an isolated oil from
microalgae that has a C16:14 fatty acid ratio of about 2:1. In
still another related aspect, the present invention provides an
isolated oil from microalgae that has a C12:C14 fatty acid ratio of
at least 5:1. In some embodiments, the microalgae contains at least
one exogenous gene. In some cases, the microalgae is of the genus
Prototheca.
[0020] In a thirteenth aspect, the present invention provides a
triglyceride oil comprising (a) a lipid profile of less than 5% or
less than 2%, preferably less than 1%, <C12; between 1%-10%,
preferably 2%-7%, C14:0; between 20%-35%, preferably 23%-30%,
C16:0; between 5%-20%, preferably 7%-15%, C18:0; between 35-60%,
preferably 40-55%, C18:1; and between 1%-20%, preferably 2-15%,
C18:2 fatty acids; and (b) one or more of the following attributes:
(i) 0.01-0.5 mcg/g, 0.025-0.3 mcg/g, preferably 0.05-0.244 mcg/g,
total carotenoids; (ii) less than 0.01 mcg/g, less than 0.005
mcg/g, preferably less than 0.003 mcg/g, lycopene; (iii) less than
0.01 mcg/g, less than 0.005 mcg/g, preferably less than 0.003
mcg/g, beta carotene; (iv) 0.01-0.5 mcg/g, 0.025-0.3 mcg/g,
preferably 0.045-0.268 mcg/g, chlorophyll A; (v) 1-300 mcg/g,
35-175 mcg/g, preferably 38.3-164 mcg/g, gamma tocopherol; (vi)
less than 1%, less than 0.5%, preferably less than 0.25%,
brassicasterol, campesterol, stignasterol, or beta-sitosterol;
(vii) 100-500 mcg/g, 225-350 mcg/g, preferably 249.6-325.3 mcg/g,
total tocotrienols; (viii) 0.001-0.1 mcg/g, 0.0025-0.05 mcg/g,
preferably 0.003-0.039 mcg/g, lutein; or (ix) 10-500 mcg/g, 50-300,
preferably 60.8-261.7 mcg/g, tocopherols.
[0021] In some cases, the triglyceride oil is isolated from a
microbe comprising one or more exogenous gene. In some embodiments,
the one or more exogenous gene encodes a fatty acyl-ACP
thioesterase. In some cases, the fatty acyl-ACP thioesterase has
hydrolysis activity towards fatty acyl-ACP substrates of chain
length C14. In some embodiments, the microbe further comprises a
mutated endogenous desaturase gene, wherein the mutation renders
the gene or desaturase inactive.
[0022] In a fourteenth aspect, the present invention provides a
method of producing a triglyceride oil comprising a lipid profile
of less than 5%, or less than 2%, preferably less than 1%, <C12;
between 1%-10%, preferably 2%-7%, C14:0; between 20%-35%,
preferably 23%-30%, C16:0; between 5%-20%, preferably 7%-15%,
C18:0; between 35%-60%, preferably 40-55%, C18:1; and between
1%-20%, preferably 2-15%, C18:2 fatty acids, wherein the
triglyceride oil is isolated from a microbe comprising one or more
exogenous gene. In some cases, the triglyceride oil comprises a
lipid profile of 1%-10%, preferably 3-5%, C14:0; 20%-30%,
preferably 25-27%, C16:0; 5%-20%, preferably 10-15%, C18:0; and
35%-50%, preferably 40-45%, C18:1. In some embodiments, the one or
more exogenous gene encodes a fatty acyl-ACP thioesterase. In some
cases, the fatty acyl-ACP thioesterase has hydrolysis activity
towards fatty acyl-ACP substrates of chain length C14. In some
cases, the microbe further comprises a mutated endogenous
desaturase gene, wherein the mutation renders the gene or
desaturase inactive. In some cases, the one or more exogenous gene
is a sucrose invertase. In some embodiments, the mutated endogenous
desaturase gene is a stearoyl-acyl carrier protein desaturase (SAD)
(e.g., SEQ ID NOs: 199-200). In some embodiments, the mutated
endogenous desaturase gene is a fatty acid desaturase (FAD).
[0023] In a fifteenth aspect, the present invention provides a
oleaginous microbial cell, preferably a microalgal cell, comprising
a triglyceride oil, wherein the fatty acid profile of the
triglyceride oil is selected from the group consisting of at least
about 1% C8:0, at least about 1% C10:0, at least about 1% C12:0, at
least about 2% C14:0, at least about 30% C16:0, at least about 5%
C18:0, at least about 60% C18:1, less than about 7% C18:2, and at
least about 35% saturated fatty acids. In some cases, the
oleaginous microbial cell comprises an exogenous gene, and
optionally, an endogenous desaturase of the oleaginous microbial
cell has been inactivated or mutated to have less enzymatic
activity.
[0024] In some cases, the fatty acid profile of the triglyceride
oil is similar to the fatty acid profile of a naturally occurring
oil. In some cases, the naturally occurring oil is selected from
the group consisting of cocoa butter, coconut oil, palm oil, palm
kernel oil, shea butter, beef tallow and lard. In some cases, the
fatty acid profile of the triglyceride oil comprises a profile
selected from the group consisting of, the total combined amounts
of C8:0 and C10:0 is at least about 10%, the total combined amount
of C10:0, C12:0, and C14:0 is at least about 50%, the total
combined amount of C16:0, C18:0 and C18:1 is at least about 60%,
the total combined amount of C18:0, C18:1 and C18:2 is at least
about 60%, the total combined amount of C14:0, C16:0, C18:0 and
C18:1 is at least about 60%, and the total combined amount of C18:1
and C18:2 is less than about 30%. In some cases, the fatty acid
profile of the triglyceride oil comprises a ratio of fatty acids
selected from the group consisting of C8:0 to C10:0 ratio of at
least about 5 to 1, C10:0 to C12:0 ratio of at least about 6 to 1,
C12:0 to C14:0 ratio of at least about 5 to 1, C14:0 to C12:0 ratio
of at least about 7:1, and C14:0 to C16:0 ratio of at least about 1
to 2.
[0025] In some cases, the endogenous desaturase is selected from
the group consisting of stearoyl ACP desaturase and delta 12 fatty
acid desaturase. In some cases, the exogenous gene is selected from
the group consisting of a gene encoding an acyl-ACP thioesterase.
In some cases, the exogenous gene encodes an acyl-ACP thioesterase
selected from the group consisting of those identified in Table 4.
In some cases, the oleaginous microbial cell further comprises a
gene encoding a sucrose invertase.
[0026] In various embodiments, the oleaginous microbial cell is a
cell of a microalgal genus or species selected from Achnanthes
orientalis, Agmenellum, Amphiprora hyaline, Amphora coffeiformis,
Amphora coffeiformis linea, Amphora coffeiformis punctata, Amphora
coffeiformis taylori, Amphora coffeiformis tenuis, Amphora
delicatissima, Amphora delicatissima capitata, Amphora sp.,
Anabaena, Ankistrodesmus, Ankistrodesmus falcatus, Boekelovia
hooglandii, Borodinella sp., Botryococcus braunii, Botryococcus
sudeticus, Carteria, Chaetoceros gracilis, Chaetoceros muelleri,
Chaetoceros muelleri subsalsum, Chaetoceros sp., Chlorella
anitrata, Chlorella Antarctica, Chlorella aureoviridis, Chlorella
candida, Chlorella capsulate, Chlorella desiccate, Chlorella
ellipsoidea, Chlorella emersonii, Chlorella fusca, Chlorella fusca
var. vacuolate, Chlorella glucotropha, Chlorella infusionum,
Chlorella infusionum var. actophila, Chlorella infusionum var.
auxenophila, Chlorella kessleri, Chlorella lobophora (strain SAG
37.88), Chlorella luteoviridis, Chlorella luteoviridis var.
aureoviridis, Chlorella luteoviridis var. lutescens, Chlorella
miniata, Chlorella minutissima, Chlorella mutabilis, Chlorella
nocturna, Chlorella parva, Chlorella photophila, Chlorella
pringsheimii, Chlorella protothecoides (including any of UTEX
strains 1806, 411, 264, 256, 255, 250, 249, 31, 29, 25, and CCAP
strains 211/17 and 211/8d), Chlorella protothecoides var.
acidicola, Chlorella regularis, Chlorella regularis var. minima,
Chlorella regularis var. umbricata, Chlorella reisiglii, Chlorella
saccharophila, Chlorella saccharophila var. ellipsoidea, Chlorella
salina, Chlorella simplex, Chlorella sorokiniana, Chlorella sp.,
Chlorella sphaerica, Chlorella stigmatophora, Chlorella vanniellii,
Chlorella vulgaris, Chlorella vulgaris, Chlorella vulgaris f.
tertia, Chlorella vulgaris var. autotrophica, Chlorella vulgaris
var. viridis, Chlorella vulgaris var. vulgaris, Chlorella vulgaris
var. vulgaris f. tertia, Chlorella vulgaris var. vulgaris f.
viridis, Chlorella xanthella, Chlorella zofingiensis, Chlorella
trebouxioides, Chlorella vulgaris, Chlorococcum infusionum,
Chlorococcum sp., Chlorogonium, Chroomonas sp., Chrysosphaera sp.,
Cricosphaera sp., Cryptomonas sp., Cyclotella cryptica, Cyclotella
meneghiniana, Cyclotella sp., Dunaliella sp., Dunaliella bardawil,
Dunaliella bioculata, Dunaliella granulate, Dunaliella maritime,
Dunaliella minuta, Dunaliella parva, Dunaliella peircei, Dunaliella
primolecta, Dunaliella sauna, Dunaliella terricola, Dunaliella
tertiolecta, Dunaliella viridis, Dunaliella tertiolecta,
Eremosphaera viridis, Eremosphaera sp., Ellipsoidon sp., Euglena,
Franceia sp., Fragilaria crotonensis, Fragilaria sp., Gleocapsa
sp., Gloeothamnion sp., Hymenomonas sp., Isochrysis aff galbana,
Isochrysis galbana, Lepocinclis, Micractinium, Micractinium (UTEX
LB 2614), Monoraphidium minutum, Monoraphidium sp., Nannochloris
sp., Nannochloropsis sauna, Nannochloropsis sp., Navicula
acceptata, Navicula biskanterae, Navicula pseudotenelloides,
Navicula pelliculosa, Navicula saprophila, Navicula sp.,
Nephrochloris sp., Nephroselmis sp., Nitschia communis, Nitzschia
alexandrina, Nitzschia communis, Nitzschia dissipata, Nitzschia
frustulum, Nitzschia hantzschiana, Nitzschia inconspicua, Nitzschia
intermedia, Nitzschia microcephala, Nitzschia pusilla, Nitzschia
pusilla elliptica, Nitzschia pusilla monoensis, Nitzschia
quadrangular, Nitzschia sp., Ochromonas sp., Oocystis parva,
Oocystis pusilla, Oocystis sp., Oscillatoria limnetica,
Oscillatoria sp., Oscillatoria subbrevis, Pascheria acidophila,
Pavlova sp., Phagus, Phormidium, Platymonas sp., Pleurochrysis
carterae, Pleurochrysis dentate, Pleurochrysis sp., Prototheca
wickerhamii, Prototheca stagnora, Prototheca portoricensis,
Prototheca moriformis, Prototheca zopfii, Pyramimonas sp.,
Pyrobotrys, Sarcinoid chrysophyte, Scenedesmus armatus, Spirogyra,
Spirulina platensis, Stichococcus sp., Synechococcus sp.,
Tetraedron, Tetraselmis sp., Tetraselmis suecica, Thalassiosira
weissflogii, and Viridiella fridericiana.
[0027] In some cases, the oleaginous microbial cell is a cell of
the genus Prototheca. In some cases, the oleaginous microbial cell
is a cell of the genus Prototheca moriformis.
[0028] In some cases, the oleaginous microbial cell is an
oleaginous yeast cell. In some cases, the oleaginous microbial cell
is an oleaginous bacterial cell.
[0029] In some cases, the naturally occurring oil is cocoa butter
and the exogenous gene comprises a Carthamus tinctorus thioesterase
gene. In some cases, the naturally occurring oil is coconut oil. In
some cases, the naturally occurring oil is palm oil and the
exogenous gene comprises a Elaeis guiniensis thioesterase gene, a
Cuphea hookeriana thioesterase gene, a combination of a Cuphea
hookeriana KAS IV gene and a Cuphea wrightii FATB2 gene, or a
construct designed to disrupt an endogenous KAS II gene. In some
cases, the naturally occurring oil is palm kernel oil and the
exogenous gene comprises a combination of a Cuphea wrightii FATB2
gene and a construct designed to disrupt an endogenous SAD2B gene.
In some cases, the naturally occurring oil is shea butter. In some
cases, the naturally occurring oil is beef tallow. In some cases,
the naturally occurring oil is lard and the exogenous gene
comprises a combination of U. californica thioesterase gene and a
construct designed to disrupt an endogenous SAD2B gene, a
combination of a Garcinia mangostana thioesterase gene and a
construct designed to disrupt an endogenous SAD2B gene, a Brassica
napus thioesterase gene, or a Cuphea hookeriana thioesterase
gene.
[0030] In a sixteenth aspect, the present invention provides an
oleaginous microbial triglyceride oil composition, wherein the
fatty acid profile of the triglyceride oil is selected from the
group consisting of at least about 1% C8:0, at least about 1%
C10:0, at least about 1% C12:0, at least about 2% C14:0, at least
about 30% C16:0, at least about 5% C18:0, at least about 60% C18:1,
less than about 7% C18:2, and at least about 35% saturated fatty
acids. In various embodiments, the triglyceride oil composition is
produced by cultivating a population of oleaginous microbial cells
or recombinant oleaginous microbial cells in a culture medium,
wherein the oleaginous microbial cells are as described above, in
particular those described above in connection with the fifteeth
aspect of the invention.
[0031] In some cases, the oleaginous microbial triglyceride oil
composition further comprises an attribute selected from the group
consisting of: (i) less than 0.3 mcg/g total carotenoids; (ii) less
than 0.005 mcg/g lycopene; (iii) less than 0.005 mcg/g beta
carotene; (iv) less than 0.3 mcg/g chlorophyll A; (v) less than 175
mcg/g gamma tocopherol; (vi) less than 0.25% brassicasterol,
campesterol, stignasterol, or beta-sitosterol; (vii) less than 350
mcg/g total tocotrienols; (viii) less than 0.05 mcg/g lutein; or
(ix) less than 275 mcg/g tocopherols.
[0032] In a seventeenth aspect, the present invention provides a
method of producing an oleaginous microbial triglyceride oil
composition having a fatty acid profile selected from the group
consisting of at least about 1% C8:0, at least about 1% C10:0, at
least about 1% C12:0, at least about 2% C14:0, at least about 30%
C16:0, at least about 5% C18:0, at least about 60% C18:1, less than
about 7% C18:2, and at least about 35% saturated fatty acids,
wherein the method comprises the steps of: (a) cultivating a
population of oleaginous microbial cells in a culture medium until
at least 10% of the dry cell weight of the oleaginous microbial
cells is triglyceride oil; and (b) isolating the triglyceride oil
composition from the oleaginous microbial cells. In various
embodiments, the triglyceride oil composition is produced via
cultivation of a population of oleaginous microbial cells or
recombinant oleaginous microbial cells as described above, in
particular those described above in connection with the fifteenth
aspect of the invention.
[0033] In an eighteenth aspect, the present invention provides a
method of making an oil-based product, wherein the method comprises
the steps of: (a) subjecting the oleaginous microbial triglyceride
oil composition, as described above in connection with the
sixteenth aspect of the invention, to at least one chemical
reaction selected from the group consisting of: saponification;
metathesis; acid hydrolysis; alkaline hydrolysis; enzymatic
hydrolysis; catalytic hydrolysis; hot-compressed water hydrolysis;
a catalytic hydrolysis reaction wherein the lipid is split into
glycerol and fatty acids; an amination reaction to produce fatty
nitrogen compounds; an ozonolysis reaction to produce mono- and
dibasic-acids; a triglyceride splitting reaction selected from the
group consisting of enzymatic splitting and pressure splitting; a
condensation reaction that follows a hydrolysis reaction; a
hydroprocessing reaction; a hydroprocessing reaction and a
deoxygenation reaction or a condensation reaction prior to or
simultaneous with the hydroprocessing reaction; a gas removal
reaction; a deoxygenation reaction selected from the group
consisting of a hydrogenolysis reaction, hydrogenation, a
consecutive hydrogenation-hydrogenolysis reaction, a consecutive
hydrogenolysis-hydrogenation reaction, and a combined
hydrogenation-hydrogenolysis reaction; a condensation reaction
following a deoxygenation reaction; an esterification reaction; an
interestification reaction; a transesterification reaction; a
hydroxylation reaction; and a condensation reaction following a
hydroxylation reaction; and (b) isolating the product of the
reaction from the other components.
[0034] In some cases, the oil-based product is selected from the
group consisting of a soap, a fuel, a dielectric fluid, a hydraulic
fluid, a plasticizer, a lubricant, a heat transfer fluid, and a
metal working fluid. In some cases, the oil-based product is a fuel
product selected from the group consisting of: (a) biodiesel; (b)
renewable diesel; and (c) jet fuel.
[0035] In some cases, the fuel product is biodiesel with one or
more of the following attributes: (i) less than 0.3 mcg/g total
carotenoids; (ii) less than 0.005 mcg/g lycopene; (iii) less than
0.005 mcg/g beta carotene; (iv) less than 0.3 mcg/g chlorophyll A;
(v) less than 175 mcg/g gamma tocopherol; (vi) less than 0.25%
brassicasterol, campesterol, stignasterol, or beta-sitosterol;
(vii) less than 350 mcg/g total tocotrienols; (viii) less than 0.05
mcg/g lutein; or (ix) less than 275 mcg/g tocopherols.
[0036] In some cases, the fuel product is renewable diesel that has
a T10-T90 of at least 20.degree. C., 40.degree. C. or 60.degree.
C.
[0037] In some cases, the fuel product is jet fuel that meets HRJ-5
and/or ASTM specification D1655.
[0038] In another aspect, the oleaginous microbial cell of the
invention is edible. The triglyceride oils of the invention are
also edible. In some cases, the microbial strain is cultivated and
processed under good manufacturing process (GMP) conditions. As a
food or a food ingredient, the oleaginous microbial cell can be
consumed whole. Alternatively, the microbial biomass is processed
into a microbial flakes, powder or flour. Microbial flour is
prepared by completely or partially lysing the cells in the form of
a powder. When processed into microbial flour, the average particle
size of lysed microbial biomass is between about 1 to 30 .mu.m. The
lysed microbial cells can agglomerate to form bigger particles of
up to 1,000 .mu.m. In one embodiment, the flour further comprises a
flow agent, antioxidants and the like. The microbial cells and the
microbial oils of the present invention can be consumed by itself.
Alternatively, the microbial cells and the microbial oils of the
present invention can be combined with at least one other
ingredient. By way of example, the microbial cells and the
microbial oils can be combined with edible ingredients, e.g., egg,
egg products, milk, dairy products, meats, grains, other edible
fats, natural sweetners, artificial sweetners, etc. The microbial
cells and the microbial oils can also be combined with
preservatives and other ingredients added to processed foods.
[0039] All of the processes described herein can be performed in
accordance with GMP or equivalent regulations. In the United
States, GMP regulations for manufacturing, packing, or holding
human food are codified at 21 C.F.R. 110. These provisions, as well
as ancillary provisions referenced therein, are hereby incorporated
by reference in their entirety for all purposes. GMP conditions in
the Unites States, and equivalent conditions in other
jurisdictions, apply in determining whether a food is adulterated
(the food has been manufactured under such conditions that it is
unfit for food) or has been prepared, packed, or held under
unsanitary conditions such that it may have become contaminated or
otherwise may have been rendered injurious to health. GMP
conditions can include adhering to regulations governing: disease
control; cleanliness and training of personnel; maintenance and
sanitary operation of buildings and facilities; provision of
adequate sanitary facilities and accommodations; design,
construction, maintenance, and cleanliness of equipment and
utensils; provision of appropriate quality control procedures to
ensure all reasonable precautions are taken in receiving,
inspecting, transporting, segregating, preparing, manufacturing,
packaging, and storing food products according to adequate
sanitation principles to prevent contamination from any source; and
storage and transportation of finished food under conditions that
will protect food against physical, chemical, or undesirable
microbial contamination, as well as against deterioration of the
food and the container.
[0040] In some embodiments, the oleaginous microbial cells are
algal cells of a species of the genus Chlorella or Prototheca. In
one embodiment, the algae is Chlorella protothecoides. In another
embodiment, the algae is Prototheca moriformis. In some cases, the
biomass is derived from an algae that is a color mutant with
reduced color pigmentation compared to the strain from which it was
derived. Mutants with reduced color pigmentation are typically
prepared using standard mutagenesis techniques. There are many
fee-for-service laboratories that will generate mutants with
reduced color pigmentation. In some embodiments, the microbial
biomass is prepared by cultivating the microorganism
heterotrophically and optionally in the absence of light.
[0041] In one embodiment, the microalgal strain is Chlorella
protothecoides 33-55, deposited on Oct. 13, 2009 at the American
Type Culture Collection under deposit designation PTA-10397. In one
embodiment, the microalgal strain is Chlorella protothecoides
25-32, deposited on Oct. 13, 2009 at the American Type Culture
Collection under deposit designation PTA-10396. In some cases, the
microalgal strain providing the biomass has been grown and
processed under good manufacturing process (GMP) conditions.
[0042] In another aspect, the present invention provides methods
for preparing recombinant oleaginous microbial biomass suitable for
use as a foodstuff. In these methods, the recombinant oleaginous
microbes are fermented under heterotrophic conditions and so lack
or have a significantly reduced amount of green pigment that
characterizes other recombinant microalgal derived foodstuffs. In
one embodiment, the recombinant oleaginous microbes lack or have
significantly reduced amounts of any pigment. One aspect of the
invention provides recombinant microalgae of the genus Chlorella
and Protothecoides. In some embodiments, the invention is a
microalgae of the genus recombinant Protothecoides. Another
embodiment provides recombinant Protothecoides moriformis for use
in foods and food ingredients. In one embodiment, the fermentation
conditions are manipulated to provide a biomass rich in lipid. In
another embodiment, the fermentation conditions are manipulated to
provide a biomass rich in protein. In all embodiments, the methods
can be carried out cheaply and efficiently at large scale (biomass
produced in 4500 L or larger fermentors).
[0043] In another aspect, the present invention provides
recombinant oleaginous microbial biomass, preferably microalgal
biomass, suitable for incorporation into human foodstuffs. In one
embodiment, this recombinant microbial biomass is the concentrated
biomass resulting directly from the biomass preparation methods of
the present invention. In another embodiment, this biomass is in
the form of dried flakes resulting from drying, e.g., drum drying,
such biomass preparations. In this latter embodiment, an
antioxidant can be added to the biomass prior to the drying step to
extend the shelf-life of the biomass and any food product
containing such biomass.
[0044] Yet another aspect of the invention provides methods for
further processing the biomass into flakes or a homogenate. In one
embodiment, the dried flakes are rehydrated in deionized water to
create a suspension. This suspension is then micronized with a high
pressure homogenizer so that the average particle size is less than
20 .mu.m, preferably 10 .mu.m in size, creating a homogenate.
[0045] A further aspect of the present invention provides methods
for processing the recombinant oleaginous microbial biomass,
preferably microalgal biomass, into a food ingredient that is
multifunctional in that it provides healthy oils to foods and
provides structural benefits to foods such as baked goods. In one
embodiment, the processing involves pneumatic drying (e.g., spray
drying or flash drying) the biomass preparation to form a powder
that contains a large percentage of intact recombinant cells. In
another embodiment, the biomass is first micronized to disrupt the
cells before pneumatic drying to form a flour that contains only a
small percentage (or no) intact cells; in some embodiments a flow
or dispersal agent is added prior to the drying step.
[0046] In yet another aspect, the present invention is directed to
a method of producing an oil or oil-containing recombinant
oleaginous microbial biomass suitable for human consumption. In
some embodiments, the process involves extracting the lipid
(triglyceride) from the biomass to form an oil. In one embodiment,
the method comprises providing a microorganism, and culturing the
microorganism in the presence of a feedstock that is not derived
from a food composition suitable for human consumption, in which
the microorganism converts at least some portion of the feedstock
into triglyceride oil. In some cases, the triglyceride oil
comprises at least 50%, 60%, 70%, 80% or 90% C18:1 lipid.
[0047] The present invention further provides foods that
incorporate a recombinant microbial powder, recombinant microbial
flour, and/or recombinant microbial oil. In one embodiment, the
food is a baked good, dressing, sauce, or mayonnaise in which,
relative to the same food produced using conventional recipes, all
or a portion of the egg or butter has been replaced by a
recombinant microbial flour rich in oil. In another embodiment, the
food is a powdered egg product containing a recombinant microbial
flour rich in oil. In another embodiment, the food is a liquid egg
product containing a microbial flour rich in oil. In another
embodiment, the food is a liquid milk product containing microbial
protein, fiber, and oil. In another embodiment, the food is a meat
product in which, relative to previously available meat products, a
portion or all (a meat substitute) of the meat has been replaced by
a recombinant microbial flour, recombinant microbial powder, or
recombinant microbial flake rich in protein.
[0048] The invention also provides methods of inducing satiety by
providing recombinant microbial foods or microbial food ingredients
containing microbial fiber and optionally microbial protein and/or
microbial oil.
[0049] These and other aspects and embodiments of the invention are
described in the accompanying drawing, a brief description of which
immediately follows, the detailed description of the invention
below, and are exemplified in the examples below. Any or all of the
features discussed above and throughout the application can be
combined in various embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] FIG. 1 shows a chromatogram of renewable diesel produced
from Prototheca triglyceride oil.
DETAILED DESCRIPTION OF THE INVENTION
[0051] The present invention arises from the discovery that
Prototheca and certain related microorganisms have unexpectedly
advantageous properties for the production of oils, fuels, and
other hydrocarbon or lipid compositions economically and in large
quantities, as well as from the discovery of methods and reagents
for genetically altering these microorganisms to improve these
properties. The oils produced by these microorganisms can be used
in the transportation fuel, oleochemical, and/or food and cosmetic
industries, among other applications. Transesterification of lipids
yields long-chain fatty acid esters useful as biodiesel. Other
enzymatic and chemical processes can be tailored to yield fatty
acids, aldehydes, alcohols, alkanes, and alkenes. In some
applications, renewable diesel, jet fuel, or other hydrocarbon
compounds are produced. The present invention also provides methods
of cultivating microalgae for increased productivity and increased
lipid yield, and/or for more cost-effective production of the
compositions described herein.
[0052] This detailed description of the invention is divided into
sections for the convenience of the reader. Section I provides
definitions of terms used herein. Section II provides a description
of culture conditions useful in the methods of the invention.
Section III provides a description of genetic engineering methods
and materials. Section IV provides a description of genetic
engineering of microorganisms (e.g., Prototheca) to enable sucrose
utilization. Section V provides a description of genetic
engineering of microorganisms (e.g., Prototheca) to modify lipid
biosynthesis. Section VI describes methods for making fuels and
chemicals. Section VII describes methods for preparing recombinant
microbial biomass. Section VIII describes methods for processing
recombinant microbial biomass into finished food products. Section
IX describes methods for combining recombinant microbial biomass or
materials derived therefrom withn other food ingredients. Section X
discloses examples and embodiments of the invention. The detailed
description of the invention is followed by examples that
illustrate the various aspects and embodiments of the
invention.
I. DEFINITIONS
[0053] Unless defined otherwise, all technical and scientific terms
used herein have the meaning commonly understood by a person
skilled in the art to which this invention belongs. The following
references provide one of skill with a general definition of many
of the terms used in this invention: Singleton et al., Dictionary
of Microbiology and Molecular Biology (2nd ed. 1994); The Cambridge
Dictionary of Science and Technology (Walker ed., 1988); The
Glossary of Genetics, 5th Ed., R. Rieger et al. (eds.), Springer
Verlag (1991); and Hale & Marham, The Harper Collins Dictionary
of Biology (1991). As used herein, the following terms have the
meanings ascribed to them unless specified otherwise.
[0054] "Active in microalgae" refers to a nucleic acid that is
functional in microalgae. For example, a promoter that has been
used to drive an antibiotic resistance gene to impart antibiotic
resistance to a transgenic microalgae is active in microalgae.
[0055] "Acyl carrier protein" or "ACP" is a protein that binds a
growing acyl chain during fatty acid synthesis as a thiol ester at
the distal thiol of the 4'-phosphopantetheine moiety and comprises
a component of the fatty acid synthase complex.
[0056] "Acyl-CoA molecule" or "acyl-CoA" is a molecule comprising
an acyl moiety covalently attached to coenzyme A through a thiol
ester linkage at the distal thiol of the 4'-phosphopantetheine
moiety of coenzyme A.
[0057] "Area Percent" refers to the area of peaks observed using
FAME GC/FID detection methods in which every fatty acid in the
sample is converted into a fatty acid methyl ester (FAME) prior to
detection. For example, a separate peak is observed for a fatty
acid of 14 carbon atoms with no unsaturation (C14:0) compared to
any other fatty acid such as C14:1. The peak area for each class of
FAME is directly proportional to its percent composition in the
mixture and is calculated based on the sum of all peaks present in
the sample (i.e. [area under specific peak/total area of all
measured peaks] X 100). When referring to lipid profiles of oils
and cells of the invention, "at least 4% C8-C14" means that at
least 4% of the total fatty acids in the cell or in the extracted
glycerolipid composition have a chain length that includes 8, 10,
12 or 14 carbon atoms.
[0058] "Axenic" is a culture of an organism free from contamination
by other living organisms.
[0059] "Baked good" means a food item, typically found in a bakery,
that is prepared by using an oven. Baked goods include, but are not
limited to brownies, cookies, pies, cakes and pastries.
[0060] "Bread" means a food item that contains wheat flour, liquid,
and a leavening agent. Breads are usually prepared by baking in an
oven, although other methods of cooking are also acceptable. The
leavening agent can be chemical or organic in nature. Typically,
the organic leavening agent is yeast. In the case where the
leavening agent is chemical in nature (such as baking powder and/or
baking soda), these food products are referred to as "quick
breads".
[0061] "Biodiesel" is a biologically produced fatty acid alkyl
ester suitable for use as a fuel in a diesel engine.
[0062] "Biomass" is material produced by growth and/or propagation
of cells. Biomass may contain cells and/or intracellular contents
as well as extracellular material, includes, but is not limited to,
compounds secreted by a cell.
[0063] "Bioreactor" is an enclosure or partial enclosure in which
cells are cultured, optionally in suspension.
[0064] "Catalyst" is an agent, such as a molecule or macromolecular
complex, capable of facilitating or promoting a chemical reaction
of a reactant to a product without becoming a part of the product.
A catalyst increases the rate of a reaction, after which, the
catalyst may act on another reactant to form the product. A
catalyst generally lowers the overall activation energy required
for the reaction such that it proceeds more quickly or at a lower
temperature. Thus, a reaction equilibrium may be more quickly
attained. Examples of catalysts include enzymes, which are
biological catalysts; heat, which is a non-biological catalyst; and
metals used in fossil oil refining processes.
[0065] "Cellulosic material" is the product of digestion of
cellulose, including glucose and xylose, and optionally additional
compounds such as disaccharides, oligosaccharides, lignin,
furfurals and other compounds. Nonlimiting examples of sources of
cellulosic material include sugar cane bagasses, sugar beet pulp,
corn stover, wood chips, sawdust and switchgrass.
[0066] "Co-culture", and variants thereof such as "co-cultivate"
and "co-ferment", refer to the presence of two or more types of
cells in the same bioreactor. The two or more types of cells may
both be microorganisms, such as microalgae, or may be a microalgal
cell cultured with a different cell type. The culture conditions
may be those that foster growth and/or propagation of the two or
more cell types or those that facilitate growth and/or
proliferation of one, or a subset, of the two or more cells while
maintaining cellular growth for the remainder.
[0067] "Cofactor" is any molecule, other than the substrate,
required for an enzyme to carry out its enzymatic activity.
[0068] "Complementary DNA" or "cDNA" is a DNA copy of mRNA, usually
obtained by reverse transcription of messenger RNA (mRNA) or
amplification (e.g., via polymerase chain reaction ("PCR")).
[0069] "Conventional food product" means a composition intended for
consumption, e.g., by a human, that lacks algal biomass or other
algal components and includes ingredients ordinarily associated
with the food product, particularly a vegetable oil, animal fat,
and/or egg(s), together with other edible ingredients. Conventional
food products include food products sold in shops and restaurants
and those made in the home. Conventional food products are often
made by following conventional recipes that specify inclusion of an
oil or fat from a non-algal source and/or egg(s) together with
other edible ingredient(s).
[0070] "Cooked product" means a food that has been heated, e.g., in
an oven, for a period of time.
[0071] "Creamy salad dressing" means a salad dressing that is a
stable dispersion with high viscosity and a slow pour-rate.
Generally, creamy salad dressings are opaque.
[0072] "Cultivated", and variants thereof such as "cultured" and
"fermented", refer to the intentional fostering of growth
(increases in cell size, cellular contents, and/or cellular
activity) and/or propagation (increases in cell numbers via
mitosis) of one or more cells by use of selected and/or controlled
conditions. The combination of both growth and propagation may be
termed proliferation. Examples of selected and/or controlled
conditions include the use of a defined medium (with known
characteristics such as pH, ionic strength, and carbon source),
specified temperature, oxygen tension, carbon dioxide levels, and
growth in a bioreactor. Cultivate does not refer to the growth or
propagation of microorganisms in nature or otherwise without human
intervention; for example, natural growth of an organism that
ultimately becomes fossilized to produce geological crude oil is
not cultivation.
[0073] "Cytolysis" is the lysis of cells in a hypotonic
environment. Cytolysis is caused by excessive osmosis, or movement
of water, towards the inside of a cell (hyperhydration). The cell
cannot withstand the osmotic pressure of the water inside, and so
it explodes.
[0074] "Delipidated meal" and "delipidated microbial biomass" is
microbial biomass after oil (including lipids) has been extracted
or isolated from it, either through the use of mechanical (i.e.,
exerted by an expeller press) or solvent extraction or both.
Delipidated meal has a reduced amount of oil/lipids as compared to
before the extraction or isolation of oil/lipids from the microbial
biomass but does contain some residual oil/lipid.
[0075] "Dietary fiber" means non-starch carbohydrates found in
plants and other organisms containing cell walls, including
microalgae. Dietary fiber can be soluble (dissolved in water) or
insoluble (not able to be dissolved in water). Soluble and
insoluble fiber makes up total dietary fiber.
[0076] "Digestible crude protein" is the portion of protein that is
available or can be converted into free nitrogen (amino acids)
after digesting with gastric enzymes. In vitro measurement of
digestible crude protein is accomplished by using gastric enzymes
such as pepsin and digesting a sample and measuring the free amino
acid after digestion. In vivo measurement of digestible crude
protein is accomplished by measuring the protein levels in a
feed/food sample and feeding the sample to an animal and measuring
the amount of nitrogen collected in the animal's feces.
[0077] "Dry weight" and "dry cell weight" mean weight determined in
the relative absence of water. For example, reference to
recombinant microalgal biomass as comprising a specified percentage
of a particular component by dry weight means that the percentage
is calculated based on the weight of the biomass after
substantially all water has been removed.
[0078] "Edible ingredient" means any substance or composition which
is fit to be eaten. "Edible ingredients" include, without
limitation, grains, fruits, vegetables, proteins, herbs, spices,
carbohydrates, and fats.
[0079] "Expression vector" or "expression construct" or "plasmid"
or "recombinant DNA construct" refer to a nucleic acid that has
been generated via human intervention, including by recombinant
means or direct chemical synthesis, with a series of specified
nucleic acid elements that permit transcription and/or translation
of a particular nucleic acid in a host cell. The expression vector
can be part of a plasmid, virus, or nucleic acid fragment.
Typically, the expression vector includes a nucleic acid to be
transcribed operably linked to a promoter.
[0080] "Exogenous gene" is a nucleic acid that codes for the
expression of an RNA and/or protein that has been introduced
("transformed") into a cell. A transformed cell may be referred to
as a recombinant cell, into which additional exogenous gene(s) may
be introduced. The exogenous gene may be from a different species
(and so heterologous), or from the same species (and so
homologous), relative to the cell being transformed. Thus, an
exogenous gene can include a homologous gene that occupies a
different location in the genome of the cell or is under different
control, relative to the endogenous copy of the gene. An exogenous
gene may be present in more than one copy in the cell. An exogenous
gene may be maintained in a cell as an insertion into the genome or
as an episomal molecule.
[0081] "Exogenously provided" refers to a molecule provided to the
culture media of a cell culture.
[0082] "Expeller pressing" is a mechanical method for extracting
oil from raw materials such as soybeans and rapeseed. An expeller
press is a screw type machine, which presses material through a
caged barrel-like cavity. Raw materials enter one side of the press
and spent cake exits the other side while oil seeps out between the
bars in the cage and is collected. The machine uses friction and
continuous pressure from the screw drives to move and compress the
raw material. The oil seeps through small openings that do not
allow solids to pass through. As the raw material is pressed,
friction typically causes it to heat up.
[0083] "Fat" means a lipid or mixture of lipids that is generally
solid at ordinary room temperatures and pressures. "Fat" includes,
without limitation, lard and butter.
[0084] "Fatty acyl-ACP thioesterase" is an enzyme that catalyzes
the cleavage of a fatty acid from an acyl carrier protein (ACP)
during lipid synthesis.
[0085] "Fatty acyl-CoA/aldehyde reductase" is an enzyme that
catalyzes the reduction of an acyl-CoA molecule to a primary
alcohol.
[0086] "Fatty acyl-CoA reductase" is an enzyme that catalyzes the
reduction of an acyl-CoA molecule to an aldehyde.
[0087] "Fatty aldehyde decarbonylase" is an enzyme that catalyzes
the conversion of a fatty aldehyde to an alkane.
[0088] "Fatty aldehyde reductase" is an enzyme that catalyzes the
reduction of an aldehyde to a primary alcohol.
[0089] "Fiber" means non-starch carbohydrates in the form of
polysaccharide. Fiber can be soluble in water or insoluble in
water. Many microalgae produce both soluble and insoluble fiber,
typically residing in the cell wall.
[0090] "Finished food product" and "finished food ingredient" mean
a food composition that is ready for packaging, use, or
consumption. For example, a "finished food product" may have been
cooked or the ingredients comprising the "finished food product"
may have been mixed or otherwise integrated with one another. A
"finished food ingredient" is typically used in combination with
other ingredients to form a food product.
[0091] "Fixed carbon source" is a molecule(s) containing carbon,
typically an organic molecule, that is present at ambient
temperature and pressure in solid or liquid form in a culture media
that can be utilized by a microorganism cultured therein.
[0092] "Food", "food composition", "food product" and "foodstuff"
mean any composition intended to be or expected to be ingested by
humans as a source of nutrition and/or calories. Food compositions
are composed primarily of carbohydrates, fats, water and/or
proteins and make up substantially all of a person's daily caloric
intake. A "food composition" can have a weight minimum that is at
least ten times the weight of a typical tablet or capsule (typical
tablet/capsule weight ranges are from less than or equal to 100 mg
up to 1500 mg). A "food composition" is not encapsulated or in
tablet form.
[0093] "Good manufacturing practice" and "GMP" mean those
conditions established by regulations set forth at 21 C.F.R. 110
(for human food) and 111 (for dietary supplements), or comparable
regulatory schemes established in locales outside the United
States. The U.S. regulations are promulgated by the U.S. Food and
Drug Administration under the authority of the Federal Food, Drug,
and Cosmetic Act to regulate manufacturers, processors, and
packagers of food products and dietary supplements for human
consumption.
[0094] "Homogenate" means biomass that has been physically
disrupted. Homogenization is a fluid mechanical process that
involves the subdivision of particles into smaller and more uniform
sizes, forming a dispersion that may be subjected to further
processing. Homogenization is used in treatment of several foods
and dairy products to improve stability, shelf-life, digestion, and
taste.
[0095] "Hydrocarbon" is (a) a molecule containing only hydrogen and
carbon atoms wherein the carbon atoms are covalently linked to form
a linear, branched, cyclic, or partially cyclic backbone to which
the hydrogen atoms are attached. The molecular structure of
hydrocarbon compounds varies from the simplest, in the form of
methane (CH.sub.4), which is a constituent of natural gas, to the
very heavy and very complex, such as some molecules such as
asphaltenes found in crude oil, petroleum, and bitumens.
Hydrocarbons may be in gaseous, liquid, or solid form, or any
combination of these forms, and may have one or more double or
triple bonds between adjacent carbon atoms in the backbone.
Accordingly, the term includes linear, branched, cyclic, or
partially cyclic alkanes, alkenes, lipids, and paraffin. Examples
include propane, butane, pentane, hexane, octane, and squalene.
[0096] "Hydrogen:carbon ratio" is the ratio of hydrogen atoms to
carbon atoms in a molecule on an atom-to-atom basis. The ratio may
be used to refer to the number of carbon and hydrogen atoms in a
hydrocarbon molecule. For example, the hydrocarbon with the highest
ratio is methane CH.sub.4 (4:1).
[0097] "Hydrophobic fraction" is the portion, or fraction, of a
material that is more soluble in a hydrophobic phase in comparison
to an aqueous phase. A hydrophobic fraction is substantially
insoluble in water and usually non-polar.
[0098] "Increase lipid yield" refers to an increase in the
productivity of a microbial culture by, for example, increasing dry
weight of cells per liter of culture, increasing the percentage of
cells that constitute lipid, or increasing the overall amount of
lipid per liter of culture volume per unit time.
[0099] "Inducible promoter" is a promoter that mediates
transcription of an operably linked gene in response to a
particular stimulus. Examples of such promoters may be promoter
sequences that are induced in conditions of changing pH or nitrogen
levels.
[0100] "In operable linkage" is a functional linkage between two
nucleic acid sequences, such a control sequence (typically a
promoter) and the linked sequence (typically a sequence that
encodes a protein, also called a coding sequence). A promoter is in
operable linkage with an exogenous gene if it can mediate
transcription of the gene.
[0101] "In situ" means "in place" or "in its original
position".
[0102] "Limiting concentration of a nutrient" is a concentration of
a compound in a culture that limits the propagation of a cultured
organism. A "non-limiting concentration of a nutrient" is a
concentration that supports maximal propagation during a given
culture period. Thus, the number of cells produced during a given
culture period is lower in the presence of a limiting concentration
of a nutrient than when the nutrient is non-limiting. A nutrient is
said to be "in excess" in a culture, when the nutrient is present
at a concentration greater than that which supports maximal
propagation.
[0103] "Lipase" is a water-soluble enzyme that catalyzes the
hydrolysis of ester bonds in water-insoluble, lipid substrates.
Lipases catalyze the hydrolysis of lipids into glycerols and fatty
acids.
[0104] "Lipid modification enzyme" refers to an enayme that alters
the covalent structure of a lipid. Examples of lipid modification
enzymes include a lipase, a fatty acyl-ACP thioesterase, a fatty
acyl-CoA/aldehyde reductase, a fatty acyl-CoA reductase, a fatty
aldehyde reductase, a desaturase, including a stearoyl acyl carrier
protein desaturase (SAD) and a fatty acyl destaurase (FAD), and a
fatty aldehyde decarbonylase.
[0105] "Lipid pathway enzyme" is any enzyme that plays a role in
lipid metabolism, i.e., either lipid synthesis, modification, or
degradation, and any proteins that chemically modify lipids, as
well as carrier proteins.
[0106] "Lipids" are a class of molecules that are soluble in
nonpolar solvents (such as ether and chloroform) and are relatively
or completely insoluble in water. Lipid molecules have these
properties, because they consist largely of long hydrocarbon tails
which are hydrophobic in nature. Examples of lipids include fatty
acids (saturated and unsaturated); glycerides or glycerolipids
(such as monoglycerides, diglycerides, triglycerides or neutral
fats, and phosphoglycerides or glycerophospholipids); nonglycerides
(sphingolipids, sterol lipids including cholesterol and steroid
hormones, prenol lipids including terpenoids, fatty alcohols,
waxes, and polyketides); and complex lipid derivatives
(sugar-linked lipids, or glycolipids, and protein-linked lipids).
"Fats" are a subgroup of lipids called "triacylglycerides."
[0107] "Lysate" is a solution containing the contents of lysed
cells.
[0108] "Lysis" is the breakage of the plasma membrane and
optionally the cell wall of a biological organism sufficient to
release at least some intracellular content, often by mechanical,
viral or osmotic mechanisms that compromise its integrity.
[0109] "Lysing" is disrupting the cellular membrane and optionally
the cell wall of a biological organism or cell sufficient to
release at least some intracellular content.
[0110] "Microalgae" is a eukarytotic microbial organism that
contains a chloroplast or plastid, and optionally that is capable
of performing photosynthesis, or a prokaryotic microbial organism
capable of performing photosynthesis. Microalgae include obligate
photoautotrophs, which cannot metabolize a fixed carbon source as
energy, as well as heterotrophs, which can live solely off of a
fixed carbon source. Microalgae include unicellular organisms that
separate from sister cells shortly after cell division, such as
Chlamydomonas, as well as microbes such as, for example, Volvox,
which is a simple multicellular photosynthetic microbe of two
distinct cell types. Microalgae include cells such as Chlorella,
Dunaliella, and Prototheca. Microalgae also include other microbial
photosynthetic organisms that exhibit cell-cell adhesion, such as
Agmenellum, Anabaena, and Pyrobotrys. Microalgae also include
obligate heterotrophic microorganisms that have lost the ability to
perform photosynthesis, such as certain dinoflagellate algae
species and species of the genus Prototheca.
[0111] "Microbial biomass," "Microalgal biomass," "algal biomass,"
and "biomass" mean a material produced by growth and/or propagation
of microbial or microalgal cells. Biomass may contain cells and/or
intracellular contents as well as extracellular material.
Extracellular material includes, but is not limited to, compounds
secreted by a cell.
[0112] "Micronized" means biomass that has been homogenized under
high pressure (or an equivalent process) so that at least 50% of
the particle size is no more 10 .mu.m in their longest dimension.
Typically, at least 50% to 90% or more of such particles are less
than 5 .mu.m in their longest dimension. In any case, the average
particle size of micronized biomass is smaller than the intact
recombinant microalgal cell.
[0113] "Microorganism" and "microbe" are microscopic unicellular
organisms.
[0114] "Naturally co-expressed" with reference to two proteins or
genes means that the proteins or their genes are co-expressed
naturally in a tissue or organism from which they are derived,
e.g., because the genes encoding the two proteins are under the
control of a common regulatory sequence or because they are
expressed in response to the same stimulus.
[0115] "Oil" means any triacylglyceride, produced by organisms,
including microalgae, other plants, and/or animals. "Oil," as
distinguished from "fat", refers, unless otherwise indicated, to
lipids that are generally liquid at ordinary room temperatures and
pressures. For example, "oil" includes vegetable or seed oils
derived from plants, including without limitation, an oil derived
from soy, rapeseed, canola, palm, palm kernel, coconut, corn,
olive, sunflower, cotton seed, cuphea, peanut, camelina sativa,
mustard seed, cashew nut, oats, lupine, kenaf, calendula, hemp,
coffee, linseed, hazelnut, euphorbia, pumpkin seed, coriander,
camellia, sesame, safflower, rice, tung oil tree, cocoa, copra,
pium poppy, castor beans, pecan, jojoba, jatropha, macadamia,
Brazil nuts, and avocado, as well as combinations thereof.
[0116] "Osmotic shock" is the rupture of cells in a solution
following a sudden reduction in osmotic pressure. Osmotic shock is
sometimes induced to release cellular components of such cells into
a solution.
[0117] "Pasteurization" means a process of heating which is
intended to slow microbial growth in food products. Typically
pasteurization is performed at a high temperature (but below
boiling) for a short amount of time. As described herein,
pasteurization can not only reduce the number of undesired microbes
in food products, but can also inactivate certain enzymes present
in the food product.
[0118] "Polysaccharide-degrading enzyme" is any enzyme capable of
catalyzing the hydrolysis, or saccharification, of any
polysaccharide. For example, cellulases catalyze the hydrolysis of
cellulose.
[0119] "Polysaccharides" or "glycans" are carbohydrates made up of
monosaccharides joined together by glycosidic linkages. Cellulose
is a polysaccharide that makes up certain plant cell walls.
Cellulose can be depolymerized by enzymes to yield monosaccharides
such as xylose and glucose, as well as larger disaccharides and
oligosaccharides.
[0120] "Port" means an opening in a bioreactor that allows influx
or efflux of materials such as gases, liquids, and cells; a port is
usually connected to tubing.
[0121] "Predominantly encapsulated" means that more than 50% and
typically more than 75% to 90% of a referenced component, e.g.,
algal oil, is sequestered in a referenced container, which can
include, e.g., a recombinant microalgal cell.
[0122] "Predominantly intact cells" and "predominantly intact
biomass" mean a population of cells that comprise more than 50, and
often more than 75, 90, and 98% intact cells. "Intact", in this
context, means that the physical continuity of the cellular
membrane and/or cell wall enclosing the intracellular components of
the cell has not been disrupted in any manner that would release
the intracellular components of the cell to an extent that exceeds
the permeability of the cellular membrane in culture.
[0123] "Predominantly lysed" means a population of cells in which
more than 50%, and typically more than 75 to 90%, of the cells have
been disrupted such that the intracellular components of the cell
are no longer completely enclosed within the cell membrane.
[0124] "Proliferation" means a combination of both growth and
propagation.
[0125] "Promoter" is a nucleic acid control sequence that directs
transcription of a nucleic acid. As used herein, a promoter
includes necessary nucleic acid sequences near the start site of
transcription, such as, in the case of a polymerase II type
promoter, a TATA element. A promoter also optionally includes
distal enhancer or repressor elements, which can be located as much
as several thousand base pairs from the start site of
transcription.
[0126] "Propagation" means an increase in cell number via mitosis
or other cell division.
[0127] "Proximate analysis" means analysis of foodstuffs for fat,
nitrogen/protein, crude fiber (cellulose and lignin as main
components), moisture and ash. Soluble carbohydrate (total dietary
fiber and free sugars) can be calculated by subtracting the total
of the known values of the proximate analysis from 100
(carbohydrate by difference).
[0128] "Recombinant" is a cell, nucleic acid, protein or vector,
that has been modified due to the introduction of an exogenous
nucleic acid or the alteration of a native nucleic acid. Thus,
e.g., recombinant cells express genes that are not found within the
native (non-recombinant) form of the cell or express native genes
differently than those genes are expressed by a non-recombinant
cell. A "recombinant nucleic acid" is a nucleic acid originally
formed in vitro, in general, by the manipulation of nucleic acid,
e.g., using polymerases and endonucleases, or otherwise is in a
form not normally found in nature. Recombinant nucleic acids may be
produced, for example, to place two or more nucleic acids in
operable linkage. Thus, an isolated nucleic acid or an expression
vector formed in vitro by ligating DNA molecules that are not
normally joined in nature, are both considered recombinant for the
purposes of this invention. Once a recombinant nucleic acid is made
and introduced into a host cell or organism, it may replicate using
the in vivo cellular machinery of the host cell; however, such
nucleic acids, once produced recombinantly, although subsequently
replicated intracellularly, are still considered recombinant for
purposes of this invention. Similarly, a "recombinant protein" is a
protein made using recombinant techniques, i.e., through the
expression of a recombinant nucleic acid.
[0129] "Recombinant microbial oil," "Recombinant microalgal oil"
and "algal oil" mean any of the lipid components produced by
recombinant microbial or microalgal cells or algal cells,
respectively, including triacylglycerols.
[0130] "Renewable diesel" is a mixture of alkanes (such as C10:0,
C12:0, C14:0, C16:0 and C18:0) produced through hydrogenation and
deoxygenation of lipids.
[0131] "Saccharification" is a process of converting biomass,
usually cellulosic or lignocellulosic biomass, into monomeric
sugars, such as glucose and xylose. "Saccharified" or
"depolymerized" cellulosic material or biomass refers to cellulosic
material or biomass that has been converted into monomeric sugars
through saccharification.
[0132] The term "similar," when used in the context of a comparison
to a naturally occurring oil, without further qualification, means
that the oil being compared to the naturally occurring oil contains
about +/-15%, or +/-10% of the top two triglycerides of the
naturally occurring oil. For example, Shea butter (the oil of B.
Parkii) contains 41.2-56.8% C18:0 and 34.0-46.9% C18:1 as the two
most common triglyceride components (see Table 5). A "similar" oil
that is within +/-10% would contain from about 37% to about 62%
C18:0 and from 31% to about 52% C18:1 as the two most common
triglyceride components. When used in this context, the term
"similar" includes +/-9%, +/-8%, +/-7%, +/-6%, +/-5%, +/-4%, +/-3%,
+/-2%, or +/-1%, and can further represent a comparison to the top
three or top four triglycerides of the naturally occurring oil, or
two out of the top three triglycerides, or three out of the top
four triglycerides.
[0133] "Sonication" is a process of disrupting biological
materials, such as a cell, by use of sound wave energy.
[0134] "Species of furfural" is 2-furancarboxaldehyde or a
derivative that retains the same basic structural
characteristics.
[0135] "Stover" is the dried stalks and leaves of a crop remaining
after a grain has been harvested.
[0136] "Sucrose utilization gene" is a gene that, when expressed,
aids the ability of a cell to utilize sucrose as an energy source.
Proteins encoded by a sucrose utilization gene are referred to
herein as "sucrose utilization enzymes" and include sucrose
transporters, sucrose invertases, and hexokinases such as
glucokinases and fructokinases.
[0137] "Suitable for human consumption" means a composition can be
consumed by humans as dietary intake without ill health effects and
can provide significant caloric intake due to uptake of digested
material in the gastrointestinal tract.
[0138] "Uncooked product" means a composition that has not been
subjected to heating but may include one or more components
previously subjected to heating.
[0139] "V/V" or "v/v", in reference to proportions by volume, means
the ratio of the volume of one substance in a composition to the
volume of the composition. For example, reference to a composition
that comprises 5% v/v recombinant microalgal oil means that 5% of
the composition's volume is composed of recombinant microalgal oil
(e.g., such a composition having a volume of 100 mm.sup.3 would
contain 5 mm.sup.3 of recombinant microalgal oil), and the
remainder of the volume of the composition (e.g., 95 mm.sup.3 in
the example) is composed of other ingredients.
[0140] "W/W" or "w/w", in reference to proportions by weight, means
the ratio of the weight of one substance in a composition to the
weight of the composition. For example, reference to a composition
that comprises 5% w/w recombinant microalgal biomass means that 5%
of the composition's weight is composed of recombinant microalgal
biomass (e.g., such a composition having a weight of 100 mg would
contain 5 mg of recombinant microalgal biomass) and the remainder
of the weight of the composition (e.g., 95 mg in the example) is
composed of other ingredients.
II. CULTIVATION
[0141] The present invention generally relates to cultivation of
microorganisms (e.g., microalgae, oleaginous yeast, fungi, and
bacteria), particularly recombinant microalgal strains, including
Prototheca strains, for the production of lipid. For the
convenience of the reader, this section is subdivided into
subsections. Subsection 1 describes Prototheca species and strains
and how to identify new Prototheca species and strains and related
microalgae by genomic DNA comparison, as well as other
microorganisms. Subsection 2 describes bioreactors useful for
cultivation. Subsection 3 describes media for cultivation.
Subsection 4 describes oil production in accordance with
illustrative cultivation methods of the invention. These
descriptions are also more generally applicable to other
microorganisms.
1. Prototheca Species and Strains and Other Microorganisms
[0142] Prototheca is a remarkable microorganism for use in the
production of lipid, because it can produce high levels of lipid,
particularly lipid suitable for fuel production. The lipid produced
by Prototheca has hydrocarbon chains of shorter chain length and a
higher degree of saturation than that produced by other microalgae.
Moreover, Prototheca lipid is generally free of pigment (low to
undetectable levels of chlorophyll and certain carotenoids) and in
any event contains much less pigment than lipid from other
microalgae. Moreover, recombinant Prototheca cells provided by the
invention can be used to produce lipid in greater yield and
efficiency, and with reduced cost, relative to the production of
lipid from other microorganisms. Illustrative Prototheca strains
for use in the methods of the invention include In addition, this
microalgae grows heterotrophically and can be genetically
engineered as Prototheca wickerhamii, Prototheca stagnora
(including UTEX 327), Prototheca portoricensis, Prototheca
moriformis (including UTEX strains 1441, 1435), and Prototheca
zopfii. Species of the genus Prototheca are obligate
heterotrophs.
[0143] Species of Prototheca for use in the invention can be
identified by amplification of certain target regions of the
genome. For example, identification of a specific Prototheca
species or strain can be achieved through amplification and
sequencing of nuclear and/or chloroplast DNA using primers and
methodology using any region of the genome, for example using the
methods described in Wu et al., Bot. Bull. Acad. Sin. (2001)
42:115-121 Identification of Chlorella spp. isolates using
ribosomal DNA sequences. Well established methods of phylogenetic
analysis, such as amplification and sequencing of ribosomal
internal transcribed spacer (ITS1 and ITS2 rDNA), 23S rRNA, 18S
rRNA, and other conserved genomic regions can be used by those
skilled in the art to identify species of not only Prototheca, but
other hydrocarbon and lipid producing organisms with similar lipid
profiles and production capability. For examples of methods of
identification and classification of algae also see for example
Genetics, 2005 August; 170(4):1601-10 and RNA, 2005 April;
11(4):361-4.
[0144] Thus, genomic DNA comparison can be used to identify
suitable species of microalgae to be used in the present invention.
Regions of conserved genomic DNA, such as but not limited to DNA
encoding for 23S rRNA, can be amplified from microalgal species and
compared to consensus sequences in order to screen for microalgal
species that are taxonomically related to the preferred microalgae
used in the present invention. Examples of such DNA sequence
comparison for species within the Prototheca genus are shown below.
Genomic DNA comparison can also be useful to identify microalgal
species that have been misidentified in a strain collection. Often
a strain collection will identify species of microalgae based on
phenotypic and morphological characteristics. The use of these
characteristics may lead to miscategorization of the species or the
genus of a microalgae. The use of genomic DNA comparison can be a
better method of categorizing microalgae species based on their
phylogenetic relationship.
[0145] Microalgae for use in the present invention typically have
genomic DNA sequences encoding for 23S rRNA that have at least 99%,
least 95%, at least 90%, or at least 85% nucleotide identity to at
least one of the sequences listed in SEQ ID NOs: 11-19.
[0146] For sequence comparison to determine percent nucleotide or
amino acid identity, typically one sequence acts as a reference
sequence, to which test sequences are compared. When using a
sequence comparison algorithm, test and reference sequences are
input into a computer, subsequence coordinates are designated, if
necessary, and sequence algorithm program parameters are
designated. The sequence comparison algorithm then calculates the
percent sequence identity for the test sequence(s) relative to the
reference sequence, based on the designated program parameters.
[0147] Optimal alignment of sequences for comparison can be
conducted, e.g., by the local homology algorithm of Smith &
Waterman, Adv. Appl. Math. 2:482 (1981), by the homology alignment
algorithm of Needleman & Wunsch, J. Mol. Biol. 48:443 (1970),
by the search for similarity method of Pearson & Lipman, Proc.
Nat'l. Acad. Sci. USA 85:2444 (1988), by computerized
implementations of these algorithms (GAP, BESTFIT, FASTA, and
TFASTA in the Wisconsin Genetics Software Package, Genetics
Computer Group, 575 Science Dr., Madison, Wis.), or by visual
inspection (see generally Ausubel et al., supra).
[0148] Another example algorithm that is suitable for determining
percent sequence identity and sequence similarity is the BLAST
algorithm, which is described in Altschul et al., J. Mol. Biol.
215:403-410 (1990). Software for performing BLAST analyses is
publicly available through the National Center for Biotechnology
Information (at the web address www.ncbi.nlm.nih.gov). This
algorithm involves first identifying high scoring sequence pairs
(HSPs) by identifying short words of length W in the query
sequence, which either match or satisfy some positive-valued
threshold score T when aligned with a word of the same length in a
database sequence. T is referred to as the neighborhood word score
threshold (Altschul et al., supra.). These initial neighborhood
word hits act as seeds for initiating searches to find longer HSPs
containing them. The word hits are then extended in both directions
along each sequence for as far as the cumulative alignment score
can be increased. Cumulative scores are calculated using, for
nucleotide sequences, the parameters M (reward score for a pair of
matching residues; always >0) and N (penalty score for
mismatching residues; always <0). For amino acid sequences, a
scoring matrix is used to calculate the cumulative score. Extension
of the word hits in each direction are halted when: the cumulative
alignment score falls off by the quantity X from its maximum
achieved value; the cumulative score goes to zero or below due to
the accumulation of one or more negative-scoring residue
alignments; or the end of either sequence is reached. For
identifying whether a nucleic acid or polypeptide is within the
scope of the invention, the default parameters of the BLAST
programs are suitable. The BLASTN program (for nucleotide
sequences) uses as defaults a word length (W) of 11, an expectation
(E) of 10, M=5, N=-4, and a comparison of both strands. For amino
acid sequences, the BLASTP program uses as defaults a word length
(W) of 3, an expectation (E) of 10, and the BLOSUM62 scoring
matrix. The TBLATN program (using protein sequence for nucleotide
sequence) uses as defaults a word length (W) of 3, an expectation
(E) of 10, and a BLOSUM 62 scoring matrix. (see Henikoff &
Henikoff, Proc. Natl. Acad. Sci. USA 89:10915 (1989)).
[0149] In addition to calculating percent sequence identity, the
BLAST algorithm also performs a statistical analysis of the
similarity between two sequences (see, e.g., Karlin & Altschul,
Proc. Nat'l. Acad. Sci. USA 90:5873-5787 (1993)). One measure of
similarity provided by the BLAST algorithm is the smallest sum
probability (P(N)), which provides an indication of the probability
by which a match between two nucleotide or amino acid sequences
would occur by chance. For example, a nucleic acid is considered
similar to a reference sequence if the smallest sum probability in
a comparison of the test nucleic acid to the reference nucleic acid
is less than about 0.1, more preferably less than about 0.01, and
most preferably less than about 0.001.
[0150] Other considerations affecting the selection of
microorganisms for use in the invention include, in addition to
production of suitable lipids or hydrocarbons for production of
oils, fuels, and oleochemicals: (1) high lipid content as a
percentage of cell weight; (2) ease of growth; (3) ease of genetic
engineering; and (4) ease of biomass processing. In particular
embodiments, the wild-type or genetically engineered microorganism
yields cells that are at least 40%, at least 45%, at least 50%, at
least 55%, at least 60%, at least 65%, or at least 70% or more
lipid. Preferred organisms grow heterotrophically (on sugars in the
absence of light).
[0151] Examples of algae that can be used to practice the present
invention include, but are not limited to the following algae
listed in Table 1.
TABLE-US-00001 TABLE 1 Examples of algae. Achnanthes orientalis,
Agmenellum, Amphiprora hyaline, Amphora coffeiformis, Amphora
coffeiformis linea, Amphora coffeiformis punctata, Amphora
coffeiformis taylori, Amphora coffeiformis tenuis, Amphora
delicatissima, Amphora delicatissima capitata, Amphora sp.,
Anabaena, Ankistrodesmus, Ankistrodesmus falcatus, Boekelovia
hooglandii, Borodinella sp., Botryococcus braunii, Botryococcus
sudeticus, Carteria, Chaetoceros gracilis, Chaetoceros muelleri,
Chaetoceros muelleri subsalsum, Chaetoceros sp., Chlorella
anitrata, Chlorella Antarctica, Chlorella aureoviridis, Chlorella
candida, Chlorella capsulate, Chlorella desiccate, Chlorella
ellipsoidea, Chlorella emersonii, Chlorella fusca, Chlorella fusca
var. vacuolata, Chlorella glucotropha, Chlorella infusionum,
Chlorella infusionum var. actophila, Chlorella infusionum var.
auxenophila, Chlorella kessleri, Chlorella lobophora (strain SAG
37.88), Chlorella luteoviridis, Chlorella luteoviridis var.
aureoviridis, Chlorella luteoviridis var. lutescens, Chlorella
miniata, Chlorella minutissima, Chlorella mutabilis, Chlorella
nocturna, Chlorella parva, Chlorella photophila, Chlorella
pringsheimii, Chlorella protothecoides (including any of UTEX
strains 1806, 411, 264, 256, 255, 250, 249, 31, 29, 25, and CCAP
strains 211/17 and 211/8d), Chlorella protothecoides var.
acidicola, Chlorella regularis, Chlorella regularis var. minima,
Chlorella regularis var. umbricata, Chlorella reisiglii, Chlorella
saccharophila, Chlorella saccharophila var. ellipsoidea, Chlorella
salina, Chlorella simplex, Chlorella sorokiniana, Chlorella sp.,
Chlorella sphaerica, Chlorella stigmatophora, Chlorella vanniellii,
Chlorella vulgaris, Chlorella vulgaris, Chlorella vulgaris f.
tertia, Chlorella vulgaris var. autotrophica, Chlorella vulgaris
var. viridis, Chlorella vulgaris var. vulgaris, Chlorella vulgaris
var. vulgaris f. tertia, Chlorella vulgaris var. vulgaris f.
viridis, Chlorella xanthella, Chlorella zofingiensis, Chlorella
trebouxioides, Chlorella vulgaris, Chlorococcum infusionum,
Chlorococcum sp., Chlorogonium, Chroomonas sp., Chrysosphaera sp.,
Cricosphaera sp., Cryptomonas sp., Cyclotella cryptica, Cyclotella
meneghiniana, Cyclotella sp., Dunaliella sp., Dunaliella bardawil,
Dunaliella bioculata, Dunaliella granulate, Dunaliella maritime,
Dunaliella minuta, Dunaliella parva, Dunaliella peircei, Dunaliella
primolecta, Dunaliella salina, Dunaliella terricola, Dunaliella
tertiolecta, Dunaliella viridis, Dunaliella tertiolecta,
Eremosphaera viridis, Eremosphaera sp., Ellipsoidon sp., Euglena,
Franceia sp., Fragilaria crotonensis, Fragilaria sp., Gleocapsa
sp., Gloeothamnion sp., Hymenomonas sp., Isochrysis aff. galbana,
Isochrysis galbana, Lepocinclis, Micractinium, Micractinium (UTEX
LB 2614), Monoraphidium minutum, Monoraphidium sp., Nannochloris
sp., Nannochloropsis salina, Nannochloropsis sp., Navicula
acceptata, Navicula biskanterae, Navicula pseudotenelloides,
Navicula pelliculosa, Navicula saprophila, Navicula sp.,
Nephrochloris sp., Nephroselmis sp., Nitschia communis, Nitzschia
alexandrina, Nitzschia communis, Nitzschia dissipata, Nitzschia
frustulum, Nitzschia hantzschiana, Nitzschia inconspicua, Nitzschia
intermedia, Nitzschia microcephala, Nitzschia pusilla, Nitzschia
pusilla elliptica, Nitzschia pusilla monoensis, Nitzschia
quadrangular, Nitzschia sp., Ochromonas sp., Oocystis parva,
Oocystis pusilla, Oocystis sp., Oscillatoria limnetica,
Oscillatoria sp., Oscillatoria subbrevis, Pascheria acidophila,
Pavlova sp., Phagus, Phormidium, Platymonas sp., Pleurochrysis
carterae, Pleurochrysis dentate, Pleurochrysis sp., Prototheca
wickerhamii, Prototheca stagnora, Prototheca portoricensis,
Prototheca moriformis, Prototheca zopfii, Pyramimonas sp.,
Pyrobotrys, Sarcinoid chrysophyte, Scenedesmus armatus, Spirogyra,
Spirulina platensis, Stichococcus sp., Synechococcus sp.,
Tetraedron, Tetraselmis sp., Tetraselmis suecica, Thalassiosira
weissflogii, and Viridiella fridericiana
[0152] Examples of oleaginous yeast that can be used to practice
the present invention include, but are not limited to the following
oleaginous yeast listed in Table 26.
TABLE-US-00002 TABLE 26 Examples of oleaginous yeast. Cryptococcus
curvatus, Cryptococcus terricolus, Candida sp., Lipomyces starkeyi,
Lipomyces lipofer, Endomycopsis vernalis, Rhodotorula glutinis,
Rhodotorula gracilis, and Yarrowia lipolytica
[0153] Examples of other fungi that can be used to practice the
present invention include, but are not limited to the following
fungi listed in Table 27.
TABLE-US-00003 TABLE 27 Examples of fungi. Mortierella, Mortierrla
vinacea, Mortierella alpine, Pythium debaryanum, Mucor
circinelloides, Aspergillus ochraceus, Aspergillus terreus,
Pennicillium iilacinum, Hensenulo, Chaetomium, Cladosporium,
Malbranchea, Rhizopus, and Pythium
[0154] In some embodiments of the present invention, the
microorganism is a bacterium. Examples of expression of exogenous
genes in bacteria, such as E. coli, are well known; see for example
Molecular Cloning: A Laboratory Manual, Sambrook et al. (3d
edition, 2001, Cold Spring Harbor Press).
2. Bioreactor
[0155] Microrganisms are cultured both for purposes of conducting
genetic manipulations and for production of hydrocarbons (e.g.,
lipids, fatty acids, aldehydes, alcohols, and alkanes). The former
type of culture is conducted on a small scale and initially, at
least, under conditions in which the starting microorganism can
grow. Culture for purposes of hydrocarbon production is usually
conducted on a large scale (e.g., 10,000 L, 40,000 L, 100,000 L or
larger bioreactors) in a bioreactor. Microalgae, including
Prototheca species are typically cultured in the methods of the
invention in liquid media within a bioreactor. Typically, the
bioreactor does not allow light to enter.
[0156] The bioreactor or fermentor is used to culture oleaginous
microbial cells, preferably microalgal cells through the various
phases of their physiological cycle. Bioreactors offer many
advantages for use in heterotrophic growth and propagation methods.
To produce biomass for use in food, microalgae are preferably
fermented in large quantities in liquid, such as in suspension
cultures as an example. Bioreactors such as steel fermentors can
accommodate very large culture volumes (40,000 liter and greater
capacity bioreactors are used in various embodiments of the
invention). Bioreactors also typically allow for the control of
culture conditions such as temperature, pH, oxygen tension, and
carbon dioxide levels. For example, bioreactors are typically
configurable, for example, using ports attached to tubing, to allow
gaseous components, like oxygen or nitrogen, to be bubbled through
a liquid culture. Other culture parameters, such as the pH of the
culture media, the identity and concentration of trace elements,
and other media constituents can also be more readily manipulated
using a bioreactor.
[0157] Bioreactors can be configured to flow culture media though
the bioreactor throughout the time period during which the
microalgae reproduce and increase in number. In some embodiments,
for example, media can be infused into the bioreactor after
inoculation but before the cells reach a desired density. In other
instances, a bioreactor is filled with culture media at the
beginning of a culture, and no more culture media is infused after
the culture is inoculated. In other words, the microalgal biomass
is cultured in an aqueous medium for a period of time during which
the microalgae reproduce and increase in number; however,
quantities of aqueous culture medium are not flowed through the
bioreactor throughout the time period. Thus in some embodiments,
aqueous culture medium is not flowed through the bioreactor after
inoculation.
[0158] Bioreactors equipped with devices such as spinning blades
and impellers, rocking mechanisms, stir bars, means for pressurized
gas infusion can be used to subject microalgal cultures to mixing.
Mixing may be continuous or intermittent. For example, in some
embodiments, a turbulent flow regime of gas entry and media entry
is not maintained for reproduction of microalgae until a desired
increase in number of said microalgae has been achieved.
[0159] Bioreactor ports can be used to introduce, or extract,
gases, solids, semisolids, and liquids, into the bioreactor chamber
containing the microalgae. While many bioreactors have more than
one port (for example, one for media entry, and another for
sampling), it is not necessary that only one substance enter or
leave a port. For example, a port can be used to flow culture media
into the bioreactor and later used for sampling, gas entry, gas
exit, or other purposes. Preferably, a sampling port can be used
repeatedly without altering compromising the axenic nature of the
culture. A sampling port can be configured with a valve or other
device that allows the flow of sample to be stopped and started or
to provide a means of continuous sampling. Bioreactors typically
have at least one port that allows inoculation of a culture, and
such a port can also be used for other purposes such as media or
gas entry.
[0160] Bioreactors ports allow the gas content of the culture of
microalgae to be manipulated. To illustrate, part of the volume of
a bioreactor can be gas rather than liquid, and the gas inlets of
the bioreactor to allow pumping of gases into the bioreactor. Gases
that can be beneficially pumped into a bioreactor include air,
air/CO.sub.2 mixtures, noble gases, such as argon, and other gases.
Bioreactors are typically equipped to enable the user to control
the rate of entry of a gas into the bioreactor. As noted above,
increasing gas flow into a bioreactor can be used to increase
mixing of the culture.
[0161] Increased gas flow affects the turbidity of the culture as
well. Turbulence can be achieved by placing a gas entry port below
the level of the aqueous culture media so that gas entering the
bioreactor bubbles to the surface of the culture. One or more gas
exit ports allow gas to escape, thereby preventing pressure buildup
in the bioreactor. Preferably a gas exit port leads to a "one-way"
valve that prevents contaminating microorganisms from entering the
bioreactor.
3. Media
[0162] Microalgal culture media typically contains components such
as a fixed nitrogen source, a fixed carbon source, trace elements,
optionally a buffer for pH maintenance, and phosphate (typically
provided as a phosphate salt). Other components can include salts
such as sodium chloride, particularly for seawater microalgae.
Nitrogen sources include organic and inorganic nitrogen sources,
including, for example, without limitation, molecular nitrogen,
nitrate, nitrate salts, ammonia (pure or in salt form, such as,
(NH.sub.4).sub.2SO.sub.4 and NH.sub.4OH), protein, soybean meal,
cornsteep liquor, and yeast extract. Examples of trace elements
include zinc, boron, cobalt, copper, manganese, and molybdenum in,
for example, the respective forms of ZnCl.sub.2, H.sub.3BO.sub.3,
CoCl.sub.2.6H.sub.2O, CuCl.sub.2.2H.sub.2O, MnCl.sub.2.4H.sub.2O
and (NH.sub.4).sub.6Mo.sub.7O.sub.24.4H.sub.2O.
[0163] Microorganisms useful in accordance with the methods of the
present invention are found in various locations and environments
throughout the world. As a consequence of their isolation from
other species and their resulting evolutionary divergence, the
particular growth medium for optimal growth and generation of lipid
and/or hydrocarbon constituents can be difficult to predict. In
some cases, certain strains of microorganisms may be unable to grow
on a particular growth medium because of the presence of some
inhibitory component or the absence of some essential nutritional
requirement required by the particular strain of microorganism.
[0164] Solid and liquid growth media are generally available from a
wide variety of sources, and instructions for the preparation of
particular media that is suitable for a wide variety of strains of
microorganisms can be found, for example, online at
http://www.utex.org/, a site maintained by the University of Texas
at Austin, 1 University Station A6700, Austin, Tex., 78712-0183,
for its culture collection of algae (UTEX). For example, various
fresh water and salt water media include those described in PCT
Pub. No. 2008/151149, incorporated herein by reference.
[0165] In a particular example, Proteose Medium is suitable for
axenic cultures, and a 1 L volume of the medium (pH .about.6.8) can
be prepared by addition of 1 g of proteose peptone to 1 liter of
Bristol Medium. Bristol medium comprises 2.94 mM NaNO.sub.3, 0.17
mM CaCl.sub.2.2H.sub.2O, 0.3 mM MgSO.sub.4.7H.sub.2O, 0.43 mM, 1.29
mM KH.sub.2PO.sub.4, and 1.43 mM NaCl in an aqueous solution. For
1.5% agar medium, 15 g of agar can be added to 1 L of the solution.
The solution is covered and autoclaved, and then stored at a
refrigerated temperature prior to use. Another example is the
Prototheca isolation medium (PIM), which comprises 10 g/L
postassium hydrogen phthalate (KHP), 0.9 g/L sodium hydroxide, 0.1
g/L magnesium sulfate, 0.2 g/L potassium hydrogen phosphate, 0.3
g/L ammonium chloride, 10 g/L glucose 0.001 g/L thiamine
hydrochloride, 20 g/L agar, 0.25 g/L 5-fluorocytosine, at a pH in
the range of 5.0 to 5.2 (see Pore, 1973, App. Microbiology, 26:
648-649). Other suitable media for use with the methods of the
invention can be readily identified by consulting the URL
identified above, or by consulting other organizations that
maintain cultures of microorganisms, such as SAG, CCAP, or CCALA.
SAG refers to the Culture Collection of Algae at the University of
Gottingen (Gottingen, Germany), CCAP refers to the culture
collection of algae and protozoa managed by the Scottish
Association for Marine Science (Scotland, United Kingdom), and
CCALA refers to the culture collection of algal laboratory at the
Institute of Botany (T{circumflex over (r)}ebo{circumflex over
(n)}, Czech Republic). Additionally, U.S. Pat. No. 5,900,370
describes media formulations and conditions suitable for
heterotrophic fermentation of Prototheca species.
[0166] For oil production, selection of a fixed carbon source is
important, as the cost of the fixed carbon source must be
sufficiently low to make oil production economical. Thus, while
suitable carbon sources include, for example, acetate, floridoside,
fructose, galactose, glucuronic acid, glucose, glycerol, lactose,
mannose, N-acetylglucosamine, rhamnose, sucrose, and/or xylose,
selection of feedstocks containing those compounds is an important
aspect of the methods of the invention. Suitable feedstocks useful
in accordance with the methods of the invention include, for
example, black liquor, corn starch, depolymerized cellulosic
material, milk whey, molasses, potato, sorghum, sucrose, sugar
beet, sugar cane, rice, and wheat. Carbon sources can also be
provided as a mixture, such as a mixture of sucrose and
depolymerized sugar beet pulp. The one or more carbon source(s) can
be supplied at a concentration of at least about 50 .mu.M, at least
about 100 .mu.M, at least about 500 .mu.M, at least about 5 mM, at
least about 50 mM, and at least about 500 mM, of one or more
exogenously provided fixed carbon source(s). Carbon sources of
particular interest for purposes of the present invention include
cellulose (in a depolymerized form), glycerol, sucrose, and
sorghum, each of which is discussed in more detail below.
[0167] In accordance with the present invention, microorganisms can
be cultured using depolymerized cellulosic biomass as a feedstock.
Cellulosic biomass (e.g., stover, such as corn stover) is
inexpensive and readily available; however, attempts to use this
material as a feedstock for yeast have failed. In particular, such
feedstocks have been found to be inhibitory to yeast growth, and
yeast cannot use the 5-carbon sugars produced from cellulosic
materials (e.g., xylose from hemi-cellulose). By contrast,
microalgae can grow on processed cellulosic material. Cellulosic
materials generally include about 40-60% cellulose; about 20-40%
hemicellulose; and 10-30% lignin.
[0168] Suitable cellulosic materials include residues from
herbaceous and woody energy crops, as well as agricultural crops,
i.e., the plant parts, primarily stalks and leaves, not removed
from the fields with the primary food or fiber product. Examples
include agricultural wastes such as sugarcane bagasse, rice hulls,
corn fiber (including stalks, leaves, husks, and cobs), wheat
straw, rice straw, sugar beet pulp, citrus pulp, citrus peels;
forestry wastes such as hardwood and softwood thinnings, and
hardwood and softwood residues from timber operations; wood wastes
such as saw mill wastes (wood chips, sawdust) and pulp mill waste;
urban wastes such as paper fractions of municipal solid waste,
urban wood waste and urban green waste such as municipal grass
clippings; and wood construction waste. Additional cellulosics
include dedicated cellulosic crops such as switchgrass, hybrid
poplar wood, and miscanthus, fiber cane, and fiber sorghum.
Five-carbon sugars that are produced from such materials include
xylose.
[0169] Cellulosic materials are treated to increase the efficiency
with which the microbe can utilize the sugar(s) contained within
the materials. The invention provides novel methods for the
treatment of cellulosic materials after acid explosion so that the
materials are suitable for use in a heterotrophic culture of
microbes (e.g., microalgae and oleaginous yeast). As discussed
above, lignocellulosic biomass is comprised of various fractions,
including cellulose, a crystalline polymer of beta 1,4 linked
glucose (a six-carbon sugar), hemicellulose, a more loosely
associated polymer predominantly comprised of xylose (a five-carbon
sugar) and to a lesser extent mannose, galactose, arabinose,
lignin, a complex aromatic polymer comprised of sinapyl alcohol and
its derivatives, and pectins, which are linear chains of an alpha
1,4 linked polygalacturonic acid. Because of the polymeric
structure of cellulose and hemicellulose, the sugars (e.g.,
monomeric glucose and xylose) in them are not in a form that can be
efficiently used (metabolized) by many microbes. For such microbes,
further processing of the cellulosic biomass to generate the
monomeric sugars that make up the polymers can be very helpful to
ensuring that the cellulosic materials are efficiently utilized as
a feedstock (carbon source).
[0170] Celluose or cellulosic biomass is subjected to a process,
termed "explosion", in which the biomass is treated with dilute
sulfuric (or other) acid at elevated temperature and pressure. This
process conditions the biomass such that it can be efficiently
subjected to enzymatic hydrolysis of the cellulosic and
hemicellulosic fractions into glucose and xylose monomers. The
resulting monomeric sugars are termed cellulosic sugars. Cellulosic
sugars can subsequently be utilized by microorganisms to produce a
variety of metabolites (e.g., lipid). The acid explosion step
results in a partial hydrolysis of the hemicellulose fraction to
constitutent monosaccharides. These sugars can be completely
liberated from the biomass with further treatment. In some
embodiments, the further treatment is a hydrothermal treatment that
includes washing the exploded material with hot water, which
removes contaminants such as salts. This step is not necessary for
cellulosic ethanol fermentations due to the more dilute sugar
concentrations used in such processes. In other embodiments, the
further treatment is additional acid treatment. In still other
embodiments, the further treatment is enzymatic hydrolysis of the
exploded material. These treatments can also be used in any
combination. The type of treatment can affect the type of sugars
liberated (e.g., five carbon sugars versus six carbon sugars) and
the stage at which they are liberated in the process. As a
consequence, different streams of sugars, whether they are
predominantly five-carbon or six-carbon, can be created. These
enriched five-carbon or six-carbon streams can thus be directed to
specific microorganisms with different carbon utilization
cabilities.
[0171] The methods of the present invention typically involve
fermentation to higher cell densities than what is achieved in
ethanol fermentation. Because of the higher densities of the
cultures for heterotrophic cellulosic oil production, the fixed
carbon source (e.g., the cellulosic derived sugar stream(s)) is
preferably in a concentrated form. The glucose level of the
depolymerized cellulosic material is preferably at least 300
g/liter, at least 400 g/liter, at least 500 g/liter or at least 600
g/liter prior to the cultivation step, which is optionally a fed
batch cultivation in which the material is fed to the cells over
time as the cells grow and accumulate lipid. Cellulosic sugar
streams are not used at or near this concentration range in the
production of cellulosic ethanol. Thus, in order to generate and
sustain the very high cell densities during the production of
lignocellulosic oil, the carbon feedstock(s) must be delivered into
the heterotrophic cultures in a highly concentrated form. However,
any component in the feedstream that is not a substrate for, and is
not metabolized by, the oleaginous microorganism will accumulate in
the bioreactor, which can lead to problems if the component is
toxic or inhibitory to production of the desired end product. While
ligin and lignin-derived by-products, carbohydrate-derived
byproducts such as furfurals and hydroxymethyl furfurals and salts
derived from the generation of the cellulosic materials (both in
the explosion process and the subsequent neutralization process),
and even non-metabolized pentose/hexose sugars can present problems
in ethanolic fermentations, these effects are amplified
significantly in a process in which their concentration in the
initial feedstock is high. To achieve sugar concentrations in the
300 g/L range (or higher) for six-carbon sugars that may be used in
large scale production of lignocellulosic oil described in the
present invention, the concentration of these toxic materials can
be 20 times higher than the concentrations typically present in
ethanolic fermentations of cellulosic biomass.
[0172] The explosion process treatment of the cellulosic material
utilizes significant amounts of sulfuric acid, heat and pressure,
thereby liberating by-products of carbohydrates, namely furfurals
and hydroxymethyl furfurals. Furfurals and hydroxymethyl furfurals
are produced during hydrolysis of hemicellulose through dehydration
of xylose into furfural and water. In some embodiments of the
present invention, these by-products (e.g., furfurals and
hydroxymethyl furfurals) are removed from the saccharified
lignocellulosic material prior to introduction into the bioreactor.
In certain embodiments of the present invention, the process for
removal of the by-products of carbohydrates is hydrothermal
treatment of the exploded cellulosic materials. In addition, the
present invention provides methods in which strains capable of
tolerating compounds such as furfurals or hydroxymethyl furfurals
are used for lignocellulosic oil production. In another embodiment,
the present invention also provides methods and microorganisms that
are not only capable of tolerating furfurals in the fermentation
media, but are actually able to metabolize these by-products during
the production of lignocellulosic oil.
[0173] The explosion process also generates significant levels of
salts. For example, typical conditions for explosion can result in
conductivites in excess of 5 mS/cm when the exploded cellulosic
biomass is resuspended at a ratio of 10:1 water:solids (dry
weight). In certain embodiments of the present invention, the
diluted exploded biomass is subjected to enzymatic
saccharification, and the resulting supernatant is concentrated up
to 25 fold for use in the bioreactor. The salt level (as measured
by conductivity) in the concentrated sugar stream(s) can be
unacceptably high (up to 1.5 M Na.sup.+ equivalents). Additional
salts are generated upon neutralization of the exploded materials
for the subsequent enzymatic saccharification process as well. The
present invention provides methods for removing these salts so that
the resulting concentrated cellulosic sugar stream(s) can be used
in heterotrophic processes for producing lignocellulosic oil. In
some embodiments, the method of removing these salts is
deionization with resins, such as, but not limited to, DOWEX
Marathon MR3. In certain embodiments, the deionization with resin
step occurs before sugar concentration or pH adjustment and
hydrothermal treatment of biomass prior to saccharification, or any
combination of the preceding; in other embodiments, the step is
conducted after one or more of these processes. In other
embodiments, the explosion process itself is changed so as to avoid
the generation of salts at unacceptably high levels. For example, a
suitable alternative to sulfuric acid (or other acid) explosion of
the cellulosic biomass is mechanical pulping to render the
cellulosic biomass receptive to enzymatic hydrolysis
(saccharification). In still other embodiments, native strains of
microorganisms resistant to high levels of salts or genetically
engineered strains with resistance to high levels of salts are
used.
[0174] A preferred embodiment for the process of preparing of
exploded cellulosic biomass for use in heterotrophic
lignocellulosic oil production using oleaginous microbes. A first
step comprises adjusting the pH of the resuspended exploded
cellulosic biomass to the range of 5.0-5.3 followed by washing the
cellulosic biomass three times. This washing step can be
accomplished by a variety of means including the use of desalting
and ion exchange resins, reverse omosis, hydrothermal treatment (as
described above), or just repeated re-suspension and centrifugation
in deionized water. This wash step results in a cellulosic stream
whose conductivity is between 100-300 .mu.S/cm and the removal of
significant amounts of furfurals and hydroxymethyl furfurals.
Decants from this wash step can be saved to concentrate five-carbon
sugars liberated from the hemicellulose fraction. A second step
comprises enzymatic saccharification of the washed cellulosic
biomass. In a preferred embodiment, Accellerase (Genencor) is used.
A third step comprises the recovery of sugars via centrifugation or
decanting and rinsing of the saccharified biomass. The resulting
biomass (solids) is an energy dense, lignin rich component that can
be used as fuel or sent to waste. The recovered sugar stream in the
centrifugation/decanting and rinse process is collected. A fourth
step comprises microfiltration to remove contaminating solids with
recovery of the permeate. A fifth step comprises a concentration
step which can be accomplished using a vacuum evaporator. This step
can optionally include the addition of antifoam agents such as
P'2000 (Sigma/Fluka), which is sometimes necessary due to the
protein content of the resulting sugar feedstock.
[0175] In another embodiment of the methods of the invention, the
carbon source is glycerol, including acidulated and non-acidulated
glycerol byproduct from biodiesel transesterification. In one
embodiment, the carbon source includes glycerol and at least one
other carbon source. In some cases, all of the glycerol and the at
least one other fixed carbon source are provided to the
microorganism at the beginning of the fermentation. In some cases,
the glycerol and the at least one other fixed carbon source are
provided to the microorganism simultaneously at a predetermined
ratio. In some cases, the glycerol and the at least one other fixed
carbon source are fed to the microbes at a predetermined rate over
the course of fermentation.
[0176] Some microalgae undergo cell division faster in the presence
of glycerol than in the presence of glucose (see PCT Pub. No.
2008/151149). In these instances, two-stage growth processes in
which cells are first fed glycerol to rapidly increase cell
density, and are then fed glucose to accumulate lipids can improve
the efficiency with which lipids are produced. The use of the
glycerol byproduct of the transesterification process provides
significant economic advantages when put back into the production
process. Other feeding methods are provided as well, such as
mixtures of glycerol and glucose. Feeding such mixtures also
captures the same economic benefits. In addition, the invention
provides methods of feeding alternative sugars to microalgae such
as sucrose in various combinations with glycerol.
[0177] In another embodiment of the methods of the invention, the
carbon source is invert sugar. Invert sugar is produced by
splitting the sucrose into its monosaccharide components, fructose
and glucose. Production of invert sugar can be achieved through
several methods that are known in the art. One such method is
heating an aqueous solution of sucrose. Often, catalysts are
employed in order to accelerate the conversion of sucrose into
invert sugar. These catalysts can be biological, for example
enzymes such as invertases and sucrases can be added to the sucrose
to accelerate the hydrolysis reaction to produce invert sugar. Acid
is an example of non-biological catalyst, when paired with heat,
can accelerate the hydrolysis reaction. Once the invert sugar is
made, it is less prone to crystallization compared to sucrose and
thus, provides advantages for storage and in fed batch
fermentation, which in the case of heterotrophic cultivation of
microbes, including microalgae, there is a need for concentrated
carbon source. In one embodiment, the carbon source is invert
sugar, preferably in a concentrated form, preferably at least 800
g/liter, at least 900 g/liter, at least 1000 g/liter or at least
1100 g/liter prior to the cultivation step, which is optionally a
fed batch cultivation. The invert sugar, preferably in a
concentrated form, is fed to the cells over time as the cells grow
and accumulate lipid.
[0178] In another embodiment of the methods of the invention, the
carbon source is sucrose, including a complex feedstock containing
sucrose, such as thick cane juice from sugar cane processing.
Because of the higher densities of the cultures for heterotrophic
oil production, the fixed carbon source (e.g., sucrose, glucose,
etc.) is preferably in a concentrated form, preferably at least 500
g/liter, at least 600 g/liter, at least 700 g/liter or at least 800
g/liter of the fixed carbon source prior to the cultivation step,
which is optionally a fed batch cultivation in which the material
is fed to the cells over time as the cells grow and accumulate
lipid. In the some cases, the carbon source is sucrose in the form
of thick cane juice, preferably in a concentrated form, preferably
at least 60% solids or about 770 g/liter sugar, at least 70% solids
or about 925 g/liter sugar, or at least 80% solids or about 1125
g/liter sugar prior to the cultivation step, which is optionally a
fed batch cultivation. The concentrated thick cane juice is fed to
the cells over time as the cells grow and accumulate lipid.
[0179] In one embodiment, the culture medium further includes at
least one sucrose utilization enzyme. In some cases, the culture
medium includes a sucrose invertase. In one embodiment, the sucrose
invertase enzyme is a secrectable sucrose invertase enzyme encoded
by an exogenous sucrose invertase gene expressed by the population
of microorganisms. Thus, in some cases, as described in more detail
in Section IV, below, the microalgae has been genetically
engineered to express a sucrose utilization enzyme, such as a
sucrose transporter, a sucrose invertase, a hexokinase, a
glucokinase, or a fructokinase.
[0180] Complex feedstocks containing sucrose include waste molasses
from sugar cane processing; the use of this low-value waste product
of sugar cane processing can provide significant cost savings in
the production of hydrocarbons and other oils. Another complex
feedstock containing sucrose that is useful in the methods of the
invention is sorghum, including sorghum syrup and pure sorghum.
Sorghum syrup is produced from the juice of sweet sorghum cane. Its
sugar profile consists of mainly glucose (dextrose), fructose and
sucrose.
4. Oil Production
[0181] For the production of oil in accordance with the methods of
the invention, it is preferable to culture cells in the dark, as is
the case, for example, when using extremely large (40,000 liter and
higher) fermentors that do not allow light to strike the culture.
Prototheca species are grown and propagated for the production of
oil in a medium containing a fixed carbon source and in the absence
of light; such growth is known as heterotrophic growth.
[0182] As an example, an inoculum of lipid-producing oleaginous
microbial cells, preferably microalgal cells are introduced into
the medium; there is a lag period (lag phase) before the cells
begin to propagate. Following the lag period, the propagation rate
increases steadily and enters the log, or exponential, phase. The
exponential phase is in turn followed by a slowing of propagation
due to decreases in nutrients such as nitrogen, increases in toxic
substances, and quorum sensing mechanisms. After this slowing,
propagation stops, and the cells enter a stationary phase or steady
growth state, depending on the particular environment provided to
the cells. For obtaining lipid rich biomass, the culture is
typically harvested well after then end of the exponential phase,
which may be terminated early by allowing nitrogen or another key
nutrient (other than carbon) to become depleted, forcing the cells
to convert the carbon sources, present in excess, to lipid. Culture
condition parameters can be manipulated to optimize total oil
production, the combination of lipid species produced, and/or
production of a specific oil.
[0183] As discussed above, a bioreactor or fermentor is used to
allow cells to undergo the various phases of their growth cycle. As
an example, an inoculum of lipid-producing cells can be introduced
into a medium followed by a lag period (lag phase) before the cells
begin growth. Following the lag period, the growth rate increases
steadily and enters the log, or exponential, phase. The exponential
phase is in turn followed by a slowing of growth due to decreases
in nutrients and/or increases in toxic substances. After this
slowing, growth stops, and the cells enter a stationary phase or
steady state, depending on the particular environment provided to
the cells. Lipid production by cells disclosed herein can occur
during the log phase or thereafter, including the stationary phase
wherein nutrients are supplied, or still available, to allow the
continuation of lipid production in the absence of cell
division.
[0184] Preferably, microorganisms grown using conditions described
herein and known in the art comprise at least about 20% by weight
of lipid, preferably at least about 40% by weight, more preferably
at least about 50% by weight, and most preferably at least about
60% by weight. Process conditions can be adjusted to increase the
yield of lipids suitable for a particular use and/or to reduce
production cost. For example, in certain embodiments, a microalgae
is cultured in the presence of a limiting concentration of one or
more nutrients, such as, for example, nitrogen, phosphorous, or
sulfur, while providing an excess of fixed carbon energy such as
glucose. Nitrogen limitation tends to increase microbial lipid
yield over microbial lipid yield in a culture in which nitrogen is
provided in excess. In particular embodiments, the increase in
lipid yield is at least about: 10%, 50%, 100%, 200%, or 500%. The
microbe can be cultured in the presence of a limiting amount of a
nutrient for a portion of the total culture period or for the
entire period. In particular embodiments, the nutrient
concentration is cycled between a limiting concentration and a
non-limiting concentration at least twice during the total culture
period. Lipid content of cells can be increased by continuing the
culture for increased periods of time while providing an excess of
carbon, but limiting or no nitrogen.
[0185] In another embodiment, lipid yield is increased by culturing
a lipid-producing microbe (e.g., microalgae) in the presence of one
or more cofactor(s) for a lipid pathway enzyme (e.g., a fatty acid
synthetic enzyme). Generally, the concentration of the cofactor(s)
is sufficient to increase microbial lipid (e.g., fatty acid) yield
over microbial lipid yield in the absence of the cofactor(s). In a
particular embodiment, the cofactor(s) are provided to the culture
by including in the culture a microbe (e.g., microalgae) containing
an exogenous gene encoding the cofactor(s). Alternatively,
cofactor(s) may be provided to a culture by including a microbe
(e.g., microalgae) containing an exogenous gene that encodes a
protein that participates in the synthesis of the cofactor. In
certain embodiments, suitable cofactors include any vitamin
required by a lipid pathway enzyme, such as, for example: biotin,
pantothenate. Genes encoding cofactors suitable for use in the
invention or that participate in the synthesis of such cofactors
are well known and can be introduced into microbes (e.g.,
microalgae), using contructs and techniques such as those described
above.
[0186] The specific examples of bioreactors, culture conditions,
and heterotrophic growth and propagation methods described herein
can be combined in any suitable manner to improve efficiencies of
microbial growth and lipid and/or protein production.
[0187] Microalgal biomass with a high percentage of oil/lipid
accumulation by dry weight has been generated using different
methods of culture, which are known in the art (see PCT Pub. No.
2008/151149). Microalgal biomass generated by the culture methods
described herein and useful in accordance with the present
invention comprises at least 10% microalgal oil by dry weight. In
some embodiments, the microalgal biomass comprises at least 25%, at
least 50%, at least 55%, or at least 60% microalgal oil by dry
weight. In some embodiments, the microalgal biomass contains from
10-90% microalgal oil, from 25-75% microalgal oil, from 40-75%
microalgal oil, or from 50-70% microalgal oil by dry weight.
[0188] The microalgal oil of the biomass described herein, or
extracted from the biomass for use in the methods and compositions
of the present invention can comprise glycerolipids with one or
more distinct fatty acid ester side chains. Glycerolipids are
comprised of a glycerol molecule esterified to one, two or three
fatty acid molecules, which can be of varying lengths and have
varying degrees of saturation. The length and saturation
characteristics of the fatty acid molecules (and the microalgal
oils) can be manipulated to modify the properties or proportions of
the fatty acid molecules in the microalgal oils of the present
invention via culture conditions or via lipid pathway engineering,
as described in more detail in Section IV, below. Thus, specific
blends of algal oil can be prepared either within a single species
of algae by mixing together the biomass or algal oil from two or
more species of microalgae, or by blending algal oil of the
invention with oils from other sources such as soy, rapeseed,
canola, palm, palm kernel, coconut, corn, waste vegetable, Chinese
tallow, olive, sunflower, cottonseed, chicken fat, beef tallow,
porcine tallow, microalgae, macroalgae, microbes, Cuphea, flax,
peanut, choice white grease, lard, Camelina sativa, mustard seed,
cashew nut, oats, lupine, kenaf, calendula, help, coffee, linseed
(flax), hazelnut, euphorbia, pumpkin seed, coriander, camellia,
sesame, safflower, rice, tung tree, cocoa, copra, pium poppy,
castor beans, pecan, jojoba, macadamia, Brazil nuts, avocado,
petroleum, or a distillate fraction of any of the preceding
oils.
[0189] The oil composition, i.e., the properties and proportions of
the fatty acid consitutents of the glycerolipids, can also be
manipulated by combining biomass or oil from at least two distinct
species of microalgae. In some embodiments, at least two of the
distinct species of microalgae have different glycerolipid
profiles. The distinct species of microalgae can be cultured
together or separately as described herein, preferably under
heterotrophic conditions, to generate the respective oils.
Different species of microalgae can contain different percentages
of distinct fatty acid consituents in the cell's glycerolipids.
[0190] Generally, Prototheca strains have very little or no fatty
acids with the chain length C8-C14. For example, Prototheca
moriformis (UTEX 1435), Prototheca krugani (UTEX 329), Prototheca
stagnora (UTEX 1442) and Prototheca zopfii (UTEX 1438) contains no
(or undectable amounts) C8 fatty acids, between 0-0.01% C10 fatty
acids, between 0.03-2.1% C12 fatty acids and between 1.0-1.7% C14
fatty acids.
[0191] In some cases, the Prototheca strains containing a transgene
encoding a fatty acyl-ACP thioesterase that has activity towards
fatty acyl-ACP substrate of chain lengths C8 or C8-10 has at least
1%, at least 1.5%, at least 2%, at least 3%, at least 4%, at least
5%, at least 10%, at least 12%, or at least 15% or more, fatty
acids of chain length C8. In other instances, the Prototheca
strains containing a transgene encoding a fatty acyl ACP
thioesterase that has activity towards fatty acyl-ACP substrate of
chain lengths C10 has at least at least 1%, at least 5%, at least
10%, at least 15%, at least 20%, at least 24%, or at least 25% or
more, fatty acids of chain length C10. In other instances, the
Prototheca strains containing a transgene encoding a fatty acyl-ACP
thioesterase that has activity towards fatty acyl-ACP substrate of
chain length C12 has at least 1%, at least 5%, at least 10%, at
least 15%, at least 20%, at least 25%, at least 30%, at least 34%,
at least 35% or at least 40% or more, fatty acids of the chain
length C12. In other cases, the Prototheca strains containing a
transgene encoding a fatty acyl-ACP thioesterase that has activity
towards fatty acyl-ACP substrate of chain length C14 has at least
1%, at least 2%, at least 3%, at least 4%, at least 5%, at least
6%, at least 7%, at least 10%, at least 15%, at least 30%, at least
43%, or at least 45% or more, fatty acids of the chain length
C14.
[0192] In non-limiting examples, the Prototheca strains containing
a transgene encoding a fatty acyl-ACP thioesterase that has
activity towards fatty acyl-ACP substrate of chain length C8 has
between 1%-25%, or between 1%-15%, preferably 1.8-12.29%, fatty
acids of chain length C8. In other non-limiting examples,
Prototheca strains containing a transgene encoding a fatty acyl-ACP
thioesterase that has activity towards fatty acyl-ACP substrate of
chain length C10 has between 1%-50%, or between 1%-25%, preferably
1.91-23.97% fatty acids of chain length C10. In other non-limiting
examples, Prototheca strains containing a transgene encoding a
fatty acyl-ACP thioesterase that has activity towards fatty
acyl-ACP substrate of chain length C12 has between 5%-50%, or
between 10%-40, preferably 13.55-34.01%, fatty acids of the chain
length C12. In other non-limiting examples, Prototheca strains
containing a transgene encoding a fatty acyl-ACP thioesterase that
has activity towards fatty acyl-ACP substrate of chain length C14
has between 1%-60%, or between 2%-45%, preferably 2.59-43.27%,
fatty acids of the chain length C14. In other non-limiting
examples, Prototheca strains containing a transgene encoding a
fatty acyl-ACP thioesterase that has broad specificity towards
fatty acyl-ACP substrates of varying carbon chain length has up to
30%, up to 35%, or preferably up to 39.45% fatty acids of the chain
length C16. In some cases, the Prototheca strains containing a
transgene encoding a fatty acyl-ACP thioesterase that has activity
towards fatty acyl-ACP substrate of chain lengths between C8 and
C14 have between 1%-75%, or between 2%-60%, preferably 2.69-57.98%,
medium chain (C8-C14) fatty acids. In some cases, the Prototheca
strains containing a transgene encoding a fatty acyl-ACP
thioesterase that has activity towards fatty acyl-ACP substrates of
chain lengths between C12 and C14 have at least 30%, at least 40%,
or at least 49% C12-C14 fatty acids. In some instances, keeping the
transgenic Prototheca strains under constant and high selective
pressure to retain exogenous genes is advantageous due to the
increase in the desired fatty acid of a specific chain length. High
levels of exogenous gene retention can also be achieved by
inserting exogenous genes into the nuclear chromosomes of the cells
using homologous recombination vectors and methods disclosed
herein. Recombinant cells containing exogenous genes integrated
into nuclear chromosomes are an object of the invention.
[0193] Microalgal oil can also include other constituents produced
by the microalgae, or incorporated into the microalgal oil from the
culture medium. These other constituents can be present in varying
amount depending on the culture conditions used to culture the
microalgae, the species of microalgae, the extraction method used
to recover microalgal oil from the biomass and other factors that
may affect microalgal oil composition. Non-limiting examples of
such constituents include carotenoids, present from 0.01-0.5 mcg/g,
0.025-0.3 mcg/g, preferably 0.05 to 0.244 micrograms/gram, of oil;
chlorophyll A present from 0.01-0.5 mcg/g, 0.025-0.3 mcg/g,
preferably 0.045 to 0.268 micrograms/gram, of oil; total
chlorophyll of less than 0.1 mcg/g, less than 0.05 mcg/g,
preferably less than 0.025 micrograms/gram, of oil; gamma
tocopherol present from 1-300 mcg/g, 35-175 mcg/g, preferably
38.3-164 micrograms/gram, of oil; total tocopherols present from
10-500 mcg/g, 50-300 mcg/g, preferably 60.8 to 261.7
microgram/gram, of oil; less than 1%, less than 0.5%, preferably
less than 0.25% brassicasterol, campesterol, stigmasterol, or
betasitosterol; total tocotrienols less than 400 mcg/g, preferably
less than 300 micrograms/gram, of oil; or total tocotrienols
present from 100-500 mcg/g, 225-350 mcg/g, preferably 249.6 to
325.3 micrograms/gram, of oil.
[0194] The other constituents can include, without limitation,
phospholipids, tocopherols, tocotrienols, carotenoids (e.g.,
alpha-carotene, beta-carotene, lycopene, etc.), xanthophylls (e.g.,
lutein, zeaxanthin, alpha-cryptoxanthin and beta-crytoxanthin), and
various organic or inorganic compounds. In some cases, the oil
extracted from Prototheca species comprises between 0.001-0.01
mcg/g, 0.0025-0.05 mcg/g, preferably 0.003 to 0.039 microgram
lutein/gram, of oil, less than 0.01 mcg/g, less than 0.005 mcg/g,
preferably less than 0.003 micrograms lycopene/gram, of oil; and
less than 0.01 mcg/g, less than 0.005 mcg/g, preferably less than
0.003 microgram beta carotene/gram, of oil.
[0195] In some embodiments, the present invention provides an
oleaginous microbial cell comprising a triglyceride oil, wherein
the fatty acid profile of the triglyceride oil is selected from the
group consisting of: at least about 1%, at least about 2%, at least
about 5%, at least about 7%, at least about 10%, or at least about
15%, C8:0; at least about 1%, at least about 5%, at least about
15%, at least about 20%, at least about 25%, or at least about 30%,
C10:0; at least about 1%, at least about 5%, at least about 10%, at
least about 15%, at least about 20%, 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%, at least about 70%, at least about 75%, or at
least about 80%, C12:0; at least about 2%, at least about 5%, at
least about 10%, at least about 15%, at least about 20%, at least
about 25%, at least about 30%, at least about 35%, at least about
40%, at least about 45%, or at least about 50%, C14:0; 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%, at least about 70%, at least about 75%, at least
about 80%, at least about 85%, or at least about 90%, C16:0; at
least about 5%, at least about 10%, at least about 15%, at least
about 20%, at least about 25%, at least about 30%, at least about
35%, at least about 40%, at least about 45%, or at least about 50%,
C18:0; at least about 60%, at least about 65%, at least about 70%,
at least about 75%, at least about 80%, at least about 85%, or at
least about 90%, C18:1; less than about 7%, less than about 5%,
less than about 3%, less than about 1%, or about 0%, C18:2; and 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%, at least about 70%, at least about 75%, at least about 80%, at
least about 85%, or at least about 90%, saturated fatty acids.
[0196] In some embodiments, the oleaginous microbial cell comprises
triglyceride oil comprising a fatty acid profile selected from the
group consisting of: total combined amounts of C8:0 and C10:0 of 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 about 100%; total
combined amounts of C10:0, C12:0, and C14:0 of at least about 50%,
at least about 60%, at least about 70%, at least about 80%, at
least about 90%, or about 100%; total combined amounts of C16:0,
C18:0 and C18:1 of at least about 60%, at least about 70%, at least
about 80%, at least about 90%, or about 100%; total combined
amounts of C18:0, C18:1 and C18:2 of at least about 60%, at least
about 70%, at least about 80%, at least about 90%, or about 100%;
total combined amounts of C14:0, C16:0, C18:0 and C18:1 of at least
about 60%, at least about 70s %, at least about 80%, at least about
90%, or about 100%; and total combined amounts of C18:1 and C18:2
of less than about 30%, less than about 25%, less than about 20%,
less than about 15%, less than about 10%, less than about 5%, or
about 0%,
[0197] In some embodiments, the oleaginous microbial cell comprises
triglyceride oil having a fatty acid profile comprising a ratio of
fatty acids selected from the group consisting of: a C8:0 to C10:0
ratio of at least about 5 to 1, at least 6 to 1, at least 7 to 1,
at least 8 to 1, at least 9 to 1, or at least 10 to 1; a C10:0 to
C12:0 ratio of at least about 6 to 1, at least 7 to 1, at least 8
to 1, at least 9 to 1, or at least 10 to 1; a C12:0 to C14:0 ratio
of at least about 5 to 1, at least 6 to 1, at least 7 to 1, at
least 8 to 1, at least 9 to 1, or at least 10 to 1; a C14:0 to
C12:0 ratio of at least 7 to 1, at least 8 to 1, at least 9 to 1,
or at least 10 to 1; and a C14:0 to C16:0 ratio of at least 1 to 2,
at least 1 to 3, at least 1 to 4, at least 1 to 5, at least 1 to 6,
at least 1 to 7, at least 1 to 8, at least 1 to 9, or at least 1 to
10.
[0198] In some embodiments, the present invention provides an
oleaginous microbial triglyceride oil composition, wherein the
fatty acid profile of the triglyceride oil is selected from the
group consisting of: at least about 1%, at least about 2%, at least
about 5%, at least about 7%, at least about 10%, or at least about
15%, C8:0; at least about 1%, at least about 5%, at least about
15%, at least about 20%, at least about 25%, or at least about 30%
C10:0; at least about 1%, at least about 5%, at least about 10%, at
least about 15%, at least about 20%, 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%, at least about 70%, at least about 75%, or at
least about 80%, C12:0; at least about 2%, at least about 5%, at
least about 10%, at least about 15%, at least about 20%, at least
about 25%, at least about 30%, at least about 35%, at least about
40%, at least about 45%, or at least about 50%, C14:0; 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%, at least about 70%, at least about 75%, at least
about 80%, at least about 85%, or at least about 90%, C16:0; at
least about 5%, at least about 10%, at least about 15%, at least
about 20%, at least about 25%, at least about 30%, at least about
35%, at least about 40%, at least about 45%, or at least about 50%,
C18:0; at least about 60%, at least about 65%, at least about 70%,
at least about 75%, at least about 80%, at least about 85%, or at
least about 90%, C18:1; less than about 7%, less than about 5%,
less than about 3%, less than about 1%, or about 0%, C18:2; and 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%, at least about 70%, at least about 75%, at least about 80%, at
least about 85%, or at least about 90%, saturated fatty acids.
[0199] In some embodiments, the oleaginous microbial triglyceride
oil composition comprises triglyceride oil comprising a fatty acid
profile in which: the total combined amount of C10:0, C12:0 and
C14:0 is at least about 50%, at least bout 60%, at least about 70%,
at least about 80%, at least about 90%, or about 100%; the total
combined amount of C16:0, C18:0 and C18:1 is at least about 60%, at
least about 70%, at least about 80%, at least about 90%, or about
100%; the total combined amount of C18:0, C18:1 and C18:2 is at
least about 60%, at least about 70%, at least about 80%, at least
about 90%, or about 100%; the total combined amount of C14:0,
C16:0, C18:0 and C18:1 is at least about 60%, at least about 70%,
at least about 80%, at least about 90%, or about 100%; the total
combined amounts of C8:0 and C10:0 is less than about 50%, less
than about 45%, less than about 40%, less than about 35%, less than
about 30%, less than about 25%, less than about 20%, less than
about 15%, less than about 10%, less than about 5%, or about
0%.
[0200] In some embodiments, the oleaginous microbial triglyceride
oil composition comprises triglyceride oil having a fatty acid
profile comprising a ratio of fatty acids selected from the group
consisting of: a C8:0 to C10:0 ratio of at least about 5 to 1, at
least about 6 to 1, at least about 7 to 1, at least about 8 to 1,
at least about 9 to 1, or at least about 10 to 1; a C10:0 to C12:0
ratio of at least about 6 to 1, at least about 7 to 1, at least
about 8 to 1, at least about 9 to 1, or at least about 10 to 1; a
C12:0 to C14:0 ratio of at least about 5 to 1, at least about 6 to
1, at least about 7 to 1, at least about 8 to 1, at least about 9
to 1, or at least about 10 to 1; a C14:0 to C12:0 ratio of at least
about 7 to 1, at least about 8 to 1, at least about 9 to 1, or at
least about 10 to 1; a C14:0 to C16:0 ratio of at least about 1 to
2, at least about 1 to 3, at least about 1 to 4, at least about 1
to 5, at least about 1 to 6, at least about 1 to 7, at least about
1 to 8, at least about 1 to 9, or at least about 1 to 10.
[0201] In some embodiments, the present invention provides a method
of producing an oleaginous microbial triglyceride oil composition
having a fatty acid profile selected from the group consisting of:
at least about 1%, at least about 2%, at least about 5%, at least
about 7%, at least about 10%, or at least about 15%, C8:0; at least
about 1%, at least about 5%, at least about 10%, at least about
15%, at least about 20%, at least about 25%, or at least about 30%,
C10:0; at least about 1%, at least about 5%, at least about 10%, at
least about 15%, at least about 20%, 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%, at least about 70%, at least about 75%, or at
least about 80%, C12:0; at least about 2%, at least about 5%, at
least about 10%, at least about 15%, at least about 20%, at least
about 25%, at least about 30%, at least about 35%, at least about
40%, at least about 45%, or at least about 50%, C14:0; 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%, at least about 70%, at least about 75%, at least
about 80%, at least about 85%, or at least about 90%, C16:0; at
least about 5%, at least about 10%, at least about 15%, at least
about 20%, at least about 25%, at least about 30%, at least about
35%, at least about 40%, at least about 45%, or at least about 50%
C18:0; at least about 60%, at least about 65%, at least about 70%,
at least about 75%, at least about 80%, at least about 85%, or at
least about 90%, C18:1; less than about 7%, less than about 5%,
less than about 3%, less than about 1%, or about 0%, C18:2; and 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%, at least about 70%, at least about 75%, at least about 80%, at
least about 85%, or at least about 90%, saturated fatty acids,
wherein the method comprises the steps of: (a) cultivating a
population of oleaginous microbial cells in a culture medium until
at least 10% of the dry cell weight of the oleaginous microbial
cells is triglyceride oil; and (b) isolating the triglyceride oil
composition from the oleaginous microbial cells.
[0202] In some embodiments, the method of producing oleaginous
microbial triglyceride oil compositions yields triglyceride oils
comprising a fatty acid profile in which: the total combined amount
of C10:0, C12:0 and C14:0 is at least about 50%, at least about
60%, at least about 70%, at least about 80%, at least about 90%, or
about 100%; the total combined amount of C16:0, C18:0 and C18:1 is
at least about 60%, at least about 70%, at least about 80%, at
least about 90%, or about 100%; the total combined amount of C18:0,
C18:1 and C18:2 is at least about 60%, at least about 70%, at least
about 80%, at least about 90%, or about 100%; the total combined
amount of C14:0, C16:0, C18:0 and C18:1 is at least about 60%, at
least about 70%, at least about 80%, at least about 90%, or about
100%; the total combined amount of C8:0 and C10:0 is less than
about 50%, less than about 45%, less than about 40%, less than
about 35%, less than about 30%, less than about 25%, less than
about 20%, less than about 15%, less than about 10%, less than
about 5%, or about 0%.
[0203] In some embodiments, the method of producing oleaginous
microbial triglyceride oil compositions yields triglyceride oils
having a fatty acid profile comprising a ratio of triglyceride oils
selected from the group consisting of: a C8:0 to C10:0 ratio of at
least about 5 to 1, at least about 6 to 1, at least about 7 to 1,
at least about 8 to 1, at least about 9 to 1, or at least about 10
to 1; a C10:0 to C12:0 ratio of at least about 6 to 1, at least
about 7 to 1, at least about 8 to 1, at least about 9 to 1, or at
least about 10 to 1; a C12:0 to C14:0 ratio of at least about 5 to
1, at least about 6 to 1, at least about 7 to 1, at least about 8
to 1, at least about 9 to 1, or at least about 10 to 1; a C14:0 to
C12:0 ratio of at least about 7 to 1, at least about 8 to 1, at
least about 9 to 1, or at least about 10 to 1; and a C14:0 to C16:0
ratio of at least about 1 to 2, at least about 1 to 3, at least
about 1 to 4, at least about 1 to 5, at least about 1 to 6, at
least about 1 to 7, at least about 1 to 8, at least about 1 to 9,
or at least about 1 to 10.
III. GENETIC ENGINEERING METHODS AND MATERIALS
[0204] The present invention provides methods and materials for
genentically modifying microorganisms, including Prototheca cells
and recombinant host cells, useful in the methods of the present
invention, including but not limited to recombinant Prototheca
moriformis, Prototheca zopfii, Prototheca krugani, and Prototheca
stagnora host cells. The description of these methods and materials
is divided into subsections for the convenience of the reader. In
subsection 1, transformation methods are described. In subsection
2, genetic engineering methods using homologous recombination are
described. In subsection 3, expression vectors and components are
described.
[0205] In certain embodiments of the present invention it is
desirable to genentically modify a microorganism to enhance lipid
production, modify the properties or proportions of components
generated by the microorganism, or to improve or provide de novo
growth characteristics on a variety of feedstock materials.
Chlorella, particularly Chlorella protothecoides, Chlorella
minutissima, Chlorella sorokiniana, Chlorella ellipsoidea,
Chlorella sp., and Chlorella emersonii are preferred microorganisms
for use in the genetic engineering methods described herein,
although other Chlorella species as well as other varieties of
microorganisms can be used.
[0206] Promoters, cDNAs, and 3'UTRs, as well as other elements of
the vectors, can be generated through cloning techniques using
fragments isolated from native sources (see for example Molecular
Cloning: A Laboratory Manual, Sambrook et al. (3d edition, 2001,
Cold Spring Harbor Press; and U.S. Pat. No. 4,683,202).
Alternatively, elements can be generated synthetically using known
methods (see for example Gene. 1995 Oct. 16; 164(1):49-53).
1. Engineering Methods--Transformation
[0207] Cells can be transformed by any suitable technique
including, e.g., biolistics, electroporation (see Maruyama et al.
(2004), Biotechnology Techniques 8:821-826), glass bead
transformation and silicon carbide whisker transformation. Another
method that can be used involves forming protoplasts and using
CaCl.sub.2 and polyethylene glycol (PEG) to introduce recombinant
DNA into microalgal cells (see Kim et al. (2002), Mar. Biotechnol.
4:63-73, which reports the use of this method for the
transformation of Chorella ellipsoidea). Co-transformation of
microalgae can be used to introduce two distinct vector molecules
into a cell simultaneously (see for example Protist 2004 December;
155(4):381-93).
[0208] Biolistic methods (see, for example, Sanford, Trends In
Biotech. (1988) 6:299 302, U.S. Pat. No. 4,945,050; electroporation
(Fromm et al., Proc. Nat'l. Acad. Sci. (USA) (1985) 82:5824 5828);
use of a laser beam, microinjection or any other method capable of
introducing DNA into a microalgae can also be used for
transformation of a Prototheca cell.
[0209] Any convenient technique for introducing a transgene into a
microorganism, such as Chorella, can be employed in the present
invention. Dawson et al. (1997) (supra) described the use of
micro-projectile bombardment to introduce the nitrate reductase
(NR) gene from Chlorella vulgaris into NR-deficient Chlorella
sorokiniana mutants, resulting in stable transformants. Briefly,
0.4 micron tungsten beads were coated with plasmid;
3.times.10.sup.7 C. sorokiniana cells were spread in the center
third of a non-selective agar plate and bombarded with the
PDS-1000/He Biolistic Particle Delivery.RTM. system (Bio-Rad).
[0210] A preferred method for introducing a transgene into a
microorganism, such as Chlorella, is the method described by Kim et
al. (2002), Mar. Biotechnol. 4:63-73. Kim reports the
transformation of Chorella ellipsoidea protoplasts using CaCl.sub.2
and polyethylene glycol (PEG). In particular, protoplasts were
prepared by growing C. ellipsoidea cells to a density of
1-2.times.10.sup.8/Ml. Cells were recovered and washed by
centrifugation for 5 minutes at 1600 g and resuspended in 5 Ml of
phosphate buffer (Ph 6.0) containing 0.6 M sorbitol, 0.6 M
mannitol, 4% (weight/volume) cellulose (Calbiochem), 2%
(weight/volume) macerase (Calbiochem), and 50 units pectinase
(Sigma). The cell suspension was incubated at 25.degree. C. for 16
hours in the dark with gentle shaking. The resultant protoplasts
were recovered by centrifugation at 400 g for 5 minutes. The pellet
was gently resuspended in 5 Ml of f/2 medium containing 0.6 M
sorbitol and 0.6 M mannitol and centrifuged at 400 g for 5 minutes.
This pellet was resuspended in 1 Ml of 0.6 M sorbitol/mannitol
solution containing 50 mMCaCl.sub.2. Then, 5 mg of transgene DNA
was added, along with 25 .mu.g calf thymus DNA (Sigma), to
10.sup.7-10.sup.8 protoplasts in 0.4 Ml. After 15 minutes at room
temperature, 200 .mu.L of PNC (40% polyethylene glycol 4000, 0.8 M
NaCl, 50 Mm CaCl.sub.2) was added and mixed gently for 30 minutes
at room temperature. After this, 0.6 Ml of f/2 medium supplemented
with 0.6 M sorbitol/mannitol solution, 1% yeast extract and 1%
glucose was added, and the transformed cells were incubated at
25.degree. C. for 12 hours in the dark for cell wall regeneration.
A similar method was used by Huang et al. (2007) (supra) to
introduce a transgene encoding mercuric reductase into Chlorella
sp. DT.
[0211] Electorporation has also been employed to transform
microorganisms, such as Chorella. As reported by Maruyama et al.
(2004), Biotechnology Techniques 8:821-826 (incorporated by
reference herein in its entirety), this technique was used to
introduce a transgene into protoplasts of Chlorella saccharophila
c-211-1a prepared from the cells in the stationary phase. Transient
expression of the introduced plasmid was observed under a field
strength of between 600 and 900 V/cm, and a pulse duration of
around 400 ms, where high membrane permeability to 70-kDa
FITC-dextran was ascertained.
[0212] Examples of expression of transgenes in microorganisms, such
as Chlorella, can be found in the literature (see for example
Current Microbiology Vol. 35 (1997), pp. 356-362; Sheng Wu Gong
Cheng Xue Bao. 2000 July; 16(4):443-6; Current Microbiology Vol. 38
(1999), pp. 335-341; Appl Microbiol Biotechnol (2006) 72: 197-205;
Marine Biotechnology 4, 63-73, 2002; Current Genetics 39:5, 365-370
(2001); Plant Cell Reports 18:9, 778-780, (1999); Biologia
Plantarium 42(2): 209-216, (1999); Plant Pathol. J 21(1): 13-20,
(2005)). Also see Examples herein.
[0213] Examples of expression of transgenes in oleaginous yeast
(e.g., Yarrowia lipolytica) can be found in the literature (see,
for example, Bordes et al., J Microbiol Methods, Jun. 27 (2007)).
Examples of expression of transgenes in fungi (e.g., Mortierella
alpine, Mucor circinelloides, and Aspergillus ochraceus) can also
be found in the literature (see, for example, Microbiology, July;
153(Pt. 7):2013-25 (2007); Mol Genet Genomics, June; 271(5):595-602
(2004); Curr Genet, March; 21(3):215-23 (1992); Current
Microbiology, 30(2):83-86 (1995); Sakuradani, NISR Research Grant,
"Studies of Metabolic Engineering of Useful Lipid-producing
Microorganisms" (2004); and PCT/JP2004/012021). Examples of
expression of exogenous genes in bacteria such as E. coli are well
known; see for example Molecular Cloning: A Laboratory Manual,
Sambrook et al. (3d edition, 2001, Cold Spring Harbor Press.
[0214] Vectors for transformation of microorganisms in accordance
with the present invention can be prepared by known techniques
familiar to those skilled in the art. The nucleotide sequence of
the construct used for transformation of multiple Chlorella species
corresponds to SEQ ID NO: 8. In one embodiment, an exemplary vector
design for expression of a lipase gene in a microorganism such as a
microalgae contains a gene encoding a lipase in operable linkage
with a promoter active in microalgae. Alternatively, if the vector
does not contain a promoter in operable linkage with the gene of
interest, the gene can be transformed into the cells such that it
becomes operably linked to an endogenous promoter at the point of
vector integration. The promoterless method of transformation has
been proven to work in microalgae (see for example Plant Journal
14:4, (1998), pp. 441-447). The vector can also contain a second
gene that encodes a protein that, e.g., imparts resistance to an
antibiotic or herbicide, i.e., a selectable marker. Optionally, one
or both gene(s) is/are followed by a 3' untranslated sequence
containing a polyadenylation signal. Expression cassettes encoding
the two genes can be physically linked in the vector or on separate
vectors. Co-transformation of microalgae can also be used, in which
distinct vector molecules are simultaneously used to transform
cells (see for example Protist 2004 December; 155(4):381-93). The
transformed cells can be optionally selected based upon the ability
to grow in the presence of the antibiotic or other selectable
marker under conditions in which cells lacking the resistance
cassette would not grow.
2. Engineering Methods--Homologous Recombination
[0215] Homologous recombination is the ability of complementary DNA
sequences to align and exchange regions of homology. Transgenic DNA
("donor") containing sequences homologous to the genomic sequences
being targeted ("template") is introduced into the organism and
then undergoes recombination into the genome at the site of the
corresponding genomic homologous sequences. The mechanistic steps
of this process, in most casees, include: (1) pairing of homologous
DNA segments; (2) introduction of double-stranded breaks into the
donor DNA molecule; (3) invasion of the template DNA molecule by
the free donor DNA ends followed by DNA synthesis; and (4)
resolution of double-strand break repair events that result in
final recombination products.
[0216] The ability to carry out homologous recombination in a host
organism has many practical implications for what can be carried
out at the molecular genetic level and is useful in the generation
of an oleaginous microbe that can produced tailored oils. By its
very nature homologous recombination is a precise gene targeting
event, hence, most transgenic lines generated with the same
targeting sequence will be essentially identical in terms of
phenotype, necessitating the screening of far fewer transformation
events. Homologous recombination also targets gene insertion events
into the host chromosome, resulting in excellent genetic stability,
even in the absence of genetic selection. Because different
chromosomal loci will likely impact gene expression, even from
heterologous promoters/UTRs, homologous recombination can be a
method of querying loci in an unfamiliar genome environment and to
assess the impact of these environments on gene expression.
[0217] Particularly useful genetic engineering applications using
homologous recombination is to co-opt specific host regulatory
elements such as promoters/UTRs to drive heterologous gene
expression in a highly specific fashion. For example, ablation or
knockout of desaturase genes/gene families with a heterologous gene
encoding a selective marker might be expected to increase overall
percentage of saturated fatty acids produced in the host cell.
Example 11 describes the homologous recombination targeting
constructs and a working example of such desaturase gene ablations
or knockouts generated in Prototheca moriformis.
[0218] Because homologous recombination is a precise gene targeting
event, it can be used to precisely modify any nucleotide(s) within
a gene or region of interest, so long as sufficient flanking
regions have been identified. Therefore, homologous recombination
can be used as a means to modify regulatory sequences impacting
gene expression of RNA and/or proteins. It can also be used to
modify protein coding regions in an effort to modify enzyme
activites such as substrate specificity, affinities and Km, and
thus affecting the desired change in metabolism of the host cell.
Homologous recombination provides a powerful means to manipulate
the host genome resulting in gene targeting, gene conversion, gene
deletion, gene duplication, gene inversion and exchanging gene
expression regulatory elements such as promoters, enhancers and
3'UTRs.
[0219] Homologous recombination can be achieve by using targeting
constructs containing pieces of endogenous sequences to "target"
the gene or region of interest within the endogenous host cell
genome. Such targeting sequences can either be located 5' of the
gene or region of interest, 3' of the gene/region of interest or
even flank the gene/region of interest. Such targeting constructs
can be transformed into the host cell either as a supercoiled
plasmid DNA with additional vector backbone, a PCR product with no
vector backbone, or as a linearized molecule. In some cases, it may
be advantageous to first expose the homologous sequences within the
transgenic DNA (donor DNA) with a restriction enzyme. This step can
increase the recombination efficiency and decrease the occurrence
of undesired events. Other methods of increasing recombination
efficiency include using PCR to generate transforming transgenic
DNA containing linear ends homologous to the genomic sequences
being targeted.
[0220] For purposes of non-limiting illustration, regions of donor
DNA sequences that are useful for homologous recombination include
the KE858 region of DNA in Prototheca moriformis. KE858 is a 1.3
kb, genomic fragment that encompasses part of the coding region for
a protein that shares homology with the transfer RNA (tRNA) family
of proteins. Southern blots have shown that the KE858 sequence is
present in a single copy in the Prototheca moriformis (UTEX 1435)
genome. This region and Examples of using this region for
homologous recombination targeting has been described in PCT
Application No. PCT/US2009/66142. Another region of donor DNA that
is useful is portions of the 6S rRNA genomic sequence. The use of
this sequence in homologous recombination in Prototheca morifomis
are described below in the Examples.
3. Vectors and Vector Components
[0221] Vectors for transformation of microorganisms in accordance
with the present invention can be prepared by known techniques
familiar to those skilled in the art in view of the disclosure
herein. A vector typically contains one or more genes, in which
each gene codes for the expression of a desired product (the gene
product) and is operably linked to one or more control sequences
that regulate gene expression or target the gene product to a
particular location in the recombinant cell. To aid the reader,
this subsection is divided into subsections. Subsection A describes
control sequences typically contained on vectors as well as novel
control sequences provided by the present invention. Subsection B
describes genes typically contained in vectors as well as novel
codon optimization methods and genes prepared using them provided
by the invention.
[0222] A. Control Sequences
[0223] Control sequences are nucleic acids that regulate the
expression of a coding sequence or direct a gene product to a
particular location in or outside a cell. Control sequences that
regulate expression include, for example, promoters that regulate
transcription of a coding sequence and terminators that terminate
transcription of a coding sequence. Another control sequence is a
3' untranslated sequence located at the end of a coding sequence
that encodes a polyadenylation signal. Control sequences that
direct gene products to particular locations include those that
encode signal peptides, which direct the protein to which they are
attached to a particular location in or outside the cell.
[0224] Thus, an exemplary vector design for expression of an
exogenous gene in a microalgae contains a coding sequence for a
desired gene product (for example, a selectable marker, a lipid
pathway modification enzyme, or a sucrose utilization enzyme) in
operable linkage with a promoter active in microalgae.
Alternatively, if the vector does not contain a promoter in
operable linkage with the coding sequence of interest, the coding
sequence can be transformed into the cells such that it becomes
operably linked to an endogenous promoter at the point of vector
integration. The promoterless method of transformation has been
proven to work in microalgae (see for example Plant Journal 14:4,
(1998), pp. 441-447).
[0225] Many promoters are active in microalgae, including promoters
that are endogenous to the algae being transformed, as well as
promoters that are not endogenous to the algae being transformed
(i.e., promoters from other algae, promoters from higher plants,
and promoters from plant viruses or algae viruses). Illustrative
exogenous and/or endogenous promoters that are active in microalgae
(as well as antibiotic resistance genes functional in microalgae)
are described in PCT Pub. No. 2008/151149 and references cited
therein).
[0226] The promoter used to express an exogenous gene can be the
promoter naturally linked to that gene or can be a heterologous
gene. Some promoters are active in more than one species of
microalgae. Other promoters are species-specific. Illustrative
promoters include promoters such as .beta.-tubulin from
Chlamydomonas reinhardtii, used in the Examples below, and viral
promoters, such as cauliflower mosaic virus (CMV) and chlorella
virus, which have been shown to be active in multiple species of
microalgae (see for example Plant Cell Rep. 2005 March;
23(10-11):727-35; J. Microbiol. 2005 August; 43(4):361-5; Mar
Biotechnol (NY). 2002 January; 4(1):63-73). Another promoter that
is suitable for use for expression of exogenous genes in Prototheca
is the Chlorella sorokiniana glutamate dehydrogenase
promoter/5'UTR. Optionally, at least 10, 20, 30, 40, 50, or 60
nucleotides or more of these sequences containing a promoter are
used. Illustrative promoters useful for expression of exogenous
genes in Prototheca are listed in the sequence listing of this
application, such as the promoter of the Chlorella HUP1 gene (SEQ
ID NO:1) and the Chlorella ellipsoidea nitrate reductase promoter
(SEQ ID NO:2). Chlorella virus promoters can also be used to
express genes in Prototheca, such as SEQ ID NOs: 1-7 of U.S. Pat.
No. 6,395,965. Additional promoters active in Prototheca can be
found, for example, in Biochem Biophys Res Commun 1994 Oct. 14;
204(1):187-94; Plant Mol. Biol. 1994 October; 26(1):85-93;
Virology. 2004 Aug. 15; 326(1):150-9; and Virology. 2004 Jan. 5;
318(1):214-23. Other useful promoters are described in detail in
the Examples below.
[0227] A promoter can generally be characterized as either
constitutive or inducible. Constitutive promoters are generally
active or function to drive expression at all times (or at certain
times in the cell life cycle) at the same level. Inducible
promoters, conversely, are active (or rendered inactive) or are
significantly up- or down-regulated only in response to a stimulus.
Both types of promoters find application in the methods of the
invention. Inducible promoters useful in the invention include
those that mediate transcription of an operably linked gene in
response to a stimulus, such as an exogenously provided small
molecule (e.g, glucose, as in SEQ ID NO:1), temperature (heat or
cold), lack of nitrogen in culture media, etc. Suitable promoters
can activate transcription of an essentially silent gene or
upregulate, preferably substantially, transcription of an operably
linked gene that is transcribed at a low level. Examples below
describe additional inducible promoters that are useful in
Prototheca cells.
[0228] Inclusion of termination region control sequence is
optional, and if employed, then the choice is be primarily one of
convenience, as the termination region is relatively
interchangeable. The termination region may be native to the
transcriptional initiation region (the promoter), may be native to
the DNA sequence of interest, or may be obtainable from another
source. See, for example, Chen and Orozco, Nucleic Acids Res.
(1988) 16:8411.
[0229] The present invention also provides control sequences and
recombinant genes and vectors containing them that provide for the
compartmentalized expression of a gene of interest. Organelles for
targeting are chloroplasts, plastids, mitochondria, and endoplasmic
reticulum. In addition, the present invention provides control
sequences and recombinant genes and vectors containing them that
provide for the secretion of a protein outside the cell.
[0230] Proteins expressed in the nuclear genome of Prototheca can
be targeted to the plastid using plastid targeting signals. Plastid
targeting sequences endogenous to Chlorella are known, such as
genes in the Chlorella nuclear genome that encode proteins that are
targeted to the plastid; see for example GenBank Accession numbers
AY646197 and AF499684, and in one embodiment, such control
sequences are used in the vectors of the present invention to
target expression of a protein to a Prototheca plastid.
[0231] The Examples below describe the use of algal plastid
targeting sequences to target heterologous proteins to the correct
compartment in the host cell. cDNA libraries were made using
Prototheca moriformis and Chlorella protothecodies cells and are
described in PCT Application No. PCT/US2009/066142.
[0232] In another embodiment of the present invention, the
expression of a polypeptide in Prototheca is targeted to the
endoplasmic reticulum. The inclusion of an appropriate retention or
sorting signal in an expression vector ensure that proteins are
retained in the endoplasmic reticulum (ER) and do not go downstream
into Golgi. For example, the IMPACTVECTOR1.3 vector, from
Wageningen UR--Plant Research International, includes the well
known KDEL retention or sorting signal. With this vector, ER
retention has a practical advantage in that it has been reported to
improve expression levels 5-fold or more. The main reason for this
appears to be that the ER contains lower concentrations and/or
different proteases responsible for post-translational degradation
of expressed proteins than are present in the cytoplasm. ER
retention signals functional in green microalgae are known. For
example, see Proc Natl Acad Sci USA. 2005 Apr. 26;
102(17):6225-30.
[0233] In another embodiment of the present invention, a
polypeptide is targeted for secretion outside the cell into the
culture media. See Hawkins et al., Current Microbiology Vol. 38
(1999), pp. 335-341 for examples of secretion signals active in
Chlorella that can be used, in accordance with the methods of the
invention, in Prototheca.
[0234] Many promoters are active in microalgae, including promoters
that are endogenous to the algae being transformed, as well as
promoters that are not endogenous to the algae being transformed
(i.e., promoters from other algae, promoters from higher plants,
and promoters from plant viruses or algae viruses). Exogenous
and/or endogenous promoters that are active in microalgae, and
antibiotic resistance genes functional in microalgae are described
by e.g., Curr Microbiol. 1997 December; 35(6):356-62 (Chlorella
vulgaris); Mar Biotechnol (NY). 2002 January; 4(1):63-73 (Chlorella
ellipsoidea); Mol Gen Genet. 1996 Oct. 16; 252(5):572-9
(Phaeodactylum tricornutum); Plant Mol. Biol. 1996 April;
31(1):1-12 (Volvox carteri); Proc Natl Acad Sci USA. 1994 Nov. 22;
91(24):11562-6 (Volvox carteri); Falciatore A, Casotti R, Leblanc
C, Abrescia C, Bowler C, PMID: 10383998, 1999 May; 1(3):239-251
(Laboratory of Molecular Plant Biology, Stazione Zoologica, VIIIa
Comunale, I-80121 Naples, Italy) (Phaeodactylum tricornutum and
Thalassiosira weissflogii); Plant Physiol. 2002 May; 129(1):7-12.
(Porphyridium sp.); Proc Natl Acad Sci U S A. 2003 Jan. 21;
100(2):438-42. (Chlamydomonas reinhardtii); Proc Natl Acad Sci USA.
1990 February; 87(3):1228-32. (Chlamydomonas reinhardtii); Nucleic
Acids Res. 1992 Jun. 25; 20(12):2959-65; Mar Biotechnol (NY). 2002
January; 4(1):63-73 (Chlorella); Biochem Mol Biol Int. 1995 August;
36(5):1025-35 (Chlamydomonas reinhardtii); J. Microbiol. 2005
August; 43(4):361-5 (Dunaliella); Yi Chuan Xue Bao. 2005 April;
32(4):424-33 (Dunaliella); Mar Biotechnol (NY). 1999 May;
1(3):239-251. (Thalassiosira and Phaedactylum); Koksharova, Appl
Microbiol Biotechnol 2002 February; 58(2):123-37 (various species);
Mol Genet Genomics. 2004 February; 271(1):50-9 (Thermosynechococcus
elongates); J. Bacteriol. (2000), 182, 211-215; FEMS Microbiol
Lett. 2003 Apr. 25; 221(2):155-9; Plant Physiol. 1994 June;
105(2):635-41; Plant Mol. Biol. 1995 December; 29(5):897-907
(Synechococcus PCC 7942); Mar Pollut Bull. 2002; 45(1-12):163-7
(Anabaena PCC 7120); Proc Natl Acad Sci USA. 1984 March;
81(5):1561-5 (Anabaena (various strains)); Proc Natl Acad Sci USA.
2001 Mar. 27; 98(7):4243-8 (Synechocystis); Wirth, Mol Gen Genet.
1989 March; 216(1):175-7 (various species); Mol Microbiol, 2002
June; 44(6):1517-31 and Plasmid, 1993 September; 30(2):90-105
(Fremyella diplosiphon); Hall et al. (1993) Gene 124: 75-81
(Chlamydomonas reinhardtii); Gruber et al. (1991). Current Micro.
22: 15-20; Jarvis et al. (1991) Current Genet. 19: 317-322
(Chlorella); for additional promoters see also table 1 from U.S.
Pat. No. 6,027,900).
[0235] The promoter used to express an exogenous gene can be the
promoter naturally linked to that gene or can be a heterologous
gene. Some promoters are active in more than one species of
microalgae. Other promoters are species-specific. Preferred
promoters include promoters such as RBCS2 from Chlamydomonas
reinhardtii and viral promoters, such as cauliflower mosaic virus
(CMV) and chlorella virus, which have been shown to be active in
multiple species of microalgae (see for example Plant Cell Rep.
2005 March; 23(10-11):727-35; J. Microbiol. 2005 August;
43(4):361-5; Mar Biotechnol (NY). 2002 January; 4(1):63-73). In
other embodiments, the Botryococcus malate dehydrogenase promoter,
such a nucleic acid comprising any part of SEQ ID NO: 150, or the
Chlamydomonas reinhardtii RBCS2 promoter (SEQ ID NO: 151) can be
used. Optionally, at least 10, 20, 30, 40, 50, or 60 nucleotides or
more of these sequences containing a promoter are used. Preferred
promoters endogenous to species of the genus Chlorella are SEQ ID
NO:1 and SEQ ID NO:2.
[0236] Preferred promoters useful for expression of exogenous genes
in Chlorella are listed in the sequence listing of this
application, such as the promoter of the Chlorella HUP1 gene (SEQ
ID NO:1) and the Chlorella ellipsoidea nitrate reductase promoter
(SEQ ID NO:2). Chlorella virus promoters can also be used to
express genes in Chlorella, such as SEQ ID NOs: 1-7 of U.S. Pat.
No. 6,395,965. Additional promoters active in Chlorella can be
found, for example, in Biochem Biophys Res Commun. 1994 Oct. 14;
204(1):187-94; Plant Mol. Biol. 1994 October; 26(1):85-93;
Virology. 2004 Aug. 15; 326(1):150-9; and Virology. 2004 Jan. 5;
318(1):214-23.
[0237] B. Genes and Codon Optimization
[0238] Typically, a gene includes a promoter, coding sequence, and
termination control sequences. When assembled by recombinant DNA
technology, a gene may be termed an expression cassette and may be
flanked by restriction sites for convenient insertion into a vector
that is used to introduce the recombinant gene into a host cell.
The expression cassette can be flanked by DNA sequences from the
genome or other nucleic acid target to facilitate stable
integration of the expression cassette into the genome by
homologous recombination. Alternatively, the vector and its
expression cassette may remain unintegrated, in which case, the
vector typically includes an origin of replication, which is
capable of providing for replication of the heterologous vector
DNA.
[0239] A common gene present on a vector is a gene that codes for a
protein, the expression of which allows the recombinant cell
containing the protein to be differentiated from cells that do not
express the protein. Such a gene, and its corresponding gene
product, is called a selectable marker. Any of a wide variety of
selectable markers can be employed in a transgene construct useful
for transforming Prototheca. Examples of suitable selectable
markers include the G418 resistance gene, the nitrate reductase
gene (see Dawson et al. (1997), Current Microbiology 35:356-362),
the hygromycin phosphotransferase gene (HPT; see Kim et al. (2002),
Mar. Biotechnol. 4:63-73), the neomycin phosphotransferase gene,
the ble gene, which confers resistance to phleomycin (Huang et al.
(2007), Appl. Microbiol. Biotechnol. 72:197-205), and the
aminoglycoside-3'-O-phosphotransferase (SEQ ID NO: 194), which
confers resistance to kanamycin. Methods of determining sensitivity
of microalgae to antibiotics are well known. For example, Mol Gen
Genet. 1996 Oct. 16; 252(5):572-9.
[0240] Other selectable markers that are not antibiotic-based can
alsobe employed in a transgene construct useful for transforming
microalgae in general, including Prototheca species. Genes that
confers the ability to utilize certain carbon sources that were
previously unable to be utilized by the microalgae can also be used
as a selectable marker. By way of illustration, Prototheca
moriformis strains typically grow poorly, if at all, on sucrose.
Using a construct containing a sucrose invertase gene can confer
the ability of positive transformants to grow on sucrose as a
carbon substrate. Additional details on using sucrose utilization
as a selectable marker along with other selectable markers are
discussed in Section IV below.
[0241] For purposes of the present invention, the expression vector
used to prepare a recombinant host cell of the invention will
include at least two, and often three, genes, if one of the genes
is a selectable marker. For example, a genetically engineered
Prototheca of the invention can be made by transformation with
vectors of the invention that comprise, in addition to a selectable
marker, one or more exogenous genes, such as, for example, sucrose
invertase gene or acyl ACP-thioesterase gene. One or both genes can
be expressed using an inducible promoter, which allows the relative
timing of expression of these genes to be controlled to enhance the
lipid yield and conversion to fatty acid esters. Expression of the
two or more exogenous genes may be under control of the same
inducible promoter or under control of different inducible (or
constitutive) promoters. In the latter situation, expression of a
first exogenous gene can be induced for a first period of time
(during which expression of a second exogenous gene may or may not
be induced) and expression of a second exogenous gene can be
induced for a second period of time (during which expression of a
first exogenous gene may or may not be induced).
[0242] In other embodiments, the two or more exogenous genes (in
addition to any selectable marker) are: a fatty acyl-ACP
thioesterase and a fatty acyl-CoA/aldehyde reductase, the combined
action of which yields an alcohol product. Further provided are
other combinations of exogenous genes, including without
limitation, a fatty acyl-ACP thioesterase and a fatty acyl-CoA
reductase to generate aldehydes. In one embodiment, the vector
provides for the combination of a fatty acyl-ACP thioesterase, a
fatty acyl-CoA reductase, and a fatty aldehyde decarbonylase to
generate alkanes. In each of these embodiments, one or more of the
exogenous genes can be expressed using an inducible promoter.
[0243] Other illustrative vectors of the invention that express two
or more exogenous genes include those encoding both a sucrose
transporter and a sucrose invertase enzyme and those encoding both
a selectable marker and a secreted sucrose invertase. The
recombinant Prototheca transformed with either type of vector
produce lipids at lower manufacturing cost due to the engineered
ability to use sugar cane (and sugar cane-derived sugars) as a
carbon source. Insertion of the two exogenous genes described above
can be combined with the disruption of polysaccharide biosynthesis
through directed and/or random mutagenesis, which steers ever
greater carbon flux into lipid production. Individually and in
combination, trophic conversion, engineering to alter lipid
production and treatment with exogenous enzymes alter the lipid
composition produced by a microorganism. The alteration can be a
change in the amount of lipids produced, the amount of one or more
hydrocarbon species produced relative to other lipids, and/or the
types of lipid species produced in the microorganism. For example,
microalgae can be engineered to produce a higher amount and/or
percentage of TAGs.
[0244] For optimal expression of a recombinant protein, it is
beneficial to employ coding sequences that produce mRNA with codons
preferentially used by the host cell to be transformed. Thus,
proper expression of transgenes can require that the codon usage of
the transgene matches the specific codon bias of the organism in
which the transgene is being expressed. The precise mechanisms
underlying this effect are many, but include the proper balancing
of available aminoacylated tRNA pools with proteins being
synthesized in the cell, coupled with more efficient translation of
the transgenic messenger RNA (mRNA) when this need is met. When
codon usage in the transgene is not optimized, available tRNA pools
are not sufficient to allow for efficient translation of the
heterologous mRNA resulting in ribosomal stalling and termination
and possible instability of the transgenic mRNA.
[0245] The present invention provides codon-optimized nucleic acids
useful for the successful expression of recombinant proteins in
Prototheca. Codon usage in Prototheca species was analyzed by
studying cDNA sequences isolated from Prototheca moriformis. This
analysis represents the interrogation over 24,000 codons and
resulted in Table 2 below.
TABLE-US-00004 TABLE 2 Preferred codon usage in Prototheca strains.
Ala GCG 345 (0.36) Asn AAT 8 (0.04) GCA 66 (0.07) AAC 201 (0.96)
GCT 101 (0.11) Pro CCG 161 (0.29) GCC 442 (0.46) CCA 49 (0.09) Cys
TGT 12 (0.10) CCT 71 (0.13) TGC 105 (0.90) CCC 267 (0.49) Asp GAT
43 (0.12) Gln CAG 226 (0.82) GAC 316 (0.88) CAA 48 (0.18) Glu GAG
377 (0.96) Arg AGG 33 (0.06) GAA 14 (0.04) AGA 14 (0.02) Phe TTT 89
(0.29) CGG 102 (0.18) TTC 216 (0.71) CGA 49 (0.08) Gly GGG 92
(0.12) CGT 51 (0.09) GGA 56 (0.07) CGC 331 (0.57) GGT 76 (0.10) Ser
AGT 16 (0.03) GGC 559 (0.71) AGC 123 (0.22) His CAT 42 (0.21) TCG
152 (0.28) CAC 154 (0.79) TCA 31 (0.06) Ile ATA 4 (0.01) TCT 55
(0.10) ATT 30 (0.08) TCC 173 (0.31) ATC 338 (0.91) Thr ACG 184
(0.38) Lys AAG 284 (0.98) ACA 24 (0.05) AAA 7 (0.02) ACT 21 (0.05)
Leu TTG 26 (0.04) ACC 249 (0.52) TTA 3 (0.00) Val GTG 308 (0.50)
CTG 447 (0.61) GTA 9 (0.01) CTA 20 (0.03) GTT 35 (0.06) CTT 45
(0.06) GTC 262 (0.43) CTC 190 (0.26) Trp TGG 107 (1.00) Met ATG 191
(1.00) Tyr TAT 10 (0.05) TAC 180 (0.95) Stop TGA/TAG/TAA
[0246] In other embodiments, the gene in the recombinant vector has
been codon-optimized with reference to a microalgal strain other
than a Prototheca strain. For example, methods of recoding genes
for expression in microalgae are described in U.S. Pat. No.
7,135,290. Additional information for codon optimization is
available, e.g., at the codon usage database of GenBank.
[0247] Other non-limiting examples of codon usage in Chlorella
pyrenoidosa, Dunaliella sauna, and Chlorella protothecoides are
shown in Tables 28, 29, and 30, respectively.
TABLE-US-00005 TABLE 28 Codon usage in Chlorella pyrenoidosa. Phe
UUU 39 (0.82) Ser UCU 50 (1.04) UUC 56 (1.18) UCC 60 (1.25) Leu UUA
10 (0.20) UCA 6 (0.96) UUG 46 (0.91) UCG 43 (0.89) Tyr UAU 15
(0.59) Cys UGU 46 (0.77) UAC 36 (1.41) UGC 73 (1.23) ter UAA 9
(0.00) ter UGA 43 (0.00) ter UAG 15 (0.00) Trp UGG 69 (1.00) Leu
CUU 49 (0.97) Pro CCU 80 (0.98) CUC 73 (1.45) CCC 88 (1.08) CUA 22
(0.44) CCA 93 (1.14) CUG 103 (2.04) CCG 65 (0.80) His CAU 50 (0.88)
Arg CGU 39 (0.76) CAC 3 (1.12) CGC 63 (1.23) Gln CAA 59 (0.84) CGA
46 (0.90) CAG 2 (1.16) CGG 47 (0.92) Ile AUU 24 (0.69) Thr ACU 32
(0.67) AUC 61 (1.76) ACC 76 (1.60) AUA 19 (0.55) ACA 41 (0.86) Met
AUG 42 (1.00) ACG 41 (0.86) Asn AAU 26 (0.75) Ser AGU 23 (0.48) AAC
3 (1.25) AGC 67 (1.39) Lys AAA 32 (0.54) Arg AGA 51 (1.00) AAG 86
(1.46) AGG 61 (1.19) Val GUU 36 (0.75) Ala GCU 57 (0.79) GUC 54
(1.13) GCC 97 (1.34) GUA 30 (0.63) GCA 89 (1.23) GUG 71 (1.49) GCG
47 (0.65) Asp GAU 60 (0.95) Gly GGU 35 (0.60) GAC 66 (1.05) GGC 78
(1.33) Glu GAA 41 (0.68) GGA 54 (0.92) GAG 80 (1.32) GGG 67
(1.15)
TABLE-US-00006 TABLE 29 Preferred codon usage in Dunaliella salina.
TTC (Phe) TAC (Tyr) TGC (Cys) TAA (Stop) TGG (Trp) CCC (Pro) CAC
(His) CGC (Arg) CTG (Leu) CAG (Gln) ATC (Ile) ACC (Thr) AAC (Asn)
AGC (Ser) ATG (Met) AAG (Lys) GCC (Ala) GAC (Asp) GGC (Gly) GTG
(Val) GAG (Glu)
TABLE-US-00007 TABLE 30 Preferred codon usage in Chlorella
protothecoides. TTC (Phe) TAC (Tyr) TGC (Cys) TGA (Stop) TGG (Trp)
CCC (Pro) CAC (His) CGC (Arg) CTG (Leu) CAG (Gln) ATC (Ile) ACC
(Thr) GAC (Asp) TCC (Ser) ATG (Met) AAG (Lys) GCC (Ala) AAC (Asn)
GGC (Gly) GTG (Val) GAG (Glu)
[0248] C. Inducible Expression
[0249] The present invention also provides for the use of an
inducible promoter to express a gene of interest. In particular,
the use of an inducible promoter to express a lipase gene permits
production of the lipase after growth of the microorganism when
conditions have been adjusted, if necessary, to enhance
transesterification, for example, after disruption of the cells,
reduction of the water content of the reaction mixture, and/or
addition sufficient alcohol to drive conversion of TAGs to fatty
acid esters.
[0250] Inducible promoters useful in the invention include those
that mediate transcription of an operably linked gene in response
to a stimulus, such as an exogenously provided small molecule (e.g,
glucose, as in SEQ ID NO:1), temperature (heat or cold), light,
etc. Suitable promoters can activate transcription of an
essentially silent gene or upregulate, preferably substantially,
transcription of an operably linked gene that is transcribed at a
low level. In the latter case, the level of transcription of the
lipase preferably does not significantly interfere with the growth
of the microorganism in which it is expressed.
[0251] Expression of transgenes in Chlorella can be performed
inducibly through promoters such as the promoter that drives the
Chlorella hexose transporter gene (SEQ ID NO:1). This promoter is
strongly activated by the presence of glucose in the culture
media.
[0252] D. Expression of Two or More Exogenous Genes
[0253] Further, a genetically engineered microorganism, such as a
microalgae, may comprise and express two or more exogenous genes,
such as, for example, a lipase and a lytic gene, e.g., one encoding
a polysaccharide-degrading enzyme. One or both genes can be
expressed using an inducible promoter, which allows the relative
timing of expression of these genes to be controlled to enhance the
lipid yield and conversion to fatty acid esters. Expression of the
two or more exogenous genes may be under control of the same
inducible promoter or under control of a different inducible
promoters. In the latter situation, expression of a first exogenous
gene can be induced for a first period of time (during which
expression of a second exogenous gene may or may not be induced)
and expression of a second exogenous gene can be induced for a
second period of time (during which expression of a first exogenous
gene may or may not be induced). Provided herein are vectors and
methods for engineering lipid-producing microbes to metabolize
sucrose, which is an advantageous trait because it allows the
engineered cells to convert sugar cane feedstocks into lipids.
[0254] Also provided herein are genetically engineered strains of
microbes (e.g., microalgae, oleaginous yeast, bacteria, or fungi)
that express two or more exogenous genes, such as, for example, a
fatty acyl-ACP thioesterase and a fatty acyl-CoA/aldehyde
reductase, the combined action of which yields an alcohol product.
Further provided are other combinations of exogenous genes,
including without limitation, a fatty acyl-ACP thioesterase and a
fatty acyl-CoA reductase to generate aldehydes. In addition, this
application provides for the combination of a fatty acyl-ACP
thioesterase, a fatty acyl-CoA reductase, and a fatty aldehyde
decarbonylase to generate alkanes. One or more of the exogenous
genes can be expressed using an inducible promoter.
[0255] Examples of further modifications suitable for use in the
present invention are include genetically engineering strains of
microalgae to express two or more exogenous genes, one encoding a
transporter of a fixed carbon source (such as sucrose) and a second
encoding a sucrose invertase enzyme. The resulting fermentable
organisms produce hydrocarbons at lower manufacturing cost than
what has been obtainable by previously known methods of biological
hydrocarbon production. Insertion of the two exogenous genes
described above can be combined with the disruption of
polysaccharide biosynthesis through directed and/or random
mutagenesis, which steers ever greater carbon flux into hydrocarbon
production. Individually and in combination, trophic conversion,
engineering to alter hydrocarbon production and treatment with
exogenous enzymes alter the hydrocarbon composition produced by a
microorganism. The alteration can be a change in the amount of
hydrocarbons produced, the amount of one or more hydrocarbon
species produced relative to other hydrocarbons, and/or the types
of hydrocarbon species produced in the microorganism. For example,
microalgae can be engineered to produce a higher amount and/or
percentage of TAGs.
[0256] E. Compartmentalized Expression
[0257] The present invention also provides for compartmentalized
expression of a gene of interest. In particular, it can be
advantageous, in particular embodiments, to target expression of
the lipase to one or more cellular compartments, where it is
sequestered from the majority of cellular lipids until initiation
of the transesterification reaction. Preferred organelles for
targeting are chloroplasts, mitochondria, and endoplasmic
reticulum.
[0258] (1) Expression in Chloroplasts
[0259] In one embodiment of the present invention, the expression
of a polypeptide in a microorganism is targeted to chloroplasts.
Methods for targeting expression of a heterologous gene to the
chloroplast are known and can be employed in the present invention.
Methods for targeting foreign gene products into chloroplasts are
described in Shrier et al., EMBO J. (1985) 4:25 32. See also Tomai
et al. Gen. Biol. Chem. (1988) 263:15104 15109 and U.S. Pat. No.
4,940,835 for the use of transit peptides for translocating nuclear
gene products into the chloroplast. Methods for directing the
transport of proteins to the chloroplast are also reviewed in
Kenauf TIBTECH (1987) 5:40 47. Chloroplast targeting sequences
endogenous to Chlorella are known, such as genes in the Chlorella
nuclear genome that encode proteins that are targeted to the
chloroplast; see for example GenBank Accession numbers AY646197 and
AF499684.
[0260] Wageningen UR-Plant Research International sells an
IMPACTVECTOR1.4 vector, which uses the secretion signal of the
Chrysanthemum morifolium small subunit protein to deliver a
heterologous protein into the chloroplast stroma (cytoplasmic)
environment, shuttling across a double membrane system. The protein
is fused to the first 11 amino acids of the mature rubisco protein
in order to allow proper processing of the signal peptide (Wong et
al., Plant Molecular Biology 20: 81-93 (1992)). The signal peptide
contains a natural intron from the RbcS gene.
[0261] In another approach, the chloroplast genome is genetically
engineered to express the heterologous protein. Stable
transformation of chloroplasts of Chlamydomonas reinhardtii (a
green alga) using bombardment of recipient cells with high-velocity
tungsten microprojectiles coated with foreign DNA has been
described. See, for example, Boynton et al., Science (1988) 240:
1534 1538; Blowers et al. Plant Cell (1989) 1:123 132 and Debuchy
et al., EMBO J. (1989) 8: 2803 2809. The transformation technique,
using tungsten microprojectiles, is described by Klein et al.,
Nature (London) (1987) 7:70 73. Other methods of chloroplast
transformation for both plants and microalgae are known. See for
example U.S. Pat. Nos. 5,693,507; 6,680,426; and Plant Physiol.
2002 May; 129(1):7-12; and Plant Biotechnol J. 2007 May;
5(3):402-12.
[0262] As described in U.S. Pat. No. 6,320,101 (issued Nov. 20,
2001 to Kaplan et al.; which is incorporated herein by reference),
cells can be chemically treated so as to reduce the number of
chloroplasts per cell to about one. Then, the heterologous nucleic
acid can be introduced into the cells via particle bombardment with
the aim of introducing at least one heterologous nucleic acid
molecule into the chloroplasts. The heterologous nucleic acid is
selected such that it is integratable into the chloroplast's genome
via homologous recombination which is readily effected by enzymes
inherent to the chloroplast. To this end, the heterologous nucleic
acid includes, in addition to a gene of interest, at least one
nucleic acid sequence that is derived from the chloroplast's
genome. In addition, the heterologous nucleic acid typically
includes a selectable marker. Further details relating to this
technique are found in U.S. Pat. Nos. 4,945,050 and 5,693,507 which
are incorporated herein by reference. A polypeptide can thus be
produced by the protein expression system of the chloroplast.
[0263] U.S. Pat. No. 7,135,620 (issued Nov. 14, 2006 to Daniell et
al.; incorporated herein by reference) describes chloroplast
expression vectors and related methods. Expression cassettes are
DNA constructs including a coding sequence and appropriate control
sequences to provide for proper expression of the coding sequence
in the chloroplast. Typical expression cassettes include the
following components: the 5' untranslated region from a
microorganism gene or chloroplast gene such as psbA which will
provide for transcription and translation of a DNA sequence
encoding a polypeptide of interest in the chloroplast; a DNA
sequence encoding a polypeptide of interest; and a translational
and transcriptional termination region, such as a 3' inverted
repeat region of a chloroplast gene that can stabilize RNA of
introduced genes, thereby enhancing foreign gene expression. The
cassette can optionally include an antibiotic resistance gene.
[0264] Typically, the expression cassette is flanked by convenient
restriction sites for insertion into an appropriate genome. The
expression cassette can be flanked by DNA sequences from
chloroplast DNA to facilitate stable integration of the expression
cassette into the chloroplast genome, particularly by homologous
recombination. Alternatively, the expression cassette may remain
unintegrated, in which case, the expression cassette typically
includes a chloroplast origin of replication, which is capable of
providing for replication of the heterologous DNA in the
chloroplast.
[0265] The expression cassette generally includes a promoter region
from a gene capable of expression in the chloroplast. The promoter
region may include promoters obtainable from chloroplast genes,
such as the psbA gene from spinach or pea, or the rbcL and atpB
promoter region from maize and Rrna promoters. Examples of
promoters are described in Hanley-Bowdoin and Chua, TIBS (1987)
12:67 70; Mullet et al., Plant Molec Biol. (1985) 4: 39 54;
Hanley-Bowdoin (1986) PhD. Dissertation, the Rockefeller
University; Krebbers et al., Nucleic Acids Res. (1982) 10: 4985
5002; Zurawaki et al., Nucleic Acids Res. (1981) 9:3251 3270; and
Zurawski et al., Proc. Nat'l Acad. Sci. U.S.A. (1982) 79: 7699
7703. Other promoters can be identified and the relative strength
of promoters so identified evaluated, by placing a promoter of
interest 5' to a promoterless marker gene and observing its
effectiveness relative to transcription obtained from, for example,
the promoter from the psbA gene, a relatively strong chloroplast
promoter. The efficiency of heterologus gene expression
additionally can be enhanced by any of a variety of techniques.
These include the use of multiple promoters inserted in tandem 5'
to the heterologous gente, for example a double psbA promoter, the
addition of enhancer sequences and the like.
[0266] Numerous promoters active in the Chlorella chloroplast can
be used for expression of exogenous genes in the Chlorella
chloroplast, such as those found in GenBank accession number
NC.sub.--001865 (Chlorella vulgaris chloroplast, complete
genome),
[0267] Where it is desired to provide for inducible expression of
the heterologous gene, an inducible promoter and/or a 5'
untranslated region containing sequences which provide for
regulation at the level of transcription and/or translation (at the
3' end) may be included in the expression cassette. For example,
the 5' untranslated region can be from a gene wherein expression is
regulatable by light. Similarly, 3' inverted repeat regions could
be used to stabilize RNA of heterologous genes. Inducible genes may
be identified by enhanced expression in response to a particular
stimulus of interest and low or absent expression in the absence of
the stimulus. For example, a light-inducible gene can be identified
where enhanced expression occurs during irradiation with light,
while substantially reduced expression or no expression occurs in
low or no light. Light regulated promoters from green microalgae
are known (see for example Mol Genet Genomics. 2005 December;
274(6):625-36).
[0268] The termination region which is employed will be primarily
one of convenience, since the termination region appears to be
relatively interchangeable among chloroplasts and bacteria. The
termination region may be native to the transcriptional initiation
region, may be native to the DNA sequence of interest, or may be
obtainable from another source. See, for example, Chen and Orozco,
Nucleic Acids Res. (1988) 16:8411.
[0269] The expression cassettes may be transformed into a plant
cell of interest by any of a number of methods. These methods
include, for example, biolistic methods (See, for example, Sanford,
Trends In Biotech. (1988) 6:299 302, U.S. Pat. No. 4,945,050;
electroporation (Fromm et al., Proc. Nat'l. Acad. Sci. (USA) (1985)
82:5824 5828); use of a laser beam, microinjection or any other
method capable of introducing DNA into a chloroplast.
[0270] Additional descriptions of chloroplast expression vectors
suitable for use in microorganisms such as microalgae are found in
U.S. Pat. Nos. 7,081,567 (issued Jul. 25, 2006 to Xue et al.);
6,680,426 (issued Jan. 20, 2004 to Daniell et al.); and 5,693,507
(issued Dec. 2, 1997 to Daniell et al.).
[0271] Proteins expressed in the nuclear genome of Chlorella can be
targeted to the chloroplast using chloroplast targeting signals.
Chloroplast targeting sequences endogenous to Chlorella are known,
such as genes in the Chlorella nuclear genome that encode proteins
that are targeted to the chloroplast; see for example GenBank
Accession numbers AY646197 and AF499684. Proteins can also be
expressed in the Chlorella chloroplast by insertion of genes
directly into the chloroplast genome. Chloroplast transformation
typically occurs through homologous recombination, and can be
performed if chloroplast genome sequences are known for creation of
targeting vectors (see for example the complete genome sequence of
a Chlorella chloroplast; Genbank accession number NC.sub.--001865).
See previous sections herein for details of chloroplast
transformation.
[0272] (2) Expression in Mitochondria
[0273] In another embodiment of the present invention, the
expression of a polypeptide in a microorganism is targeted to
mitochondria. Methods for targeting foreign gene products into
mitochnodria (Boutry et al. Nature (London) (1987) 328:340 342)
have been described, including in green microalgae (see for example
Mol Gen Genet. 1993 January; 236(2-3):235-44).
[0274] For example, an expression vector encoding a suitable
secretion signal can target a heterologus protein to the
mitochondrion. The IMPACTVECTOR1.5 vector, from Wageningen UR-Plant
Research International, uses the yeast CoxIV secretion signal,
which was shown to deliver proteins in the mitochondrial matrix.
The protein is fused to the first 4 amino acids of the yeast CoxIV
protein in order to allow proper processing of the signal peptide
(Kohler et al. Plant J 11: 613-621 (1997)). Other mitochondrial
targeting sequences are known, including those functional in green
microalgae. For example, see FEBS Lett. 1990 Jan. 29; 260(2):165-8;
and J Biol. Chem. 2002 Feb. 22; 277(8):6051-8.
[0275] Proteins expressed in the nuclear genome of Chlorella can be
targeted to the mitochondria using mitochondrial targeting signals.
See previous sections herein for details of mitochondrial protein
targeting and transformation.
[0276] (3) Expression in Endoplasmic Reticulum
[0277] In another embodiment of the present invention, the
expression of a polypeptide in a microorganism is targeted to the
endoplasmic reticulum. The inclusion of an appropriate retention or
sorting signal in an expression vector ensure that proteins are
retained in the endoplasmic reticulum (ER) and do not go downstream
into Golgi. For example, the IMPACTVECTOR1.3 vector, from
Wageningen UR--Plant Research International, includes the well
known KDEL retention or sorting signal. With this vector, ER
retention has a practical advantage in that it has been reported to
improve expression levels 5-fold or more. The main reason for this
appears to be that the ER contains lower concentrations and/or
different proteases responsible for post-translational degradation
of expressed proteins than are present in the cytoplasm. ER
retention signals functional in green microalgae are known. For
example, see Proc Natl Acad Sci USA. 2005 Apr. 26;
102(17):6225-30.
[0278] While the methods and materials of the invention allow for
the introduction of any exogenous gene into a microorganism, for
example Prototheca, genes relating to sucrose utilization and lipid
pathway modification are of particular interest, as discussed in
the following sections.
IV. SELECTABLE MARKERS
1. Sucrose Utilization
[0279] In embodiment, the recombinant Prototheca cell of the
invention further contains one or more exogenous sucrose
utilization genes. In various embodiments, the one or more genes
encode one or more proteins selected from the group consisting of a
fructokinase, a glucokinase, a hexokinase, a sucrose invertase, a
sucrose transporter. For example, expression of a sucrose
transporter and a sucrose invertase allows Prototheca to transport
sucrose into the cell from the culture media and hydrolyze sucrose
to yield glucose and fructose. Optionally, a fructokinase can be
expressed as well in instances where endogenous hexokinase activity
is insufficient for maximum phosphorylation of fructose. Examples
of suitable sucrose transporters are Genbank accession numbers
CAD91334, CAB92307, and CAA53390. Examples of suitable
fructokinases are Genbank accession numbers P26984, P26420 and
CAA43322.
[0280] In one embodiment, the present invention provides a
Prototheca host cell that secretes a sucrose invertase. Secretion
of a sucrose invertase obviates the need for expression of a
transporter that can transport sucrose into the cell. This is
because a secreted invertase catalyzes the conversion of a molecule
of sucrose into a molecule of glucose and a molecule of fructose,
both of which can be transported and utilized by microbes provided
by the invention. For example, expression of a sucrose invertase
(such as SEQ ID NO:3) with a secretion signal (such as that of SEQ
ID NO: 4 (from yeast), SEQ ID NO: 5 (from higher plants), SEQ ID
NO: 6 (eukaryotic consensus secretion signal), and SEQ ID NO: 7
(combination of signal sequence from higher plants and eukaryotic
consensus) generates invertase activity outside the cell.
Expression of such a protein, as enabled by the genetic engineering
methodology disclosed herein, allows cells already capable of
utilizing extracellular glucose as an energy source to utilize
sucrose as an extracellular energy source.
[0281] Prototheca species expressing an invertase in media
containing sucrose are a preferred microalgal species for the
production of oil. The expression and extracellular targeting of
this fully active protein allows the resulting host cells to grow
on sucrose, whereas their non-transformed counterparts cannot.
Thus, the present invention provides Prototheca recombinant cells
with a codon-optimized invertase gene, including but not limited to
the yeast invertase gene, integrated into their genome such that
the invertase gene is expressed as assessed by invertase activity
and sucrose hydrolysis. The present invention also provides
invertase genes useful as selectable markers in Prototheca
recombinant cells, as such cells are able to grow on sucrose, while
their non-transformed counterparts cannot; and methods for
selecting recombinant host cells using an invertase as a powerful,
selectable marker for algal molecular genetics.
[0282] The successful expression of a sucrose invertase in
Prototheca also illustrates another aspect of the present invention
in that it demonstrates that heterologous (recombinant) proteins
can be expressed in the algal cell and successfully transit outside
of the cell and into the culture medium in a fully active and
functional form. Thus, the present invention provides methods and
reagents for expressing a wide and diverse array of heterologous
proteins in microalgae and secreting them outside of the host cell.
Such proteins include, for example, industrial enzymes such as, for
example, lipases, proteases, cellulases, pectinases, amylases
(e.g., SEQ ID NO: 190-191), esterases, oxidoreductases,
transferases, lactases, isomerases, and invertases, as well as
therapeutic proteins such as, for example, growth factors,
cytokines, full length antibodies comprising two light and two
heavy chains, Fabs, scFvs (single chain variable fragment),
camellid-type antibodies, antibody fragments, antibody
fragment-fusions, antibody-receptor fusions, insulin, interferons,
and insulin-like growth factors.
[0283] The successful expression of a sucrose invertase in
Prototheca also illustrates another aspect of the present invention
in that it provides methods and reagents for the use of fungal
transit peptides in algae to direct secretion of proteins in
Prototheca; and methods and reagents for determining if a peptide
can function, and the ability of it to function, as a transit
peptide in Prototheca cells. The methods and reagents of the
invention can be used as a tool and platform to identify other
transit peptides that can successfully traffic proteins outside of
a cell, and that the yeast invertase has great utility in these
methods. As demonstrated in this example, removal of the endogenous
yeast invertase transit peptide and its replacement by other
transit peptides, either endogenous to the host algae or from other
sources (eukaryotic, prokaryotic and viral), can identify whether
any peptide of interest can function as a transit peptide in
guiding protein egress from the cell.
[0284] Examples of suitable sucrose invertases include those
identified by Genbank accession numbers CAB95010, NP.sub.--012104
and CAA06839. Non-limiting examples of suitable invertases are
listed below in Table 3 Amino acid sequences for each listed
invertase are included in the Sequence Listing below. In some
cases, the exogenous sucrose utilization gene suitable for use in
the methods and vectors of the invention encodes a sucrose
invertase that has at least 40, 50, 60, 75, or 90% or higher amino
acid identity with a sucrose invertase selected from Table 3.
TABLE-US-00008 TABLE 3 Sucrose invertases. GenBank Description
Organism Accession No. SEQ ID NO: Invertase Chicorium intybus
Y11124 SEQ ID NO: 20 Invertase Schizosaccharomyces pombe AB011433
SEQ ID NO: 21 beta-fructofuranosidase Pichia anomala X80640 SEQ ID
NO: 22 (invertase) Invertase Debaryomyces occidentalis X17604 SEQ
ID NO: 23 Invertase Oryza sativa AF019113 SEQ ID NO: 24 Invertase
Allium cepa AJ006067 SEQ ID NO: 25 Invertase Beta vulgaris subsp.
Vulgaris AJ278531 SEQ ID NO: 26 beta-fructofuranosidase
Bifidobacterium breve UCC2003 AAT28190 SEQ ID NO: 27 (invertase)
Invertase Saccharomyces cerevisiae NP_012104 SEQ ID NO: 8
(nucleotide) SEQ ID NO: 28 (amino acid) Invertase A Zymomonas
mobilis AAO38865 SEQ ID NO: 29 Invertase Arabadopsis thaliana
NP_566464 SEQ ID NO: 188
[0285] The secretion of an invertase to the culture medium by
Prototheca enable the cells to grow as well on waste molasses from
sugar cane processing as they do on pure reagent-grade glucose; the
use of this low-value waste product of sugar cane processing can
provide significant cost savings in the production of lipids and
other oils. Thus, the present invention provides a microbial
culture containing a population of Prototheca microorganisms, and a
culture medium comprising (i) sucrose and (ii) a sucrose invertase
enzyme. In various embodiments the sucrose in the culture comes
from sorghum, sugar beet, sugar cane, molasses, or depolymerized
cellulosic material (which may optionally contain lignin). In
another aspect, the methods and reagents of the invention
significantly increase the number and type of feedstocks that can
be utilized by recombinant Prototheca. While the microbes
exemplified here are altered such that they can utilize sucrose,
the methods and reagents of the invention can be applied so that
feedstocks such as cellulosics are utilizable by an engineered host
microbe of the invention with the ability to secrete cellulases,
pectinases, isomerases, or the like, such that the breakdown
products of the enzymatic reactions are no longer just simply
tolerated but rather utilized as a carbon source by the host. An
example of this is described below and in the Examples of microbes
engineered to express a secretable .alpha.-galactosidase,
conferring the ability to hydrolyze .alpha.-galactosyl bonds in
oligosaccharides such as those contained in raffinose and stachyose
which are two oligosaccharides found in agricultural waste
streams.
2. Alpha-Galactosidase Expression
[0286] While the expression of a sucrose invertase, as described
above, confers the ability for Prototheca cells to more efficiently
utilize sucrose as a carbon source (via the enzyme hydrolyzing the
.alpha.-linkage between fructose and glucose molecules in the
disaccharide sucrose), the expression of other enzymes that
hydrolyze other types of .alpha.-linkages in oligosaccharides can
confer the ability for Prototheca cells to utilize other carbon
sources. The expression of these enzymes (and the resulting ability
to utilize carbon sources that Prototheca and other microalgal
cells ordinarily would not be able to) can be used as a selectable
marker for these transgenic Prototheca cells by allowing for the
selection of positive clones that are able to grow on these carbon
sources.
[0287] In an embodiment, the recombinant Prototheca cell of the
invention further contains one or more exogenous genes encoding
polysaccharide-degrading enzymes. In various embodiments, the one
or more genes encoding a polysaccharide-degrading enzyme is a gene
encoding a secreted .alpha.-galactosidase. The expression of an
exogenous secreted .alpha.-galactosidase in a Prototheca cell
confers the ability of such transformed strains to grow on sugars
(carbon sources) containing D-galactosyl linkages, such as
.alpha.-linkages between galactose and glucose monosaccharide
units. Prototheca strains expressing an exogenous, secreted
.alpha.-galactosidase will be able to utilize disaccharides such as
melibiose (disaccharide composed of
.alpha.-D-galactose-glucose).
[0288] Sugars such as raffinose (a trisaccharide comprised of
.alpha.-linked galactose-glucose-fructose) and stachyose (a
tetrasaccharide composed to two .alpha.-linked D-galactose units,
followed by .alpha.-linked glucose and fructose) are present in
significant proportions in agricultural waste streams such as beet
pulp (raffinose) and soybean meal (stachyose). Such agricultural
residues represent a significant untapped carbon source for the
conversion into oil by microbes (including Prototheca) capable of
utilizing them.
[0289] Prototheca strains are unable to utilize oligosaccharides
such as raffinose and stachyose in any significant quantity or at
all. In the case of raffinose and stachyose, although transgenic
strains expressing a sucrose invertase (as described above) have
the ability to hydrolyze the .alpha.-linkage between fructose and
glucose in .alpha.-galactosyl derivatives of sucrose, but the
remainder of the oligosaccharide remains unutilized, as sucrose
invertase will not cleave the remaining .alpha.-linkages in such
sugars and the resulting disaccharides are not utilizable. In
another embodiment, the recombinant Prototheca cell of the
invention comprises both an exogenous gene encoding a sucrose
invertase and an exogenous gene encoding an .alpha.-galactosidase.
Thus, strains expressing both a sucrose invertase and an
.alpha.-galactosidase will be capable of fully hydrolyzing
oligosaccharides such as raffinose and stachyose, enabling the
consumption of the component monomers. In addition,
.alpha.-galactosidase encoding genes may be used as a selectable
marker for transformation. Clones containing the exogenous
.alpha.-galactosidase gene will have the ability to grow on
melibiose. Examples of suitable .alpha.-galactosidase genes for use
in Prototheca strains include the MEL1 gene from Saccharomyces
carlbergensis, the AglC gene from Aspergilus niger. Interestingly,
not all .alpha.-galactosidase genes are functional in Prototheca
species, even if the genes are optimized according to the preferred
codon usage in Prototheca strains. The Examples below demonstrates
the ability of transgenic Prototheca cells to grow on melibiose
when transformed with codon-optimized MEL1 gene from S.
carlbergensis and the AglC gene from A. niger, but not an
.alpha.-galactosidase encoding gene from the higher plant,
Cyamopsis tetragonobola (Guar bean).
3. Thiamine Auxotrophy Complementation
[0290] Prototheca strains including Prototheca moriformis are known
to be thiamine auxotrophic (See, for example, Ciferri, O. (1956)
Nature, v.178, pp. 1475-1476), meaning that these strains require
thiamine in the nutrient media for growth Thiamine auxotrophy can
be the result of mutations or lack of expression of enzymes in the
thiamine biosynthetic pathway. Complemented transgenic strains
expressing the missing enzyme(s) in the thiamine biosynthetic
pathway can then be grown without added thiamine, thus reducing the
cost of the nutrient media as well as rendering the resulting
microalgal biomass more desirable from an animal nutrition
perspective. Complementation with a thiamine biosynthetic pathway
enzyme can also be used as a selectable marker as the transgenic
gene confers the ability to grow on plates/media that does not
contain thiamine.
[0291] In an embodiment, the recombinant Prototheca cell of the
invention further contains one or more exogenous genes encoding
thiamine biosynthetic pathway enzyme. In another embodiment, the
recombinant Prototheca cell of the invention comprises an exogenous
gene encoding hydroxymethylpyrimidine phosphate synthases (e.g.,
SEQ ID NO: 192) from algal, plant or cyanobacterial sources. In
still other embodiments, the hydroxymethylpyrimidine phosphate
synthase is encoded by a THIC gene. In still other embodiments, the
THIC gene is the Coccomyxa C-169 THIC, Arabidopsis thaliana THIC,
the Synechocystis sp. PCC 6803 THIC, or the Salmonella enterica
subsp. enterica serovar Typhimurium str. THIC (SEQ ID NO: 193). The
Examples below details the engineering of Prototheca moriformis
UTEX 1435 with restored thiamine prototrophy.
4. Other Selectable Markers
[0292] Any of a wide variety of selectable markers can be employed
in a transgene construct useful for transforming microorganisms,
such as Chlorella. Examples of suitable selectable markers include
the nitrate reductase gene, the hygromycin phosphotransferase gene
(HPT), the neomycin phosphotransferase gene, and the ble gene,
which confers resistance to phleomycin. Methods of determining
sensitivity of microalgae to antibiotics are well known. For
example, Mol Gen Genet. 1996 Oct. 16; 252(5):572-9.
[0293] More specifically, Dawson et al. (1997), Current
Microbiology 35:356-362 (incorporated by reference herein in its
entirety), described the use of the nitrate reductase (NR) gene
from Chlorella vulgaris as a selectable marker for NR-deficient
Chlorella sorokiniana mutants. Kim et al. (2002), Mar. Biotechnol.
4:63-73 (incorporated by reference herein in its entirety),
disclosed the use of the HPT gene as a selectable marker for
transforming Chorella ellipsoidea. Huang et al. (2007), Appl.
Microbiol. Biotechnol. 72:197-205 (incorporated by reference herein
in its entirety), reported on the use of Sh ble as a selectable
marker for Chlorella sp. DT.
V. LIPID PATHWAY ENGINEERING
[0294] In addition to altering the ability of microorganisms (e.g.,
microalgae, oleaginous yeast, fungi, or bacteria), such as
Prototheca to utilize feedstocks such as sucrose-containing
feedstocks, the present invention also provides recombinant
microorganisms (e.g., Prototheca) that have been modified to alter
the properties and/or proportions of lipids produced. The pathway
can further, or alternatively, be modified to alter the properties
and/or proportions of various lipid molecules produced through
enzymatic processing of lipids and intermediates in the fatty acid
pathway. In various embodiments, the recombinant microorganisms
(e.g., Prototheca cells) of the invention have, relative to their
untransformed counterparts, optimized lipid yield per unit volume
and/or per unit time, carbon chain length (e.g., for renewable
diesel production or for industrial chemicals applications
requiring lipid feedstock), reduced number of double or triple
bonds, optionally to zero, and increasing the hydrogen:carbon ratio
of a particular species of lipid or of a population of distinct
lipid. In addition, microorganisms that produce desirable
hydrocarbons can be engineered to produce such components in higher
quantities, or with greater specificity.
[0295] In the case of microalgae, some wild-type cells already have
good growth characteristics but do not produce the desired types or
quantities of lipids. Examples include, without limitation,
Pyrobotrys, Phormidium, Agmenellum, Carteria, Lepocinclis,
Pyrobotrys, Nitzschia, Lepocinclis, Anabaena, Euglena, Spirogyra,
Chlorococcum, Tetraedron, Oscillatoria, Phagus, and Chlorogonium,
which have the desirable growth characteristic of growing in
municipal sewage or wastewater. Such cells, as well as species of
Chlorella, Prototheca and other microbes, can be engineered to have
improved lipid production characteristics. Desired characteristics
include optimizing lipid yield per unit volume and/or per unit
time, carbon chain length (e.g., for biodiesel production or for
industrial applications requiring hydrocarbon feedstock), reducing
the number of double or triple bonds, optionally to zero, removing
or eliminating rings and cyclic structures, and increasing the
hydrogen:carbon ratio of a particular species of lipid or of a
population of distinct lipid. In addition, microalgae that produce
appropriate hydrocarbons can also be engineered to have even more
desirable hydrocarbon outputs. Examples of such microalgae include
species of the genus Chlorella and the genus Prototheca.
[0296] In particular embodiments, one or more key enzymes that
control branch points in metabolism to fatty acid synthesis have
been up-regulated or down-regulated to improve lipid production.
Up-regulation can be achieved, for example, by transforming cells
with expression constructs in which a gene encoding the enzyme of
interest is expressed, e.g., using a strong promoter and/or
enhancer elements that increase transcription. Such constructs can
include a selectable marker such that the transformants can be
subjected to selection, which can result in amplification of the
construct and an increase in the expression level of the encoded
enzyme. Examples of enzymes suitable for up-regulation according to
the methods of the invention include pyruvate dehydrogenase, which
plays a role in converting pyruvate to acetyl-CoA (examples, some
from microalgae, include Genbank accession numbers NP.sub.--415392;
AAA53047; Q1XDM1; and CAF05587). Up-regulation of pyruvate
dehydrogenase can increase production of acetyl-CoA, and thereby
increase fatty acid synthesis. Acetyl-CoA carboxylase catalyzes the
initial step in fatty acid synthesis. Accordingly, this enzyme can
be up-regulated to increase production of fatty acids (examples,
some from microalgae, include Genbank accession numbers BAA94752;
AAA75528; AAA81471; YP.sub.--537052; YP.sub.--536879;
NP.sub.--045833; and BAA57908). Fatty acid production can also be
increased by up-regulation of acyl carrier protein (ACP), which
carries the growing acyl chains during fatty acid synthesis
(examples, some from microalgae, include Genbank accession numbers
A0T0F8; P51280; NP.sub.--849041; YP.sub.--874433).
Glycerol-3-phosphate acyltransferase catalyzes the rate-limiting
step of fatty acid synthesis. Up-regulation of this enzyme can
increase fatty acid production (examples, some from microalgae,
include Genbank accession numbers AAA74319; AAA33122; AAA37647;
P44857; and ABO94442).
[0297] Up- and/or down-regulation of genes can be applied to global
regulators controlling the expression of the genes of the fatty
acid biosynthetic pathways. Accordingly, one or more global
regulators of fatty acid synthesis can be up- or down-regulated, as
appropriate, to inhibit or enhance, respectively, the expression of
a plurality of fatty acid synthetic genes and, ultimately, to
increase lipid production. Examples include sterol regulatory
element binding proteins (SREBPs), such as SREBP-1a and SREBP-1c
(for examples see Genbank accession numbers NP.sub.--035610 and
Q9WTN3).
[0298] The present invention also provides recombinant
microorganisms (e.g., Prototheca cells) that have been modified to
contain one or more exogenous genes encoding lipid modification
enzymes such as, for example, fatty acyl-ACP thioesterases (e.g.,
C. callophylla (SEQ ID NO: 145 and SEQ ID NO: 146; see also Table
4), fatty acyl-CoA/aldehyde reductases (see Table 6), fatty
acyl-CoA reductases (see Table 7), fatty aldehyde decarbonylase
(see Table 8), fatty aldehyde reductases, desaturases (such as
stearoyl-ACP desaturases (e.g., a codon optimized R. communis SAD,
SEQ ID NO: 147 and SEQ ID NO: 148) and fatty acyl desaturases and
squalene synthases (see GenBank Accession number AF205791). In some
embodiments, genes encoding a fatty acyl-ACP thioesterase and a
naturally co-expressed acyl carrier protein are transformed into a
Prototheca cell, optionally with one or more genes encoding other
lipid modification enzymes. In other embodiments, the ACP and the
fatty acyl-ACP thioesterase may have an affinity for one another
that imparts an advantage when the two are used together in the
microbes and methods of the present invention, irrespective of
whether they are or are not naturally co-expressed in a particular
tissue or organism. Thus, the present invention contemplates both
naturally co-expressed pairs of these enzymes as well as those that
share an affinity for interacting with one another to facilitate
cleavage of a length-specific carbon chain from the ACP.
[0299] In still other embodiments, an exogenous gene encoding a
desaturase is transformed into the microorganism (e.g., a
Prototheca cell) in conjunction with one or more genes encoding
other lipid modification enzymes to provide modifications with
respect to lipid saturation. In other embodiments, an endogenous
desaturase gene is overexpressed (e.g., through the introduction of
additonal copies off the gene) in the microorganism (e.g., a
Prototheca cell). Stearoyl-ACP desaturase (see, e.g., GenBank
Accession numbers AAF15308; ABM45911; and AAY86086), for example,
catalyzes the conversion of stearoyl-ACP to oleoyl-ACP.
Up-regulation of this gene can increase the proportion of
monounsaturated fatty acids produced by a cell; whereas
down-regulation can reduce the proportion of monounsaturates. For
illustrative purposes, stearoyl-ACP desaturases (SAD) are
responsible for the synthesis of C18:1 fatty acids from C18:0
precursors. Another family of desaturases are the fatty acyl
desaturases (FAD), including delta 12 fatty acid desaturases
(.DELTA.12 FAD). These desaturases also provide modifications with
respect to lipid saturation. For illustrative purposes, delta 12
fatty acid desaturases are responsible for the synthesis of C18:2
fatty acids from C18:1 precursors. Similarly, the expression of one
or more glycerolipid desaturases can be controlled to alter the
ratio of unsaturated to saturated fatty acids such as .omega.-6
fatty acid desaturase, .omega.-3 fatty acid desaturase, or
.omega.-6-oleate desaturase. In some embodiments, the desaturase
can be selected with reference to a desired carbon chain length,
such that the desaturase is capable of making location specific
modifications within a specified carbon-length substrate, or
substrates having a carbon-length within a specified range. In
another embodiment, if the desired fatty acid profile is an
increase in monounsaturates (such as C16:1 and/or C18:1)
overexpression of a SAD or expression of a heterologous SAD can be
coupled with the silencing or inactivation (e.g., through mutation,
RNAi, knockout of an endogenous desaturase gene, etc.) of a fatty
acyl desaturase (FAD).
[0300] In other embodiments, the microorganism (e.g., Prototheca
cell) has been modified to have a mutated endogenous desaturase
gene, wherein the mutation renders the gene or desaturase enzyme
inactive. In some cases, the mutated endogenous desaturase gene is
a fatty acid desaturase (FAD). In other cases, the mutated
endogenous desaturase gene is a stearoyl Acyl carrier protein
desaturase (SAD). Example 11 below describes the targeted ablation
or knockout of stearoyl-ACP desaturases and delta 12 fatty acid
desaturases.
[0301] In some cases, it may be advantageous to pair one or more of
the genetic engineering techniques in order to achieve a trangenic
cell that produces the desired lipid profile. In one embodiment, a
microorganism (e.g., a Prototheca cell) comprises a mutated
endogenous desaturase gene and one or more exogenous gene. In
non-limiting examples, a Prototheca cell with a mutated endogenous
desaturase gene can also express an exogenous fatty acyl-ACP
thioesterase gene and/or a sucrose invertase gene. Example 11 below
describes a transgenic Prototheca cell containing a targeted
ablation or knockout of an endogenous SAD and also expresses a
Cinnamomum camphora C14-preferring thioesterase and a sucrose
invertase. In this case, the transgenic Prototheca cell produces a
lipid profile that closely approximates the lipid profile found in
tallow. Tallow is typically derived from rendered beef or mutton
fat, is solid at room temperature and is utilized in a variety of
applications in the food, cosmetics, and chemicals industries. The
fatty acid profile of tallow is: 4% C14:0; 26% C16:0; 3% C16:1; 14%
C18:0; 41% C18:1; 3% C18:2; and 1% C18:3. As is shown in Example 11
below, clones of transgenic Prototheca cells with a targeted
ablation or knockout of an endogenous SAD and expressing a C.
camphora C14-preferring thioesterase have lipid profiles of: less
than 1% C12 and shorter carbon chain length fatty acids; 2.74% to
6.13% C14:0; 23.07% to 25.69% C16:0; 7.02% to 11.08% C18:0; 42.03%
to 51.21% C18:1; and 9.37% to 13.45% C18:2 (expressed in area
percent). In some cases, the transgenic Prototheca cells have lipid
profiles of: 3-5% C14:0; 25-27% C16:0; 10-15% C18:0; and 40-45%
C18:1.
[0302] Thus, in particular embodiments, microbes of the present
invention are genetically engineered to express one or more
exogenous genes selected from an acyl-ACP thioesterase, an
acyl-CoA/aldehyde reductase, a fatty acyl-CoA reductase, a fatty
aldehyde reductase, a fatty aldehyde decarbonylase, or a naturally
co-expressed acyl carrier protein. Suitable expression methods are
described above with respect to the expression of a lipase gene,
including, among other methods, inducible expression and
compartmentalized expression. A fatty acyl-ACP thioesterase cleaves
a fatty acid from an acyl carrier protein (ACP) during lipid
synthesis. Through further enzymatic processing, the cleaved fatty
acid is then combined with a coenzyme to yield an acyl-CoA
molecule. This acyl-CoA is the substrate for the enzymatic activity
of a fatty acyl-CoA reductase to yield an aldehyde, as well as for
a fatty acyl-CoA/aldehyde reductase to yield an alcohol. The
aldehyde produced by the action of the fatty acyl-CoA reductase
identified above is the substrate for further enzymatic activity by
either a fatty aldehyde reductase to yield an alcohol, or a fatty
aldehyde decarbonylase to yield an alkane or alkene.
[0303] In some embodiments, fatty acids, glycerolipids, or the
corresponding primary alcohols, aldehydes, alkanes or alkenes,
generated by the methods described herein, contain 8, 10, 12, or 14
carbon atoms. Preferred fatty acids for the production of diesel,
biodiesel, renewable diesel, or jet fuel, or the corresponding
primary alcohols, aldehydes, alkanes and alkenes, for industrial
applications contain 8 to 14 carbon atoms. In certain embodiments,
the above fatty acids, as well as the other corresponding
hydrocarbon molecules, are saturated (with no carbon-carbon double
or triple bonds); mono unsaturated (single double bond); poly
unsturated (two or more double bonds); are linear (not cyclic) or
branched. For fuel production, greater saturation is preferred.
[0304] The enzymes described directly above have a preferential
specificity for hydrolysis of a substrate containing a specific
number of carbon atoms. For example, a fatty acyl-ACP thioesterase
may have a preference for cleaving a fatty acid having 12 carbon
atoms from the ACP. In some embodiments, the ACP and the
length-specific thioesterase may have an affinity for one another
that makes them particularly useful as a combination (e.g., the
exogenous ACP and thioesterase genes may be naturally co-expressed
in a particular tissue or organism from which they are derived).
Therefore, in various embodiments, the recombinant Prototheca cell
of the invention can contain an exogenous gene that encodes a
protein with specificity for catalyzing an enzymatic activity
(e.g., cleavage of a fatty acid from an ACP, reduction of an
acyl-CoA to an aldehyde or an alcohol, or conversion of an aldehyde
to an alkane) with regard to the number of carbon atoms contained
in the substrate. The enzymatic specificity can, in various
embodiments, be for a substrate having from 8 to 34 carbon atoms,
preferably from 8 to 18 carbon atoms, and more preferably from 8 to
14 carbon atoms. A preferred specificity is for a substrate having
fewer, i.e., 12, rather than more, i.e., 18, carbon atoms.
[0305] Other fatty acyl-ACP thioesterases suitable for use with the
microbes and methods of the invention include, without limitation,
those listed in Table 4.
TABLE-US-00009 TABLE 4 Fatty acyl-ACP thioesterases and GenBank
accession numbers. Umbellularia californica fatty acyl-ACP
thioesterase (GenBank #AAC49001) (SEQ ID NO: 203) Cinnamomum
camphora fatty acyl-ACP thioesterase (GenBank #Q39473) Umbellularia
californica fatty acyl-ACP thioesterase (GenBank #Q41635) Myristica
fragrans fatty acyl-ACP thioesterase (GenBank #AAB71729) (SEQ ID
NO: 224) Myristica fragrans fatty acyl-ACP thioesterase (GenBank
#AAB71730) (SEQ ID NO: 222) Elaeis guineensis fatty acyl-ACP
thioesterase (GenBank #ABD83939) (SEQ ID NO: 204) Elaeis guineensis
fatty acyl-ACP thioesterase (GenBank #AAD42220) Populus tomentosa
fatty acyl-ACP thioesterase (GenBank #ABC47311) (SEQ ID NO: 207)
Arabidopsis thaliana fatty acyl-ACP thioesterase (GenBank
#NP_172327) (SEQ ID NO: 208) Arabidopsis thaliana fatty acyl-ACP
thioesterase (GenBank #CAA85387) (SEQ ID NO: 209) Arabidopsis
thaliana fatty acyl-ACP thioesterase (GenBank #CAA85388) (SEQ ID
NO: 210) Gossypium hirsutum fatty acyl-ACP thioesterase (GenBank
#Q9SQI3) (SEQ ID NO: 211) Cuphea lanceolata fatty acyl-ACP
thioesterase (GenBank #CAA54060) (SEQ ID NO: 212) Cuphea hookeriana
fatty acyl-ACP thioesterase (GenBank #AAC72882) (SEQ ID NO: 202)
Cuphea calophytta subsp. mesostemon fatty acyl-ACP thioesterase
(GenBank #ABB71581) (SEQ ID NO: 213) Cuphea lanceolata fatty
acyl-ACP thioesterase (GenBank #CAC19933) Elaeis guineensis fatty
acyl-ACP thioesterase (GenBank #AAL15645) (SEQ ID NO: 206) Cuphea
hookeriana fatty acyl-ACP thioesterase (GenBank #Q39513) Gossypium
hirsutum fatty acyl-ACP thioesterase (GenBank #AAD01982) (SEQ ID
NO: 214) Vitis vinifera fatty acyl-ACP thioesterase (GenBank
#CAN81819) (SEQ ID NO: 215) Garcinia mangostana fatty acyl-ACP
thioesterase (GenBank #AAB51525) Brassica juncea fatty acyl-ACP
thioesterase (GenBank #ABI18986) (SEQ ID NO: 216) Madhuca
longifolia fatty acyl-ACP thioesterase (GenBank #AAX51637) (SEQ ID
NO: 217) Brassica napus fatty acyl-ACP thioesterase (GenBank
#ABH11710) Oryza sativa (indica cultivar-group) fatty acyl-ACP
thioesterase (GenBank #EAY86877) (SEQ ID NO: 218) Oryza sativa
(japonica cultivar-group) fatty acyl-ACP thioesterase (GenBank
#NP_001068400) (SEQ ID NO: 219) Oryza sativa (indica
cultivar-group) fatty acyl-ACP thioesterase (GenBank #EAY99617)
(SEQ ID NO: 220) Cuphea hookeriana fatty acyl-ACP thioesterase
(GenBank #AAC49269) Ulmus Americana fatty acyl-ACP thioesterase
(GenBank #AAB71731) Cuphea lanceolata fatty acyl-ACP thioesterase
(GenBank #CAB60830) (SEQ ID NO: 221) Cuphea palustris fatty
acyl-ACP thioesterase (GenBank #AAC49180) Iris germanica fatty
acyl-ACP thioesterase (GenBank #AAG43858) Iris germanica fatty
acyl-ACP thioesterase (GenBank #AAG43858.1) Cuphea palustris fatty
acyl-ACP thioesterase (GenBank #AAC49179) Myristica fragrans fatty
acyl-ACP thioesterase (GenBank# AAB71729) Myristica fragrans fatty
acyl-ACP thioesterase (GenBank# AAB717291.1) Cuphea hookeriana
fatty acyl-ACP thioesterase (GenBank #U39834) (SEQ ID NO: 197)
Umbelluaria californica fatty acyl-ACP thioesterase (GenBank #
M94159) (SEQ ID NO: 285) Cinnamomum camphora fatty acyl-ACP
thioesterase (GenBank #U31813) (SEQ ID NO: 223) Cuphea wrightii
fatty acyl-ACOP thioesterase (GenBank #U56103) (SEQ ID NO: 183)
Ricinus communis fatty acyl-ACP thioesterase (GenBank #ABS30422)
(SEQ ID NO: 198)
[0306] The Examples below describe the successful targeting and
expression of heterologous fatty acyl-ACP thioesterases from Cuphea
hookeriana, Umbellularia californica, Cinnamomun camphora, Cuphea
palustris, Cuphea lanceolata, Iris germanica, Myristica fragrans
and Ulmus americana in Prototheca species. Additionally,
alterations in fatty acid profiles were confirmed in the host cells
expression these heterologous fatty acyl-ACP thioesterases. These
results were quite unexpected given the lack of sequence identity
between algal and higher plant thioesterases in general, and
between Prototheca moriformis fatty acyl-ACP thioesterase and the
above listed heterologous fatty acyl-ACP thioesterases. As shown in
the Examples, the expression of these heterologous thioesterases in
Prototheca generates a transgenic microalgae that is able to
produce oil/lipids with truly unique fatty acid profiles that are
currently not available from commercial seed crops, even through
the blending of several seed crop oils. Table 5 shows the fatty
acid profiles of common commercial seed oils. All commercial seed
oil data below were compiled from the US Pharmacopeias Food and
Chemicals Codes, 7.sup.th Ed. 2010-2011. Tallow data is from the
National Research Council: Fat Content and Composition of Animal
Products (1976).
TABLE-US-00010 TABLE 5 Lipid profiles of commercial seed oils (in
percentages). C18:0- C18:1- C8:0 C10:0 C12:0 C14:0 C16:0 C18:0
C18:1 diOH OH C18:2 C18:3 .alpha. R. communis 0 0 0 0 0.9-1.6
1.0-1.8 3.7-6.7 0.4-1.3 83.6-89.0 0 0.2-0.6 (Castor oil) C.
nucifera 5.0-9.0 4.0-8.0 44-52 15-21 8.0-11.0 1.0-4.0 5.0-8.0 0 0
.sup. 0-2.5 0 (Coconut oil) Z. mays 0 0 0 <1.0 8.0-19.0 0.5-4.0
19-50 0 0 38-65 <2.0 (Corn oil) G. barbadense 0 0 <0.1
0.5-2.0 17-29 1.0-4.0 13-44 0 0 40-63 0.1-2.1 (Cottonseed oil) B.
rapa, 0 0 <0.1 <0.2 <6.0 <2.5 >50 0 0 <40 <14
B. napus, B. juncea (Canola) O. europea 0 0 0 <0.1 6.5-20.0
0.5-5.0 56-85 0 0 3.5-20.0 <1.2 (Olive) A. hypogaea 0 0 <0.1
<0.2 7.0-16.0 1.3-6.5 35-72 0 0 13.0-43.sup. <0.6 (Peanut) E.
guineensis 3.0-5.0 2.5-6.0 40-52 14.0-18.0 7.0-10.0 1.0-3.0
11.0-19.0 0 0 0.5-4.0 0 (Palm kernel) E. guineensis 0 0 0 0.5-5.9
32.0-47.0 2.0-8.0 34-44 0 0 7.2-12.0 0 (Palm) C. tinctorus 0 0
<0.1 <0.1 2.0-10.0 1.0-10.0 7.0-16.0 0 0 72-81 <1.5
(Safflower) H. annus 0 0 <0.1 <0.5 3.0-10.0 1.0-10.0 14-65 0
0 20-75 <0.5 (Sunflower) G. max 0 0 <0.1 <0.5 7.0-12.0
2.0-5.5 19-30 0 0 48-65 5.0-10.0 (Soybean) L. usitatissimum 0 0
<0.1 <0.5 2.0-9.0 2.0-5.0 8.0-60 0 0 40-80 <5.0
(Solin-Flax) B. parkii 0 0 0 0 3.8-4.1 41.2-56.8 34.0-46.9 0 0
3.7-6.5 0 (Sheanut) Cocoa Butter 0-1 0-1 0-4 22-30 24-37 29-38 0-3
Tallow 3-4 23-28 14-23 36-43 1-4 <1 Lard 1-2 22-26 13-18 39-45
8-15 0.5-1.5
[0307] As an example, none of these common seed oils contain high
amounts of C8 or C10 fatty acids, with coconut oil and palm kernel
oil being the largest sources, but both a ratio of 1:1 (C8:C10
fatty acids). As shown in the Examples, Prototheca transformed with
Cuphea palustris C:8 preferring thioesterase was able to achieve
not only a C8 fatty acid levels of over 12%, but also, the ratio of
C8:C10 fatty acids were about a 5:1. Changes in fatty acid levels
are useful for producing oils containing a tailored fatty acid
profile for a variety of commercial applications. Additionally,
changes of ratios between different fatty acid chain lengths is
something has not been available commercially in oils that have not
been through further costly chemical processes (such as
esterification, distillation, fractionation, and
re-esterification). As another example, palm oil is the highest
C16:0 fatty acid (32-47%) containing oils, but palm oil has very
little C14:0 fatty acids. Prototheca containing the U. americana
thioesterase achieved about 33-38% C16:0 fatty acids and about a
10-16% C14:0 fatty acids (about a 2:1 C16:0 to C14:0 ratio). This
fatty acid profile is unachievable through blending of existing
oils at a commercial level because the seed oils that are high in
16:0 fatty acids usually do not contain much 14:0 fatty acids.
[0308] The Examples below also describe, for the first time, the
successful targeting and expression of at least two fatty acyl-ACP
thioesterases in one clone. The alterations in the fatty acid
profiles were confirmed in these clones and depending on which two
thioesterases were co-expressed in one clone, the fatty acid
profiles were impacted in different ways. As an example, from Table
5 above, both coconut oil and palm kernel oil have C12:C14 ratios
of roughly 3:1. As described in the Examples below, a Prototheca
transformant containing two heterologous thioesterase genes was
able to produce C12:C14 fatty acid levels at a ratio of roughly
5:1. This kind of ratio of C12:C14 fatty acids has been, up to now,
unachievable at commercial levels (i.e., through blending of seed
oils).
[0309] Another novel aspect of the oils produced by transgenic
microalgae is the degree of saturation of the fatty acids. Palm oil
is currently the largest source of saturated oil, with a total
saturates to unsaturates of 52% to 48%. As shown in the Examples
below, Prototheca with heterologous thioesterases from U. americana
and C. camphora achieved total saturates levels of over 60% in the
oil that it produced. Also shown in the Examples below, Prototheca
with heterologous thioesterase from U. americana achieved total
saturates level of over 86% in the oil that it produced.
[0310] Fatty acyl-CoA/aldehyde reductases suitable for use with the
microbes and methods of the invention include, without limitation,
those listed in Table 6.
TABLE-US-00011 TABLE 6 Fatty acyl-CoA/aldehyde reductases listed by
GenBank accession numbers. AAC45217, YP_047869, BAB85476,
YP_001086217, YP_580344, YP_001280274, YP_264583, YP_436109,
YP_959769, ZP_01736962, ZP_01900335, ZP_01892096, ZP_01103974,
ZP_01915077, YP_924106, YP_130411, ZP_01222731, YP_550815,
YP_983712, YP_001019688, YP_524762, YP_856798, ZP_01115500,
YP_001141848, NP_336047, NP_216059, YP_882409, YP_706156,
YP_001136150, YP_952365, ZP_01221833, YP_130076, NP_567936,
AAR88762, ABK28586, NP_197634, CAD30694, NP_001063962, BAD46254,
NP_001030809, EAZ10132, EAZ43639, EAZ07989, NP_001062488, CAB88537,
NP_001052541, CAH66597, CAE02214, CAH66590, CAB88538, EAZ39844,
AAZ06658, CAA68190, CAA52019, and BAC84377
[0311] Fatty acyl-CoA reductases suitable for use with the microbes
and methods of the invention include, without limitation, those
listed in Table 7.
TABLE-US-00012 TABLE 7 Fatty acyl-CoA reductases listed by GenBank
accession numbers. NP_187805, ABO14927, NP_001049083, CAN83375,
NP_191229, EAZ42242, EAZ06453, CAD30696, BAD31814, NP_190040,
AAD38039, CAD30692, CAN81280, NP_197642, NP_190041, AAL15288, and
NP_190042
[0312] Fatty aldehyde decarbonylases suitable for use with the
microbes and methods of the invention include, without limitation,
those listed in Table 8.
TABLE-US-00013 TABLE 8 Fatty aldehyde decarbonylases listed by
GenBank accession numbers. NP_850932, ABN07985, CAN60676, AAC23640,
CAA65199, AAC24373, CAE03390, ABD28319, NP_181306, EAZ31322,
CAN63491, EAY94825, EAY86731, CAL55686, XP_001420263, EAZ23849,
NP_200588, NP_001063227, CAN83072, AAR90847, and AAR97643
[0313] Combinations of naturally co-expressed fatty acyl-ACP
thioesterases and acyl carrier proteins are suitable for use with
the microbes and methods of the invention.
[0314] Additional examples of hydrocarbon or lipid modification
enzymes include amino acid sequences contained in, referenced in,
or encoded by nucleic acid sequences contained or referenced in,
any of the following U.S. Pat. Nos. 6,610,527; 6,451,576;
6,429,014; 6,342,380; 6,265,639; 6,194,185; 6,114,160; 6,083,731;
6,043,072; 5,994,114; 5,891,697; 5,871,988; 6,265,639, and further
described in GenBank Accession numbers: AA018435;
ZP.sub.--00513891; Q38710; AAK60613; AAK60610; AAK60611;
NP.sub.--113747; CAB75874; AAK60612; AAF20201; BAA11024; AF205791;
and CAA03710.
[0315] Other enzymes in the lipid biosynthetic pathways are also
suitable for use with microbes and methods of the invention. For
example, keto acyl-ACP synthase (Kas) enzymes work in conjunction
with some of the above listed enzymes in the lipid biosynthetic
pathway. There different classes of Kas enzymes: Kas I participates
in successive condensation steps between the ever-growing acyl ACP
chains and malonyl-ACP. Kas II typically participates in the final
condensation step leading from C16:0-ACP to C18:0-ACP incorporating
malonyl-ACP. As such, in higher plants and some microalgae
species/strains that synthesize predominantly C16-C18:0 fatty acids
(and their unsaturated derivatives), Kas II enzymes interact with
products of FatA genes (acyl-ACP thioesterases).
[0316] Acyl-ACP thioesterases are the terminators of higher plant
(and some microalgal species) fatty acid biosynthesis, and in most
plant species, this is carried out by members of the FatA gene
family, whose role is to terminate elongation at the C16:0 to C18:0
stage. In species that synthesize shorter chain fatty acids (such
as Cuphea, Elaeis, Myristica, or Umbellularia), a different group
of acyl-ACP thioesterases encoded by FatB genes carry out this
termination step (see e.g., the codon optimized coding region of
Cocos nucifera FatB3-B, SEQ ID NO: 189). The interaction between
Kas II enzymes and acyl-Acp thioesterases is important for the
correct termination of fatty acid chain elongation. As a
consequence, in higher plant species (and microalgal species) that
have evolved FatB genes capable of shorter chain lipid
biosynthesis, there has been a corresponding co-evolution of an
additional class of Kas genes, termed Kas IV genes. Kas IV genes
are responsible for chain length elongation of a specific size
range of fatty acids, 4-14 carbons in length.
[0317] Other suitable enzymes for use with the microbes and the
methods of the invention include those that have at least 70% amino
acid identity with one of the proteins listed in Tables 4, 6-8, and
that exhibit the corresponding desired enzymatic activity (e.g.,
cleavage of a fatty acid from an acyl carrier protein, reduction of
an acyl-CoA to an aldehyde or an alcohol, or conversion of an
aldehyde to an alkane). In additional embodiments, the enzymatic
activity is present in a sequence that has at least about 75%, at
least about 80%, at least about 85%, at least about 90%, at least
about 95%, or at least about 99% identity with one of the above
described sequences, all of which are hereby incorporated by
reference as if fully set forth.
[0318] By selecting the desired combination of exogenous genes to
be expressed, one can tailor the product generated by the microbe,
which may then be extracted from the aqueous biomass. For example,
the microbe can contain: (i) an exogenous gene encoding a fatty
acyl-ACP thioesterase; and, optionally, (ii) a naturally
co-expressed acyl carrier protein or an acyl carrier protein
otherwise having affinity for the fatty acyl-ACP thioesterase (or
conversely); and, optionally, (iii) an exogenous gene encoding a
fatty acyl-CoA/aldehyde reductase or a fatty acyl-CoA reductase;
and, optionally, (iv) an exogenous gene encoding a fatty aldehyde
reductase or a fatty aldehyde decarbonylase. The microbe, under
culture conditions described herein, synthesizes a fatty acid
linked to an ACP and the fatty acyl-ACP thioesterase catalyzes the
cleavage of the fatty acid from the ACP to yield, through further
enzymatic processing, a fatty acyl-CoA molecule. When present, the
fatty acyl-CoA/aldehyde reducatase catalyzes the reduction of the
acyl-CoA to an alcohol. Similarly, the fatty acyl-CoA reductase,
when present, catalyzes the reduction of the acyl-CoA to an
aldehyde. In those embodiments in which an exogenous gene encoding
a fatty acyl-CoA reductase is present and expressed to yield an
aldehyde product, a fatty aldehyde reductase, encoded by the third
exogenous gene, catalyzes the reduction of the aldehyde to an
alcohol Similarly, a fatty aldehyde decarbonylase catalyzes the
conversion of the aldehyde to an alkane or an alkene, when
present.
[0319] In another embodiment, the microbe can contain: (i) an
exogenous gene encoding a fatty acyl-ACP thioesterase; (ii)
optionally, a naturally co-expressed acyl carrier protein or an
acyl carrier protein having affinity for the fatty acid acyl-ACP
thioesterase; (iii) a mutated endogenous desaturase gene, wherein
the mutation renders the desaturase gene or desaturase protein
inactive, such as a desaturase knockout; (iv) overexpression of an
endogenous stearoyl acyl carrier protein desaturase or the
expression of a heterologous SAD; and (v) any combination of the
foregoing.
[0320] Genes encoding such enzymes, such as fatty acyl ACP
thioesterases, can be obtained from cells already known to exhibit
significant lipid production such as Chlorella protothecoides.
Genes already known to have a role in lipid production, e.g., a
gene encoding an enzyme that saturates double bonds, can be
transformed individually into recipient cells. However, to practice
the invention it is not necessary to make a priori assumptions as
to which genes are required. Methods for identifiying genes that
can alter (improve) lipid production in microalgae are described in
PCT Pub. No. 2008/151149.
[0321] Thus, the present invention provides a microorganism (e.g.,
a Prototheca cell) that has been genetically engineered to express
a lipid pathway enzyme at an altered level compared to a wild-type
cell of the same species. In some cases, the cell produces more
lipid compared to the wild-type cell when both cells are grown
under the same conditions. In some cases, the cell has been
genetically engineered and/or selected to express a lipid pathway
enzyme at a higher level than the wild-type cell. In some cases,
the lipid pathway enzyme is selected from the group consisting of
pyruvate dehydrogenase, acetyl-CoA carboxylase, acyl carrier
protein, and glycerol-3 phosphate acyltransferase. In some cases,
the cell has been genetically engineered and/or selected to express
a lipid pathway enzyme at a lower level than the wild-type cell. In
at least one embodiment in which the cell expresses the lipid
pathway enzyme at a lower level, the lipid pathway enzyme comprises
citrate synthase.
[0322] In some embodiments, the cell has been genetically
engineered and/or selected to express a global regulator of fatty
acid synthesis at an altered level compared to the wild-type cell,
whereby the expression levels of a plurality of fatty acid
synthetic genes are altered compared to the wild-type cell. In some
cases, the lipid pathway enzyme comprises an enzyme that modifies a
fatty acid. In some cases, the lipid pathway enzyme is selected
from a stearoyl-ACP desaturase and a glycerolipid desaturase. In
some cases, the cell has been genetically engineered and/or
selected to express a lower level of a lipid pathway enzyme, or not
to express a specific lipid pathway enzyme at all (i.e., wherein a
lipid pathway enzyme has been knockout, or replaced with an
exogenous gene).
[0323] Some microalgae produce significant quantities of non-lipid
metabolites, such as, for example, polysaccharides. Because
polysaccharide biosynthesis can use a significant proportion of the
total metabolic energy available to cells, mutagenesis of
lipid-producing cells followed by screening for reduced or
eliminated polysaccharide production generates novel strains that
are capable of producing higher yields of lipids.
[0324] In other embodiments, the present invention is directed to
an oil-producing microbe containing one or more exogenous genes,
wherein the exogenous genes encode protein(s) selected from the
group consisting of a fatty acyl-ACP thioesterase, a fatty acyl-CoA
reductase, a fatty aldehyde reductase, a fatty acyl-CoA/aldehyde
reductase, a fatty aldehyde decarbonylase, a desaturase, and an
acyl carrier protein. In another embodiment, an endogenous
desaturase gene is overexpressed in a micro containing one or more
of the above exogenous genes. In one embodiment, the exogenous gene
is in operable linkage with a promoter, which is inducible or
repressible in response to a stimulus. In some cases, the stimulus
is selected from the group consisting of an exogenously provided
small molecule, heat, cold, and limited or no nitrogen in the
culture media. In some cases, the exogenous gene is expressed in a
cellular compartment. In some embodiments, the cellular compartment
is selected from the group consisting of a chloroplast, a plastid
and a mitochondrion. In some embodiments the microbe is Prototheca
moriformis, Prototheca krugani, Prototheca stagnora or Prototheca
zopfii.
[0325] In one embodiment, the exogenous gene encodes a fatty acid
acyl-ACP thioesterase. In some cases, the thioesterase encoded by
the exogenous gene catalyzes the cleavage of an 8 to 18-carbon
fatty acid from an acyl carrier protein (ACP). In some cases, the
thioesterase encoded by the exogenous gene catalyzes the cleavage
of a 10 to 14-carbon fatty acid from an ACP. In one embodiment, the
thioesterase encoded by the exogenous gene catalyzes the cleavage
of a 12-carbon fatty acid from an ACP.
[0326] In one embodiment, the exogenous gene encodes a fatty
acyl-CoA/aldehyde reductase. In some cases, the reductase encoded
by the exogenous gene catalyzes the reduction of an 8 to 18-carbon
fatty acyl-CoA to a corresponding primary alcohol. In some cases,
the reductase encoded by the exogenous gene catalyzes the reduction
of a 10 to 14-carbon fatty acyl-CoA to a corresponding primary
alcohol. In one embodiment, the reductase encoded by the exogenous
gene catalyzes the reduction of a 12-carbon fatty acyl-CoA to
dodecanol.
[0327] The present invention also provides a recombinant Prototheca
cell containing two exogenous genes, wherein a first exogenous gene
encodes a fatty acyl-ACP thioesterase and a second exogenous gene
encodes a protein selected from the group consisting of a fatty
acyl-CoA reductase, a fatty acyl-CoA/aldehyde reductase, and an
acyl carrier protein. In some cases, the two exogenous genes are
each in operable linkage with a promoter, which is inducible in
response to a stimulus. In some cases, each promoter is inducible
in response to an identical stimulus, such as limited or no
nitrogen in the culture media. Limitation or complete lack of
nitrogen in the culture media stimulates oil production in some
microorganisms such as Prototheca species, and can be used as a
trigger to inducec oil production to high levels. When used in
combination with the genetic engineering methods disclosed herein,
the lipid as a percentage of dry cell weight can be pushed to high
levels such as at least 30%, at least 40%, at least 50%, at least
60%, at least 70% and at least 75%; methods disclosed herein
provide for cells with these levels of lipid, wherein the lipid is
at least 1%-5%, preferably at least 4%, C.sub.8-C.sub.14, at least
0.25%-1%, preferably at least 0.3%, C8, at least 1%-5%, preferably
at least 2%, C10, at least 1%-5%, preferably at least 2%, C12, and
at least 1%-5%, preferably at least 2%, C14. In some embodiments
the cells are over 10%, over 15%, over 20%, or over 25% lipid by
dry cell weight and contain lipid that is at least 5%, at least 10%
or at least 15% C.sub.8-C.sub.14, at least 10%, at least 15%, at
least 20%, at least 25% or at least 30% C.sub.8-C.sub.14, at least
20%, at least 25%, at least 30%, at least 35% or at least 40%,
C.sub.8-C.sub.14, 5%-40%, preferably 10-30%, C8-C14 and 10%-40%,
preferably 20-30%, C8-C14.
[0328] The novel oils disclosed herein are distinct from other
naturally occurring oils that are high in mid-chain fatty acids,
such as palm oil, palm kernel oil, and coconut oil. For example,
levels of contaminants such as carotenoids are far higher in palm
oil and palm kernel oil than in the oils of the invention. Palm and
palm kernel oils in particular contain alpha and beta carotenes and
lycopene in much higher amounts than is in the oils of the
invention. In addition, over 20 different carotenoids are found in
palm and palm kernel oil, whereas the Examples demonstrate that the
oils of the invention contain very few carotenoids species and very
low levels. In addition, the levels of vitamin E compounds such as
tocotrienols are far higher in palm, palm kernel, and coconut oil
than in the oils of the invention.
[0329] In one embodiment, the thioesterase encoded by the first
exogenous gene catalyzes the cleavage of an 8 to 18-carbon fatty
acid from an ACP. In some embodiments, the second exogenous gene
encodes a fatty acyl-CoA/aldehyde reductase which catalyzes the
reduction of an 8 to 18-carbon fatty acyl-CoA to a corresponding
primary alcohol. In some cases, the thioesterase encoded by the
first exogenous gene catalyzes the cleavage of a 10 to 14-carbon
fatty acid from an ACP, and the reductase encoded by the second
exogenous gene catalyzes the reduction of a 10 to 14-carbon fatty
acyl-CoA to the corresponding primary alcohol, wherein the
thioesterase and the reductase act on the same carbon chain length.
In one embodiment, the thioesterase encoded by the first exogenous
gene catalyzes the cleavage of a 12-carbon fatty acid from an ACP,
and the reductase encoded by the second exogenous gene catalyzes
the reduction of a 12-carbon fatty acyl-CoA to dodecanol. In some
embodiments, the second exogenous gene encodes a fatty acyl-CoA
reductase which catalyzes the reduction of an 8 to 18-carbon fatty
acyl-CoA to a corresponding aldehyde. In some embodiments, the
second exogenous gene encodes an acyl carrier protein that is
naturally co-expressed with the fatty acyl-ACP thioesterase.
[0330] In some embodiments, the second exogenous gene encodes a
fatty acyl-CoA reductase, and the microbe further contains a third
exogenous gene encoding a fatty aldehyde decarbonylase. In some
cases, the thioesterase encoded by the first exogenous gene
catalyzes the cleavage of an 8 to 18-carbon fatty acid from an ACP,
the reductase encoded by the second exogenous gene catalyzes the
reduction of an 8 to 18-carbon fatty acyl-CoA to a corresponding
fatty aldehyde, and the decarbonylase encoded by the third
exogenous gene catalyzes the conversion of an 8 to 18-carbon fatty
aldehyde to a corresponding alkane, wherein the thioesterase, the
reductase, and the decarbonylase act on the same carbon chain
length.
[0331] In some embodiments, the second exogenous gene encodes an
acyl carrier protein, and the microbe further contains a third
exogenous gene encoding a protein selected from the group
consisting of a fatty acyl-CoA reductase and a fatty
acyl-CoA/aldehyde reductase. In some cases, the third exogenous
gene encodes a fatty acyl-CoA reductase, and the microbe further
contains a fourth exogenous gene encoding a fatty aldehyde
decarbonylase.
[0332] The present invention also provides methods for producing an
alcohol comprising culturing a population of recombinant
microorganisms (e.g., Prototheca cells) in a culture medium,
wherein the cells contain (i) a first exogenous gene encoding a
fatty acyl-ACP thioesterase, and (ii) a second exogenous gene
encoding a fatty acyl-CoA/aldehyde reductase, and the cells
synthesize a fatty acid linked to an acyl carrier protein (ACP),
the fatty acyl-ACP thioesterase catalyzes the cleavage of the fatty
acid from the ACP to yield, through further processing, a fatty
acyl-CoA, and the fatty acyl-CoA/aldehyde reductase catalyzes the
reduction of the acyl-CoA to an alcohol.
[0333] The present invention also provides methods of producing a
lipid molecule in a microorganism (e.g., a Prototheca cell). In one
embodiment, the method comprises culturing a population of
Prototheca cells in a culture medium, wherein the cells contain (i)
a first exogenous gene encoding a fatty acyl-ACP thioesterase, and
(ii) a second exogenous gene encoding a fatty acyl-CoA reductase,
and wherein the microbes synthesize a fatty acid linked to an acyl
carrier protein (ACP), the fatty acyl-ACP thioesterase catalyzes
the cleavage of the fatty acid from the ACP to yield, through
further processing, a fatty acyl-CoA, and the fatty acyl-CoA
reductase catalyzes the reduction of the acyl-CoA to an
aldehyde.
[0334] The present invention also provides methods of producing a
fatty acid molecule having a specified carbon chain length in a
microorganism (e.g., a Prototheca cell). In one embodiment, the
method comprises culturing a population of lipid-producing
Prototheca cells in a culture medium, wherein the microbes contain
an exogenous gene encoding a fatty acyl-ACP thioesterase having an
activity specific or preferential to a certain carbon chain length,
such as 8, 10, 12 or 14 carbon atoms, and wherein the microbes
synthesize a fatty acid linked to an acyl carrier protein (ACP) and
the thioesterase catalyzes the cleavage of the fatty acid from the
ACP when the fatty acid has been synthesized to the specific carbon
chain length.
[0335] In the various embodiments described above, the
microorganism (e.g., a Prototheca cell) can contain at least one
exogenous gene encoding a lipid pathway enzyme. In some cases, the
lipid pathway enzyme is selected from the group consisting of a
stearoyl-ACP desaturase, a glycerolipid desaturase, a pyruvate
dehydrogenase, an acetyl-CoA carboxylase, an acyl carrier protein,
and a glycerol-3 phosphate acyltransferase. In other cases, the
microorganism (e.g., Prototheca cell) contains a lipid modification
enzyme selected from the group consisting of a fatty acyl-ACP
thioesterase, a fatty acyl-CoA/aldehyde reductase, a fatty acyl-CoA
reductase, a fatty aldehyde reductase, a fatty aldehyde
decarbonylase, and/or an acyl carrier protein.
[0336] A number of exemplary transformation cassettes or constructs
used to express a variety of the lipid pathway enzymes and lipid
modification enzymes discussed herein are presented in the
Examples. Other useful constructs, without limitation, are listed
in Table 37, below.
TABLE-US-00014 TABLE 37 Exemplary transformation constructs, codon-
optimized coding regions, and enzymes. SEQ ID Transformation
Construct/Coding region/Enzyme NO C. hookeriana C10:0 specific
thioesterase construct 243 coding region for C. hookeriana C10:0
specific thioesterase (codon-optimized) 244 C. hookeriana KAS IV
enzyme construct 245 coding region for C. hookeriana KAS IV enzyme
(codon-optimized) 246 C. hookeriana KAS IV enzyme 247 C. hookeriana
C10:0 specific thioesterase plus C. hookeriana KAS IV 248 enzyme
construct coding region for C. lanceolata C10:0 specific
thioesterase with UTEX 1435 249 .DELTA.12 fatty acid desaturase U.
californica C12:0 specific thioesterase construct 250 coding region
for U. californica C12:0 specific thioesterase (codon-optimized)
251 G. mangostana C16:0 thioesterase construct 252 coding region
for G. mangostana C16:0 thioesterase (codon-optimized) 253 B. napus
C18:0 thioesterase construct 254 coding region for B. napus C18:0
thioesterase (codon-optimized) 255 O. europaea stearoyl-ACP
desaturase construct 256 coding region for O. europaea stearoyl-ACP
desaturase (codon-optimized) 257 C. hookeriana C16:0 thioesterase
construct 258 coding region for C. hookeriana C16:0 thioesterase
(codon-optimized) 259 E. guineensis C16:0 thioesterase construct
260 coding region for E. guineensis C16:0 thioesterase
(codon-optimized) 261 C. tinctorius ACP-thioesterase at .DELTA.12
fatty acid desaturase locus construct 262 coding region for C.
tinctorius ACP-thioesterase (codon-optimized) 263 M. fragrans
C14:0-C18:0 broad specificity thioesterase construct 264 coding
region for M. fragrans C14:0-C18:0 broad specificity thioesterase
265 (codon-optimized) coding region for M. fragrans C:14:0 specific
thioesterase 266 M. fragrans C14:0 specfic thioesterase with
.DELTA.12 FAD transit peptide 267 Ricinus communis ACP-thioesterase
construct 268 coding region for Ricinus communis ACP-thioesterase
(codon-optimized) 269 C. camphora C14:0 thioesterase construct 270
coding region for C. camphora C14:0 thioesterase (codon-optimized)
271 C. camphora C14:0 specific thioesterase construct 272 C.
camphora C14:0 specific thioesterase construct 273 U. Americana
C10:0-C16:0 specific thioesterase in a SAD locus 274 coding region
for U. Americana C10:0-C16:0 specific thioesterase (codon- 275
optimized) C. wrightii KASA1 + C. wrightii FatB2 thioesterase +
suc2 construct 276 coding region for C. wrightii KASA1
(codon-optimized) 277 coding region for C. wrightii FatB2
thioesterase (codon-optimized) 278
VI. FUELS AND CHEMICALS PRODUCTION
[0337] For the production of fuel in accordance with the methods of
the invention lipids produced by cells of the invention are
harvested, or otherwise collected, by any convenient means. Lipids
can be isolated by whole cell extraction. The cells are first
disrupted, and then intracellular and cell membrane/cell
wall-associated lipids as well as extracellular hydrocarbons can be
separated from the cell mass, such as by use of centrifugation as
described above. Intracellular lipids produced in microorganisms
are, in some embodiments, extracted after lysing the cells of the
microorganism. Once extracted, the lipids are further refined to
produce oils, fuels, or oleochemicals.
[0338] After completion of culturing, the microorganisms can be
separated from the fermentation broth. Optionally, the separation
is effected by centrifugation to generate a concentrated paste.
Centrifugation does not remove significant amounts of intracellular
water from the microorganisms and is not a drying step. The biomass
can then optionally be washed with a washing solution (e.g., DI
water) to get rid of the fermentation broth and debris. Optionally,
the washed microbial biomass may also be dried (oven dried,
lyophilized, etc.) prior to cell disruption. Alternatively, cells
can be lysed without separation from some or all of the
fermentation broth when the fermentation is complete. For example,
the cells can be at a ratio of less than 1:1 v:v cells to
extracellular liquid when the cells are lysed.
[0339] Microorganisms containing a lipid can be lysed to produce a
lysate. As detailed herein, the step of lysing a microorganism
(also referred to as cell lysis) can be achieved by any convenient
means, including heat-induced lysis, adding a base, adding an acid,
using enzymes such as proteases and polysaccharide degradation
enzymes such as amylases, using ultrasound, mechanical lysis, using
osmotic shock, infection with a lytic virus, and/or expression of
one or more lytic genes. Lysis is performed to release
intracellular molecules which have been produced by the
microorganism. Each of these methods for lysing a microorganism can
be used as a single method or in combination simultaneously or
sequentially. The extent of cell disruption can be observed by
microscopic analysis. Using one or more of the methods described
herein, typically more than 70% cell breakage is observed.
Preferably, cell breakage is more than 80%, more preferably more
than 90% and most preferred about 100%.
[0340] In particular embodiments, the microorganism is lysed after
growth, for example to increase the exposure of cellular lipid
and/or hydrocarbon for extraction or further processing. The timing
of lipase expression (e.g., via an inducible promoter) or cell
lysis can be adjusted to optimize the yield of lipids and/or
hydrocarbons. Below are described a number of lysis techniques.
These techniques can be used individually or in combination.
[0341] In one embodiment of the present invention, the step of
lysing a microorganism comprises heating of a cellular suspension
containing the microorganism. In this embodiment, the fermentation
broth containing the microorganisms (or a suspension of
microorganisms isolated from the fermentation broth) is heated
until the microorganisms, i.e., the cell walls and membranes of
microorganisms degrade or breakdown. Typically, temperatures
applied are at least 50.degree. C. Higher temperatures, such as, at
least 30.degree. C. at least 60.degree. C., at least 70.degree. C.,
at least 80.degree. C., at least 90.degree. C., at least
100.degree. C., at least 110.degree. C., at least 120.degree. C.,
at least 130.degree. C. or higher are used for more efficient cell
lysis. Lysing cells by heat treatment can be performed by boiling
the microorganism. Alternatively, heat treatment (without boiling)
can be performed in an autoclave. The heat treated lysate may be
cooled for further treatment. Cell disruption can also be performed
by steam treatment, i.e., through addition of pressurized steam.
Steam treatment of microalgae for cell disruption is described, for
example, in U.S. Pat. No. 6,750,048. In some embodiments, steam
treatment may be achieved by sparging steam into the fermentor and
maintaining the broth at a desired temperature for less than about
90 minutes, preferably less than about 60 minutes, and more
preferably less than about 30 minutes.
[0342] In another embodiment of the present invention, the step of
lysing a microorganism comprises adding a base to a cellular
suspension containing the microorganism. The base should be strong
enough to hydrolyze at least a portion of the proteinaceous
compounds of the microorganisms used. Bases which are useful for
solubilizing proteins are known in the art of chemistry. Exemplary
bases which are useful in the methods of the present invention
include, but are not limited to, hydroxides, carbonates and
bicarbonates of lithium, sodium, potassium, calcium, and mixtures
thereof. A preferred base is KOH. Base treatment of microalgae for
cell disruption is described, for example, in U.S. Pat. No.
6,750,048.
[0343] In another embodiment of the present invention, the step of
lysing a microorganism comprises adding an acid to a cellular
suspension containing the microorganism. Acid lysis can be effected
using an acid at a concentration of 10-500 mN or preferably 40-160
nM. Acid lysis is preferably performed at above room temperature
(e.g., at 40-160.degree., and preferably a temperature of
50-130.degree.. For moderate temperatures (e.g., room temperature
to 100.degree. C. and particularly room temperature to 65.degree.,
acid treatment can usefully be combined with sonication or other
cell disruption methods.
[0344] In another embodiment of the present invention, the step of
lysing a microorganism comprises lysing the microorganism by using
an enzyme. Preferred enzymes for lysing a microorganism are
proteases and polysaccharide-degrading enzymes such as
hemicellulase (e.g., hemicellulase from Aspergillus niger; Sigma
Aldrich, St. Louis, Mo.; #H2125), pectinase (e.g., pectinase from
Rhizopus sp.; Sigma Aldrich, St. Louis, Mo.; #P2401), Mannaway 4.0
L (Novozymes), cellulase (e.g., cellulose from Trichoderma viride;
Sigma Aldrich, St. Louis, Mo.; #C9422), and driselase (e.g.,
driselase from Basidiomycetes sp.; Sigma Aldrich, St. Louis, Mo.;
#D9515.
[0345] In other embodiments of the present invention, lysis is
accomplished using an enzyme such as, for example, a cellulase such
as a polysaccharide-degrading enzyme, optionally from Chlorella or
a Chlorella virus, or a proteases, such as Streptomyces griseus
protease, chymotrypsin, proteinase K, proteases listed in
Degradation of Polylactide by Commercial Proteases, Oda Y et al.,
Journal of Polymers and the Environment, Volume 8, Number 1,
January 2000, pp. 29-32(4), Alcalase 2.4 FG (Novozymes), and
Flavourzyme 100 L (Novozymes). Any combination of a protease and a
polysaccharide-degrading enzyme can also be used, including any
combination of the preceding proteases and polysaccharide-degrading
enzymes.
[0346] In another embodiment, lysis can be performed using an
expeller press. In this process, biomass is forced through a
screw-type device at high pressure, lysing the cells and causing
the intracellular lipid to be released and separated from the
protein and fiber (and other components) in the cell.
[0347] In another embodiment of the present invention, the step of
lysing a microorganism is performed by using ultrasound, i.e.,
sonication. Thus, cells can also by lysed with high frequency
sound. The sound can be produced electronically and transported
through a metallic tip to an appropriately concentrated cellular
suspension. This sonication (or ultrasonication) disrupts cellular
integrity based on the creation of cavities in cell suspension.
[0348] In another embodiment of the present invention, the step of
lysing a microorganism is performed by mechanical lysis. Cells can
be lysed mechanically and optionally homogenized to facilitate
hydrocarbon (e.g., lipid) collection. For example, a pressure
disrupter can be used to pump a cell containing slurry through a
restricted orifice valve. High pressure (up to 1500 bar) is
applied, followed by an instant expansion through an exiting
nozzle. Cell disruption is accomplished by three different
mechanisms: impingement on the valve, high liquid shear in the
orifice, and sudden pressure drop upon discharge, causing an
explosion of the cell. The method releases intracellular molecules.
Alternatively, a ball mill can be used. In a ball mill, cells are
agitated in suspension with small abrasive particles, such as
beads. Cells break because of shear forces, grinding between beads,
and collisions with beads. The beads disrupt the cells to release
cellular contents. Cells can also be disrupted by shear forces,
such as with the use of blending (such as with a high speed or
Waring blender as examples), the french press, or even
centrifugation in case of weak cell walls, to disrupt cells.
[0349] In another embodiment of the present invention, the step of
lysing a microorganism is performed by applying an osmotic
shock.
[0350] In another embodiment of the present invention, the step of
lysing a microorganism comprises infection of the microorganism
with a lytic virus. A wide variety of viruses are known to lyse
microorganisms suitable for use in the present invention, and the
selection and use of a particular lytic virus for a particular
microorganism is within the level of skill in the art. For example,
paramecium bursaria chlorella virus (PBCV-1) is the prototype of a
group (family Phycodnaviridae, genus Chlorovirus) of large,
icosahedral, plaque-forming, double-stranded DNA viruses that
replicate in, and lyse, certain unicellular, eukaryotic
chlorella-like green algae. Accordingly, any susceptible microalgae
can be lysed by infecting the culture with a suitable chlorella
virus. Methods of infecting species of Chlorella with a chlorella
virus are known. See for example Adv. Virus Res. 2006; 66:293-336;
Virology, 1999 Apr. 25; 257(1):15-23; Virology, 2004 Jan. 5;
318(1):214-23; Nucleic Acids Symp. Ser. 2000; (44):161-2; J. Virol.
2006 March; 80(5):2437-44; and Annu. Rev. Microbiol. 1999;
53:447-94.
[0351] In another embodiment of the present invention, the step of
lysing a microorganism comprises autolysis. In this embodiment, a
microorganism according to the invention is genetically engineered
to produce a lytic protein that will lyse the microorganism. This
lytic gene can be expressed using an inducible promoter so that the
cells can first be grown to a desirable density in a fermentor,
followed by induction of the promoter to express the lytic gene to
lyse the cells. In one embodiment, the lytic gene encodes a
polysaccharide-degrading enzyme. In certain other embodiments, the
lytic gene is a gene from a lytic virus. Thus, for example, a lytic
gene from a Chlorella virus can be expressed in an algal cell; see
Virology 260, 308-315 (1999); FEMS Microbiology Letters 180 (1999)
45-53; Virology 263, 376-387 (1999); and Virology 230, 361-368
(1997). Expression of lytic genes is preferably done using an
inducible promoter, such as a promoter active in microalgae that is
induced by a stimulus such as the presence of a small molecule,
light, heat, and other stimuli.
[0352] Various methods are available for separating lipids from
cellular lysates produced by the above methods. For example, lipids
and lipid derivatives such as fatty aldehydes, fatty alcohols, and
hydrocarbons such as alkanes can be extracted with a hydrophobic
solvent such as hexane (see Frenz et al. 1989, Enzyme Microb.
Technol., 11:717). Lipids and lipid derivatives can also be
extracted using liquefaction (see for example Sawayama et al. 1999,
Biomass and Bioenergy 17:33-39 and Inoue et al. 1993, Biomass
Bioenergy 6(4):269-274); oil liquefaction (see for example Minowa
et al. 1995, Fuel 74(12):1735-1738); and supercritical CO.sub.2
extraction (see for example Mendes et al. 2003, Inorganica Chimica
Acta 356:328-334). Miao and Wu describe a protocol of the recovery
of microalgal lipid from a culture of Chlorella prototheocoides in
which the cells were harvested by centrifugation, washed with
distilled water and dried by freeze drying. The resulting cell
powder was pulverized in a mortar and then extracted with n-hexane.
Miao and Wu, Biosource Technology (2006) 97:841-846.
[0353] Thus, lipids, lipid derivatives and hydrocarbons generated
by the microorganisms of the present invention can be recovered by
extraction with an organic solvent. In some cases, the preferred
organic solvent is hexane. Typically, the organic solvent is added
directly to the lysate without prior separation of the lysate
components. In one embodiment, the lysate generated by one or more
of the methods described above is contacted with an organic solvent
for a period of time sufficient to allow the lipid and/or
hydrocarbon components to form a solution with the organic solvent.
In some cases, the solution can then be further refined to recover
specific desired lipid or hydrocarbon components. Hexane extraction
methods are well known in the art.
[0354] Lipids and lipid derivatives such as fatty aldehydes, fatty
alcohols, and hydrocarbons such as alkanes produced by cells as
described herein can be modified by the use of one or more enzymes,
including a lipase, as described above. When the hydrocarbons are
in the extracellular environment of the cells, the one or more
enzymes can be added to that environment under conditions in which
the enzyme modifies the hydrocarbon or completes its synthesis from
a hydrocarbon precursor. Alternatively, the hydrocarbons can be
partially, or completely, isolated from the cellular material
before addition of one or more catalysts such as enzymes. Such
catalysts are exogenously added, and their activity occurs outside
the cell or in vitro.
[0355] Thus, lipids and hydrocarbons produced by cells in vivo, or
enzymatically modified in vitro, as described herein can be
optionally further processed by conventional means. The processing
can include "cracking" to reduce the size, and thus increase the
hydrogen:carbon ratio, of hydrocarbon molecules. Catalytic and
thermal cracking methods are routinely used in hydrocarbon and
triglyceride oil processing. Catalytic methods involve the use of a
catalyst, such as a solid acid catalyst. The catalyst can be
silica-alumina or a zeolite, which result in the heterolytic, or
asymmetric, breakage of a carbon-carbon bond to result in a
carbocation and a hydride anion. These reactive intermediates then
undergo either rearrangement or hydride transfer with another
hydrocarbon. The reactions can thus regenerate the intermediates to
result in a self-propagating chain mechanism. Hydrocarbons can also
be processed to reduce, optionally to zero, the number of
carbon-carbon double, or triple, bonds therein. Hydrocarbons can
also be processed to remove or eliminate a ring or cyclic structure
therein. Hydrocarbons can also be processed to increase the
hydrogen:carbon ratio. This can include the addition of hydrogen
("hydrogenation") and/or the "cracking" of hydrocarbons into
smaller hydrocarbons.
[0356] Thermal methods involve the use of elevated temperature and
pressure to reduce hydrocarbon size. An elevated temperature of
about 800.degree. C. and pressure of about 700 kPa can be used.
These conditions generate "light," a term that is sometimes used to
refer to hydrogen-rich hydrocarbon molecules (as distinguished from
photon flux), while also generating, by condensation, heavier
hydrocarbon molecules which are relatively depleted of hydrogen.
The methodology provides homolytic, or symmetrical, breakage and
produces alkenes, which may be optionally enzymatically saturated
as described above.
[0357] Catalytic and thermal methods are standard in plants for
hydrocarbon processing and oil refining. Thus hydrocarbons produced
by cells as described herein can be collected and processed or
refined via conventional means. See Hillen et al. (Biotechnology
and Bioengineering, Vol. XXIV:193-205 (1982)) for a report on
hydrocracking of microalgae-produced hydrocarbons. In alternative
embodiments, the fraction is treated with another catalyst, such as
an organic compound, heat, and/or an inorganic compound. For
processing of lipids into biodiesel, a transesterification process
is used as described below in this Section.
[0358] Hydrocarbons produced via methods of the present invention
are useful in a variety of industrial applications. For example,
the production of linear alkylbenzene sulfonate (LAS), an anionic
surfactant used in nearly all types of detergents and cleaning
preparations, utilizes hydrocarbons generally comprising a chain of
10-14 carbon atoms. See, for example, U.S. Pat. Nos. 6,946,430;
5,506,201; 6,692,730; 6,268,517; 6,020,509; 6,140,302; 5,080,848;
and 5,567,359. Surfactants, such as LAS, can be used in the
manfacture of personal care compositions and detergents, such as
those described in U.S. Pat. Nos. 5,942,479; 6,086,903; 5,833,999;
6,468,955; and 6,407,044.
[0359] Increasing interest is directed to the use of hydrocarbon
components of biological origin in fuels, such as biodiesel,
renewable diesel, and jet fuel, since renewable biological starting
materials that may replace starting materials derived from fossil
fuels are available, and the use thereof is desirable. There is an
urgent need for methods for producing hydrocarbon components from
biological materials. The present invention fulfills this need by
providing methods for production of biodiesel, renewable diesel,
and jet fuel using the lipids generated by the methods described
herein as a biological material to produce biodiesel, renewable
diesel, and jet fuel.
[0360] Traditional diesel fuels are petroleum distillates rich in
paraffinic hydrocarbons. They have boiling ranges as broad as
370.degree. to 780.degree. F., which are suitable for combustion in
a compression ignition engine, such as a diesel engine vehicle. The
American Society of Testing and Materials (ASTM) establishes the
grade of diesel according to the boiling range, along with
allowable ranges of other fuel properties, such as cetane number,
cloud point, flash point, viscosity, aniline point, sulfur content,
water content, ash content, copper strip corrosion, and carbon
residue. Technically, any hydrocarbon distillate material derived
from biomass or otherwise that meets the appropriate ASTM
specification can be defined as diesel fuel (ASTM D975), jet fuel
(ASTM D1655), or as biodiesel if it is a fatty acid methyl ester
(ASTM D6751).
[0361] After extraction, lipid and/or hydrocarbon components
recovered from the microbial biomass described herein can be
subjected to chemical treatment to manufacture a fuel for use in
diesel vehicles and jet engines.
[0362] Biodiesel is a liquid which varies in color--between golden
and dark brown--depending on the production feedstock. It is
practically immiscible with water, has a high boiling point and low
vapor pressure. Biodiesel refers to a diesel-equivalent processed
fuel for use in diesel-engine vehicles. Biodiesel is biodegradable
and non-toxic. An additional benefit of biodiesel over conventional
diesel fuel is lower engine wear. Typically, biodiesel comprises
C14-C18 alkyl esters. Various processes convert biomass or a lipid
produced and isolated as described herein to diesel fuels. A
preferred method to produce biodiesel is by transesterification of
a lipid as described herein. A preferred alkyl ester for use as
biodiesel is a methyl ester or ethyl ester.
[0363] Biodiesel produced by a method described herein can be used
alone or blended with conventional diesel fuel at any concentration
in most modern diesel-engine vehicles. When blended with
conventional diesel fuel (petroleum diesel), biodiesel may be
present from about 0.1% to about 99.9%. Much of the world uses a
system known as the "B" factor to state the amount of biodiesel in
any fuel mix. For example, fuel containing 20% biodiesel is labeled
B20. Pure biodiesel is referred to as B100.
[0364] Biodiesel can also be used as a heating fuel in domestic and
commercial boilers. Existing oil boilers may contain rubber parts
and may require conversion to run on biodiesel. The conversion
process is usually relatively simple, involving the exchange of
rubber parts for synthetic parts due to biodiesel being a strong
solvent. Due to its strong solvent power, burning biodiesel will
increase the efficiency of boilers. Biodiesel can be used as an
additive in formulations of diesel to increase the lubricity of
pure Ultra-Low Sulfur Diesel (ULSD) fuel, which is advantageous
because it has virtually no sulfur content. Biodiesel is a better
solvent than petrodiesel and can be used to break down deposits of
residues in the fuel lines of vehicles that have previously been
run on petrodiesel.
[0365] Biodiesel can be produced by transesterification of
triglycerides contained in oil-rich biomass. Thus, in another
aspect of the present invention a method for producing biodiesel is
provided. In a preferred embodiment, the method for producing
biodiesel comprises the steps of (a) cultivating a lipid-containing
microorganism using methods disclosed herein (b) lysing a
lipid-containing microorganism to produce a lysate, (c) isolating
lipid from the lysed microorganism, and (d) transesterifying the
lipid composition, whereby biodiesel is produced. Methods for
growth of a microorganism, lysing a microorganism to produce a
lysate, treating the lysate in a medium comprising an organic
solvent to form a heterogeneous mixture and separating the treated
lysate into a lipid composition have been described above and can
also be used in the method of producing biodiesel.
[0366] The lipid profile of the biodiesel is usually highly similar
to the lipid profile of the feedstock oil. Other oils provided by
the methods and compositions of the invention can be subjected to
transesterification to yield biodiesel with lipid profiles
including (a) at least 1%-5%, preferably at least 4%, C8-C14; (b)
at least 0.25%-1%, preferably at least 0.3%, C8; (c) at least
1%-5%, preferably at least 2%, C10; (d) at least 1%-5%, preferably
at least 2%, C12; and (3) at least 20%-40%, preferably at least
30%, C8-C14.
[0367] Lipid compositions can be subjected to transesterification
to yield long-chain fatty acid esters useful as biodiesel.
Preferred transesterification reactions are outlined below and
include base catalyzed transesterification and transesterification
using recombinant lipases. In a base-catalyzed transesterification
process, the triacylglycerides are reacted with an alcohol, such as
methanol or ethanol, in the presence of an alkaline catalyst,
typically potassium hydroxide. This reaction forms methyl or ethyl
esters and glycerin (glycerol) as a byproduct.
[0368] Animal and plant oils are typically made of triglycerides
which are esters of free fatty acids with the trihydric alcohol,
glycerol. In transesterification, the glycerol in a
triacylglyceride (TAG) is replaced with a short-chain alcohol such
as methanol or ethanol. A typical reaction scheme is as
follows:
##STR00001##
[0369] In this reaction, the alcohol is deprotonated with a base to
make it a stronger nucleophile. Commonly, ethanol or methanol is
used in vast excess (up to 50-fold). Normally, this reaction will
proceed either exceedingly slowly or not at all. Heat, as well as
an acid or base can be used to help the reaction proceed more
quickly. The acid or base are not consumed by the
transesterification reaction, thus they are not reactants but
catalysts. Almost all biodiesel has been produced using the
base-catalyzed technique as it requires only low temperatures and
pressures and produces over 98% conversion yield (provided the
starting oil is low in moisture and free fatty acids).
[0370] Transesterification has also been carried out, as discussed
above, using an enzyme, such as a lipase instead of a base.
Lipase-catalyzed transesterification can be carried out, for
example, at a temperature between the room temperature and
80.degree. C., and a mole ratio of the TAG to the lower alcohol of
greater than 1:1, preferably about 3:1. Lipases suitable for use in
transesterification include, but are not limited to, those listed
in Table 9. Other examples of lipases useful for
transesterification are found in, e.g. U.S. Pat. Nos. 4,798,793;
4,940,845 5,156,963; 5,342,768; 5,776,741 and WO89/01032. Such
lipases include, but are not limited to, lipases produced by
microorganisms of Rhizopus, Aspergillus, Candida, Mucor,
Pseudomonas, Rhizomucor, Candida, and Humicola and pancreas
lipase.
TABLE-US-00015 TABLE 9 Lipases suitable for use in
transesterification. Aspergillus niger lipase ABG73614, Candida
antarctica lipase B (novozym-435) CAA83122, Candida cylindracea
lipase AAR24090, Candida lipolytica lipase (Lipase L; Amano
Pharmaceutical Co., Ltd.), Candida rugosa lipase (e.g., Lipase-OF;
Meito Sangyo Co., Ltd.), Mucor miehei lipase (Lipozyme IM 20),
Pseudomonas fluorescens lipase AAA25882, Rhizopus japonicas lipase
(Lilipase A-10FG) Q7M4U7_1, Rhizomucor miehei lipase B34959,
Rhizopus oryzae lipase (Lipase F) AAF32408, Serratia marcescens
lipase (SM Enzyme) ABI13521, Thermomyces lanuginosa lipase
CAB58509, Lipase P (Nagase ChemteX Corporation), and Lipase QLM
(Meito Sangyo Co., Ltd., Nagoya, Japan)
[0371] One challenge to using a lipase for the production of fatty
acid esters suitable for biodiesel is that the price of lipase is
much higher than the price of sodium hydroxide (NaOH) used by the
strong base process. This challenge has been addressed by using an
immobilized lipase, which can be recycled. However, the activity of
the immobilized lipase must be maintained after being recycled for
a minimum number of cycles to allow a lipase-based process to
compete with the strong base process in terms of the production
cost. Immobilized lipases are subject to poisoning by the lower
alcohols typically used in transesterification. U.S. Pat. No.
6,398,707 (issued Jun. 4, 2002 to Wu et al.) describes methods for
enhancing the activity of immobilized lipases and regenerating
immobilized lipases having reduced activity. Some suitable methods
include immersing an immobilized lipase in an alcohol having a
carbon atom number not less than 3 for a period of time, preferably
from 0.5-48 hours, and more preferably from 0.5-1.5 hours. Some
suitable methods also include washing a deactivated immobilized
lipase with an alcohol having a carbon atom number not less than 3
and then immersing the deactivated immobilized lipase in a
vegetable oil for 0.5-48 hours.
[0372] In particular embodiments, a recombinant lipase is expressed
in the same microorganisms that produce the lipid on which the
lipase acts. Suitable recombinant lipases include those listed
above in Table 9 and/or having GenBank Accession numbers listed
above in Table 9, or a polypeptide that has at least 70% amino acid
identity with one of the lipases listed above in Table 9 and that
exhibits lipase activity. In additional embodiments, the enzymatic
activity is present in a sequence that has at least about 75%, at
least about 80%, at least about 85%, at least about 90%, at least
about 95%, or at least about 99% identity with one of the above
described sequences, all of which are hereby incorporated by
reference as if fully set forth. DNA encoding the lipase and
selectable marker is preferably codon-optimized cDNA. Methods of
recoding genes for expression in microalgae are described in U.S.
Pat. No. 7,135,290.
[0373] The common international standard for biodiesel is EN 14214.
ASTM D6751 is the most common biodiesel standard referenced in the
United States and Canada. Germany uses DIN EN 14214 and the UK
requires compliance with BS EN 14214. Basic industrial tests to
determine whether the products conform to these standards typically
include gas chromatography, HPLC, and others. Biodiesel meeting the
quality standards is very non-toxic, with a toxicity rating
(LD.sub.50) of greater than 50 mL/kg.
[0374] Although biodiesel that meets the ASTM standards has to be
non-toxic, there can be contaminants which tend to crystallize
and/or precipitate and fall out of solution as sediment. Sediment
formation is particularly a problem when biodiesel is used at lower
temperatures. The sediment or precipitates may cause problems such
as decreasing fuel flow, clogging fuel lines, clogging filters,
etc. Processes are well-known in the art that specifically deal
with the removal of these contaminants and sediments in biodiesel
in order to produce a higher quality product. Examples for such
processes include, but are not limited to, pretreatment of the oil
to remove contaiminants such as phospholipids and free fatty acids
(e.g., degumming, caustic refining and silica adsorbant filtration)
and cold filtration. Cold filtration is a process that was
developed specifically to remove any particulates and sediments
that are present in the biodiesel after production. This process
cools the biodiesel and filters out any sediments or precipitates
that might form when the fuel is used at a lower temperature. Such
a process is well known in the art and is described in US Patent
Application Publication No. 2007-0175091. Suitable methods may
include cooling the biodiesel to a temperature of less than about
38.degree. C. so that the impurities and contaminants precipitate
out as particulates in the biodiesel liquid. Diatomaceous earth or
other filtering material may then added to the cooled biodiesel to
form a slurry, which may then filtered through a pressure leaf or
other type of filter to remove the particulates. The filtered
biodiesel may then be run through a polish filter to remove any
remaining sediments and diatomaceous earth, so as to produce the
final biodiesel product.
[0375] Example 13 describes the production of biodiesel using
triglyceride oil from Prototheca moriformis. The Cold Soak
Filterability by the ASTM D6751 A1 method of the biodiesel produced
in Example 13 was 120 seconds for a volume of 300 ml. This test
involves filtration of 300 ml of B100, chilled to 40.degree. F. for
16 hours, allowed to warm to room temp, and filtered under vacuum
using 0.7 micron glass fiber filter with stainless steel support.
Oils of the invention can be transesterified to generate biodiesel
with a cold soak time of less than 120 seconds, less than 100
seconds, and less than 90 seconds.
[0376] Subsequent processes may also be used if the biodiesel will
be used in particularly cold temperatures. Such processes include
winterization and fractionation. Both processes are designed to
improve the cold flow and winter performance of the fuel by
lowering the cloud point (the temperature at which the biodiesel
starts to crystallize). There are several approaches to winterizing
biodiesel. One approach is to blend the biodiesel with petroleum
diesel. Another approach is to use additives that can lower the
cloud point of biodiesel. Another approach is to remove saturated
methyl esters indiscriminately by mixing in additives and allowing
for the crystallization of saturates and then filtering out the
crystals. Fractionation selectively separates methyl esters into
individual components or fractions, allowing for the removal or
inclusion of specific methyl esters. Fractionation methods include
urea fractionation, solvent fractionation and thermal
distillation.
[0377] Another valuable fuel provided by the methods of the present
invention is renewable diesel, which comprises alkanes, such as
C10:0, C12:0, C14:0, C16:0 and C18:0 and thus, are distinguishable
from biodiesel. High quality renewable diesel conforms to the ASTM
D975 standard. The lipids produced by the methods of the present
invention can serve as feedstock to produce renewable diesel. Thus,
in another aspect of the present invention, a method for producing
renewable diesel is provided. Renewable diesel can be produced by
at least three processes: hydrothermal processing (hydrotreating);
hydroprocessing; and indirect liquefaction. These processes yield
non-ester distillates. During these processes, triacylglycerides
produced and isolated as described herein, are converted to
alkanes.
[0378] In one embodiment, the method for producing renewable diesel
comprises (a) cultivating a lipid-containing microorganism using
methods disclosed herein (b) lysing the microorganism to produce a
lysate, (c) isolating lipid from the lysed microorganism, and (d)
deoxygenating and hydrotreating the lipid to produce an alkane,
whereby renewable diesel is produced. Lipids suitable for
manufacturing renewable diesel can be obtained via extraction from
microbial biomass using an organic solvent such as hexane, or via
other methods, such as those described in U.S. Pat. No. 5,928,696.
Some suitable methods may include mechanical pressing and
centrifuging.
[0379] In some methods, the microbial lipid is first cracked in
conjunction with hydrotreating to reduce carbon chain length and
saturate double bonds, respectively. The material is then
isomerized, also in conjunction with hydrotreating. The naptha
fraction can then be removed through distillation, followed by
additional distillation to vaporize and distill components desired
in the diesel fuel to meet an ASTM D975 standard while leaving
components that are heavier than desired for meeting the D975
standard. Hydrotreating, hydrocracking, deoxygenation and
isomerization methods of chemically modifying oils, including
triglyceride oils, are well known in the art. See for example
European patent applications EP1741768 (A1); EP1741767 (A1);
EP1682466 (A1); EP1640437 (A1); EP1681337 (A1); EP1795576 (A1); and
U.S. Pat. Nos. 7,238,277; 6,630,066; 6,596,155; 6,977,322;
7,041,866; 6,217,746; 5,885,440; 6,881,873.
[0380] In one embodiment of the method for producing renewable
diesel, treating the lipid to produce an alkane is performed by
hydrotreating of the lipid composition. In hydrothermal processing,
typically, biomass is reacted in water at an elevated temperature
and pressure to form oils and residual solids. Conversion
temperatures are typically 300.degree. to 660.degree. F., with
pressure sufficient to keep the water primarily as a liquid, 100 to
170 standard atmosphere (atm). Reaction times are on the order of
15 to 30 minutes. After the reaction is completed, the organics are
separated from the water. Thereby a distillate suitable for diesel
is produced.
[0381] In some methods of making renewable diesel, the first step
of treating a triglyceride is hydroprocessing to saturate double
bonds, followed by deoxygenation at elevated temperature in the
presence of hydrogen and a catalyst. In some methods, hydrogenation
and deoxygenation occur in the same reaction. In other methods
deoxygenation occurs before hydrogenation. Isomerization is then
optionally performed, also in the presence of hydrogen and a
catalyst. Naphtha components are preferably removed through
distillation. For examples, see U.S. Pat. Nos. 5,475,160
(hydrogenation of triglycerides); 5,091,116 (deoxygenation,
hydrogenation and gas removal); 6,391,815 (hydrogenation); and
5,888,947 (isomerization).
[0382] One suitable method for the hydrogenation of triglycerides
includes preparing an aqueous solution of copper, zinc, magnesium
and lanthanum salts and another solution of alkali metal or
preferably, ammonium carbonate. The two solutions may be heated to
a temperature of about 20.degree. C. to about 85.degree. C. and
metered together into a precipitation container at rates such that
the pH in the precipitation container is maintained between 5.5 and
7.5 in order to form a catalyst. Additional water may be used
either initially in the precipitation container or added
concurrently with the salt solution and precipitation solution. The
resulting precipitate may then be thoroughly washed, dried,
calcined at about 300.degree. C. and activated in hydrogen at
temperatures ranging from about 100.degree. C. to about 400.degree.
C. One or more triglycerides may then be contacted and reacted with
hydrogen in the presence of the above-described catalyst in a
reactor. The reactor may be a trickle bed reactor, fixed bed
gas-solid reactor, packed bubble column reactor, continuously
stirred tank reactor, a slurry phase reactor, or any other suitable
reactor type known in the art. The process may be carried out
either batchwise or in continuous fashion. Reaction temperatures
are typically in the range of from about 170.degree. C. to about
250.degree. C. while reaction pressures are typically in the range
of from about 300 psig to about 2000 psig. Moreover, the molar
ratio of hydrogen to triglyceride in the process of the present
invention is typically in the range of from about 20:1 to about
700:1. The process is typically carried out at a weight hourly
space velocity (WHSV) in the range of from about 0.1 hr.sup.-1 to
about 5 hr.sup.-1. One skilled in the art willrecognize that the
time period required for reaction will vary according to the
temperature used, the molar ratio of hydrogen to triglyceride, and
the partial pressure of hydrogen. The products produced by the such
hydrogenation processes include fatty alcohols, glycerol, traces of
paraffins and unreacted triglycerides. These products are typically
separated by conventional means such as, for example, distillation,
extraction, filtration, crystallization, and the like.
[0383] Petroleum refiners use hydroprocessing to remove impurities
by treating feeds with hydrogen. Hydroprocessing conversion
temperatures are typically 300.degree. to 700.degree. F. Pressures
are typically 40 to 100 atm. The reaction times are typically on
the order of 10 to 60 minutes. Solid catalysts are employed to
increase certain reaction rates, improve selectivity for certain
products, and optimize hydrogen consumption.
[0384] Suitable methods for the deoxygenation of an oil includes
heating an oil to a temperature in the range of from about
350.degree. F. to about 550.degree. F. and continuously contacting
the heated oil with nitrogen under at least pressure ranging from
about atmospeheric to above for at least about 5 minutes.
[0385] Suitable methods for isomerization include using alkali
isomerization and other oil isomerization known in the art.
[0386] Hydrotreating and hydroprocessing ultimately lead to a
reduction in the molecular weight of the triglyceride feed. The
triglyceride molecule is reduced to four hydrocarbon molecules
under hydroprocessing conditions: a propane molecule and three
heavier hydrocarbon molecules, typically in the C8 to C18
range.
[0387] Thus, in one embodiment, the product of one or more chemical
reaction(s) performed on lipid compositions of the invention is an
alkane mixture that comprises ASTM D975 renewable diesel.
Production of hydrocarbons by microorganisms is reviewed by Metzger
et al. Appl Microbiol Biotechnol (2005) 66: 486-496 and A Look Back
at the U.S. Department of Energy's Aquatic Species Program:
Biodiesel from Algae, NREL/TP-580-24190, John Sheehan, Terri
Dunahay, John Benemann and Paul Roessler (1998).
[0388] The distillation properties of a diesel fuel is described in
terms of T10-T90 (temperature at 10% and 90%, respectively, volume
distilled). Renewable diesel was produced from Prototheca
moriformis triglyceride oil and is described in Example 13. The
T10-T90 of the material produced in Example 13 was 57.9.degree. C.
Methods of hydrotreating, isomerization, and other covalent
modification of oils disclosed herein, as well as methods of
distillation and fractionation (such as cold filtration) disclosed
herein, can be employed to generate renewable diesel compositions
with other T10-T90 ranges, such as 20, 25, 30, 35, 40, 45, 50, 60
and 65.degree. C. using triglyceride oils produced according to the
methods disclosed herein.
[0389] The T10 of the material produced in Example 13 was
242.1.degree. C. Methods of hydrotreating, isomerization, and other
covalent modification of oils disclosed herein, as well as methods
of distillation and fractionation (such as cold filtration)
disclosed herein, can be employed to generate renewable diesel
compositions with other T10 values, such as T10 between 180 and
295, between 190 and 270, between 210 and 250, between 225 and 245,
and at least 290.
[0390] The T90 of the material produced in Example 13 was
300.degree. C. Methods of hydrotreating, isomerization, and other
covalent modification of oils disclosed herein, as well as methods
of distillation and fractionation (such as cold filtration)
disclosed herein can be employed to generate renewable diesel
compositions with other T90 values, such as T90 between 280 and
380, between 290 and 360, between 300 and 350, between 310 and 340,
and at least 290.
[0391] The FBP of the material produced in Example 13 was
300.degree. C. Methods of hydrotreating, isomerization, and other
covalent modification of oils disclosed herein, as well as methods
of distillation and fractionation (such as cold filtration)
disclosed herein, can be employed to generate renewable diesel
compositions with other FBP values, such as FBP between 290 and
400, between 300 and 385, between 310 and 370, between 315 and 360,
and at least 300.
[0392] Other oils provided by the methods and compositions of the
invention can be subjected to combinations of hydrotreating,
isomerization, and other covalent modification including oils with
lipid profiles including (a) at least 1%-5%, preferably at least
4%, C.sub.8-C.sub.14; (b) at least 0.25%-1%, preferably at least
0.3%, C8; (c) at least 1%-5%, preferably at least 2%, C10; (d) at
least 1%-5%, preferably at least 2%, C12; and (3) at least 20%-40%,
preferably at least 30% C8-C14.
[0393] A traditional ultra-low sulfur diesel can be produced from
any form of biomass by a two-step process. First, the biomass is
converted to a syngas, a gaseous mixture rich in hydrogen and
carbon monoxide. Then, the syngas is catalytically converted to
liquids. Typically, the production of liquids is accomplished using
Fischer-Tropsch (FT) synthesis. This technology applies to coal,
natural gas, and heavy oils. Thus, in yet another preferred
embodiment of the method for producing renewable diesel, treating
the lipid composition to produce an alkane is performed by indirect
liquefaction of the lipid composition.
[0394] The present invention also provides methods to produce jet
fuel. Jet fuel is clear to straw colored. The most common fuel is
an unleaded/paraffin oil-based fuel classified as Aeroplane A-1,
which is produced to an internationally standardized set of
specifications. Jet fuel is a mixture of a large number of
different hydrocarbons, possibly as many as a thousand or more. The
range of their sizes (molecular weights or carbon numbers) is
restricted by the requirements for the product, for example,
freezing point or smoke point. Kerosone-type Aeroplane fuel
(including Jet A and Jet A-1) has a carbon number distribution
between about 8 and 16 carbon numbers. Wide-cut or naphta-type
Aeroplane fuel (including Jet B) typically has a carbon number
distribution between about 5 and 15 carbons.
[0395] Both Aeroplanes (Jet A and Jet B) may contain a number of
additives. Useful additives include, but are not limited to,
antioxidants, antistatic agents, corrosion inhibitors, and fuel
system icing inhibitor (FSII) agents. Antioxidants prevent gumming
and usually, are based on alkylated phenols, for example, AO-30,
AO-31, or AO-37. Antistatic agents dissipate static electricity and
prevent sparking. Stadis 450 with dinonylnaphthylsulfonic acid
(DINNSA) as the active ingredient, is an example. Corrosion
inhibitors, e.g., DCI-4A is used for civilian and military fuels
and DCI-6A is used for military fuels. FSII agents, include, e.g.,
Di-EGME.
[0396] In one embodiment of the invention, a jet fuel is produced
by blending algal fuels with existing jet fuel. The lipids produced
by the methods of the present invention can serve as feedstock to
produce jet fuel. Thus, in another aspect of the present invention,
a method for producing jet fuel is provided. Herewith two methods
for producing jet fuel from the lipids produced by the methods of
the present invention are provided: fluid catalytic cracking (FCC);
and hydrodeoxygenation (HDO).
[0397] Fluid Catalytic Cracking (FCC) is one method which is used
to produce olefins, especially propylene from heavy crude
fractions. The lipids produced by the method of the present
invention can be converted to olefins. The process involves flowing
the lipids produced through an FCC zone and collecting a product
stream comprised of olefins, which is useful as a jet fuel. The
lipids produced are contacted with a cracking catalyst at cracking
conditions to provide a product stream comprising olefins and
hydrocarbons useful as jet fuel.
[0398] In one embodiment, the method for producing jet fuel
comprises (a) cultivating a lipid-containing microorganism using
methods disclosed herein, (b) lysing the lipid-containing
microorganism to produce a lysate, (c) isolating lipid from the
lysate, and (d) treating the lipid composition, whereby jet fuel is
produced. In one embodiment of the method for producing a jet fuel,
the lipid composition can be flowed through a fluid catalytic
cracking zone, which, in one embodiment, may comprise contacting
the lipid composition with a cracking catalyst at cracking
conditions to provide a product stream comprising C.sub.2-C.sub.5
olefins.
[0399] In certain embodiments of this method, it may be desirable
to remove any contaminants that may be present in the lipid
composition. Thus, prior to flowing the lipid composition through a
fluid catalytic cracking zone, the lipid composition is pretreated.
Pretreatment may involve contacting the lipid composition with an
ion-exchange resin. The ion exchange resin is an acidic ion
exchange resin, such as Amberlyst.TM.-15 and can be used as a bed
in a reactor through which the lipid composition is flowed, either
upflow or downflow. Other pretreatments may include mild acid
washes by contacting the lipid composition with an acid, such as
sulfuric, acetic, nitric, or hydrochloric acid. Contacting is done
with a dilute acid solution usually at ambient temperature and
atmospheric pressure.
[0400] The lipid composition, optionally pretreated, is flowed to
an FCC zone where the hydrocarbonaceous components are cracked to
olefins. Catalytic cracking is accomplished by contacting the lipid
composition in a reaction zone with a catalyst composed of finely
divided particulate material. The reaction is catalytic cracking,
as opposed to hydrocracking, and is carried out in the absence of
added hydrogen or the consumption of hydrogen. As the cracking
reaction proceeds, substantial amounts of coke are deposited on the
catalyst. The catalyst is regenerated at high temperatures by
burning coke from the catalyst in a regeneration zone.
Coke-containing catalyst, referred to herein as "coked catalyst",
is continually transported from the reaction zone to the
regeneration zone to be regenerated and replaced by essentially
coke-free regenerated catalyst from the regeneration zone.
Fluidization of the catalyst particles by various gaseous streams
allows the transport of catalyst between the reaction zone and
regeneration zone. Methods for cracking hydrocarbons, such as those
of the lipid composition described herein, in a fluidized stream of
catalyst, transporting catalyst between reaction and regeneration
zones, and combusting coke in the regenerator are well known by
those skilled in the art of FCC processes. Exemplary FCC
applications and catalysts useful for cracking the lipid
composition to produce C.sub.2-C.sub.5 olefins are described in
U.S. Pat. Nos. 6,538,169, 7,288,685, which are incorporated in
their entirety by reference.
[0401] Suitable FCC catalysts generally comprise at least two
components that may or may not be on the same matrix. In some
embodiments, both two components may be circulated throughout the
entire reaction vessel. The first component generally includes any
of the well-known catalysts that are used in the art of fluidized
catalytic cracking, such as an active amorphous clay-type catalyst
and/or a high activity, crystalline molecular sieve. Molecular
sieve catalysts may be preferred over amorphous catalysts because
of their much-improved selectivity to desired products. IN some
preferred embodiments, zeolites may be used as the molecular sieve
in the FCC processes. Preferably, the first catalyst component
comprises a large pore zeolite, such as an Y-type zeolite, an
active alumina material, a binder material, comprising either
silica or alumina and an inert filler such as kaolin.
[0402] In one embodiment, cracking the lipid composition of the
present invention, takes place in the riser section or,
alternatively, the lift section, of the FCC zone. The lipid
composition is introduced into the riser by a nozzle resulting in
the rapid vaporization of the lipid composition. Before contacting
the catalyst, the lipid composition will ordinarily have a
temperature of about 149.degree. C. to about 316.degree. C.
(300.degree. F. to 600.degree. F.). The catalyst is flowed from a
blending vessel to the riser where it contacts the lipid
composition for a time of abort 2 seconds or less.
[0403] The blended catalyst and reacted lipid composition vapors
are then discharged from the top of the riser through an outlet and
separated into a cracked product vapor stream including olefins and
a collection of catalyst particles covered with substantial
quantities of coke and generally referred to as "coked catalyst."
In an effort to minimize the contact time of the lipid composition
and the catalyst which may promote further conversion of desired
products to undesirable other products, any arrangement of
separators such as a swirl arm arrangement can be used to remove
coked catalyst from the product stream quickly. The separator, e.g.
swirl arm separator, is located in an upper portion of a chamber
with a stripping zone situated in the lower portion of the chamber.
Catalyst separated by the swirl arm arrangement drops down into the
stripping zone. The cracked product vapor stream comprising cracked
hydrocarbons including light olefins and some catalyst exit the
chamber via a conduit which is in communication with cyclones. The
cyclones remove remaining catalyst particles from the product vapor
stream to reduce particle concentrations to very low levels. The
product vapor stream then exits the top of the separating vessel.
Catalyst separated by the cyclones is returned to the separating
vessel and then to the stripping zone. The stripping zone removes
adsorbed hydrocarbons from the surface of the catalyst by
counter-current contact with steam.
[0404] Low hydrocarbon partial pressure operates to favor the
production of light olefins. Accordingly, the riser pressure is set
at about 172 to 241 kPa (25 to 35 psia) with a hydrocarbon partial
pressure of about 35 to 172 kPa (5 to 25 psia), with a preferred
hydrocarbon partial pressure of about 69 to 138 kPa (10 to 20
psia). This relatively low partial pressure for hydrocarbon is
achieved by using steam as a diluent to the extent that the diluent
is 10 to 55 wt-% of lipid composition and preferably about 15 wt-%
of lipid composition. Other diluents such as dry gas can be used to
reach equivalent hydrocarbon partial pressures.
[0405] The temperature of the cracked stream at the riser outlet
will be about 510.degree. C. to 621.degree. C. (950.degree. F. to
1150.degree. F.). However, riser outlet temperatures above
566.degree. C. (1050.degree. F.) make more dry gas and more
olefins. Whereas, riser outlet temperatures below 566.degree. C.
(1050.degree. F.) make less ethylene and propylene. Accordingly, it
is preferred to run the FCC process at a preferred temperature of
about 566.degree. C. to about 630.degree. C., preferred pressure of
about 138 kPa to about 240 kPa (20 to 35 psia). Another condition
for the process is the catalyst to lipid composition ratio which
can vary from about 5 to about 20 and preferably from about 10 to
about 15.
[0406] In one embodiment of the method for producing a jet fuel,
the lipid composition is introduced into the lift section of an FCC
reactor. The temperature in the lift section will be very hot and
range from about 700.degree. C. (1292.degree. F.) to about
760.degree. C. (1400.degree. F.) with a catalyst to lipid
composition ratio of about 100 to about 150. It is anticipated that
introducing the lipid composition into the lift section will
produce considerable amounts of propylene and ethylene.
[0407] In another embodiment of the method for producing a jet fuel
using the lipid composition or the lipids produced as described
herein, the structure of the lipid composition or the lipids is
broken by a process referred to as hydrodeoxygenation (HDO). HDO
means removal of oxygen by means of hydrogen, that is, oxygen is
removed while breaking the structure of the material. Olefinic
double bonds are hydrogenated and any sulphur and nitrogen
compounds are removed. Sulphur removal is called
hydrodesulphurization (HDS). Pretreatment and purity of the raw
materials (lipid composition or the lipids) contribute to the
service life of the catalyst.
[0408] Generally in the HDO/HDS step, hydrogen is mixed with the
feed stock (lipid composition or the lipids) and then the mixture
is passed through a catalyst bed as a co-current flow, either as a
single phase or a two phase feed stock. After the HDO/MDS step, the
product fraction is separated and passed to a separate isomerzation
reactor. An isomerization reactor for biological starting material
is described in the literature (FI 100 248) as a co-current
reactor.
[0409] The process for producing a fuel by hydrogenating a
hydrocarbon feed, e.g., the lipid composition or the lipids herein,
can also be performed by passing the lipid composition or the
lipids as a co-current flow with hydrogen gas through a first
hydrogenation zone, and thereafter the hydrocarbon effluent is
further hydrogenated in a second hydrogenation zone by passing
hydrogen gas to the second hydrogenation zone as a counter-current
flow relative to the hydrocarbon effluent. Exemplary HDO
applications and catalysts useful for cracking the lipid
composition to produce C.sub.2-C.sub.5 olefins are described in
U.S. Pat. No. 7,232,935, which is incorporated in its entirety by
reference.
[0410] Typically, in the hydrodeoxygenation step, the structure of
the biological component, such as the lipid composition or lipids
herein, is decomposed, oxygen, nitrogen, phosphorus and sulphur
compounds, and light hydrocarbons as gas are removed, and the
olefinic bonds are hydrogenated. In the second step of the process,
i.e. in the so-called isomerization step, isomerzation is carried
out for branching the hydrocarbon chain and improving the
performance of the paraffin at low temperatures.
[0411] In the first step, i.e. HDO step, of the cracking process,
hydrogen gas and the lipid composition or lipids herein which are
to be hydrogenated are passed to a HDO catalyst bed system either
as co-current or counter-current flows, said catalyst bed system
comprising one or more catalyst bed(s), preferably 1-3 catalyst
beds. The HDO step is typically operated in a co-current manner. In
case of a HDO catalyst bed system comprising two or more catalyst
beds, one or more of the beds may be operated using the
counter-current flow principle. In the HDO step, the pressure
varies between 20 and 150 bar, preferably between 50 and 100 bar,
and the temperature varies between 200 and 500.degree. C.,
preferably in the range of 300-400.degree. C. In the HDO step,
known hydrogenation catalysts containing metals from Group VII
and/or VIB of the Periodic System may be used. Preferably, the
hydrogenation catalysts are supported Pd, Pt, Ni, NiMo or a CoMo
catalysts, the support being alumina and/or silica. Typically,
NiMo/Al.sub.2O.sub.3 and CoMo/Al.sub.2O.sub.3 catalysts are
used.
[0412] Prior to the HDO step, the lipid composition or lipids
herein may optionally be treated by prehydrogenation under milder
conditions thus avoiding side reactions of the double bonds. Such
prehydrogenation is carried out in the presence of a
prehydrogenation catalyst at temperatures of 50-400.degree. C. and
at hydrogen pressures of 1-200 bar, preferably at a temperature
between 150 and 250.degree. C. and at a hydrogen pressure between
10 and 100 bar. The catalyst may contain metals from Group VIII
and/or VIB of the Periodic System. Preferably, the prehydrogenation
catalyst is a supported Pd, Pt, Ni, NiMo or a CoMo catalyst, the
support being alumina and/or silica.
[0413] A gaseous stream from the HDO step containing hydrogen is
cooled and then carbon monoxide, carbon dioxide, nitrogen,
phosphorus and sulphur compounds, gaseous light hydrocarbons and
other impurities are removed therefrom. After compressing, the
purified hydrogen or recycled hydrogen is returned back to the
first catalyst bed and/or between the catalyst beds to make up for
the withdrawn gas stream. Water is removed from the condensed
liquid. The liquid is passed to the first catalyst bed or between
the catalyst beds.
[0414] After the HDO step, the product is subjected to an
isomerization step. It is substantial for the process that the
impurities are removed as completely as possible before the
hydrocarbons are contacted with the isomerization catalyst. The
isomerization step comprises an optional stripping step, wherein
the reaction product from the HDO step may be purified by stripping
with water vapour or a suitable gas such as light hydrocarbon,
nitrogen or hydrogen. The optional stripping step is carried out in
counter-current manner in a unit upstream of the isomerization
catalyst, wherein the gas and liquid are contacted with each other,
or before the actual isomerization reactor in a separate stripping
unit utilizing counter-current principle.
[0415] After the stripping step the hydrogen gas and the
hydrogenated lipid composition or lipids herein, and optionally an
n-paraffin mixture, are passed to a reactive isomerization unit
comprising one or several catalyst bed(s). The catalyst beds of the
isomerization step may operate either in co-current or
counter-current manner.
[0416] It is important for the process that the counter-current
flow principle is applied in the isomerization step. In the
isomerization step this is done by carrying out either the optional
stripping step or the isomerization reaction step or both in
counter-current manner. In the isomerzation step, the pressure
varies in the range of 20-150 bar, preferably in the range of
20-100 bar, the temperature being between 200 and 500.degree. C.,
preferably between 300 and 400.degree. C. In the isomerization
step, isomerization catalysts known in the art may be used.
Suitable isomerization catalysts contain molecular sieve and/or a
metal from Group VII and/or a carrier. Preferably, the
isomerization catalyst contains SAPO-11 or SAPO41 or ZSM-22 or
ZSM-23 or ferrierite and Pt, Pd or Ni and Al.sub.2O.sub.3 or
SiO.sub.2. Typical isomerization catalysts are, for example,
Pt/SAPO-11/Al.sub.2O.sub.3, Pt/ZSM-22/Al.sub.2O.sub.3,
Pt/ZSM-23/Al.sub.2O.sub.3 and Pt/SAPO-11/SiO.sub.2. The
isomerization step and the HDO step may be carried out in the same
pressure vessel or in separate pressure vessels. Optional
prehydrogenation may be carried out in a separate pressure vessel
or in the same pressure vessel as the HDO and isomerization
steps.
[0417] Thus, in one embodiment, the product of one or more chemical
reactions is an alkane mixture that comprises HRJ-5. In another
embodiment, the product of the one or more chemical reactions is an
alkane mixture that comprises ASTM D1655 jet fuel. In some
embodiments, the composition comforming to the specification of
ASTM 1655 jet fuel has a sulfur content that is less than 10 ppm.
In other embodiments, the composition conforming to the
specification of ASTM 1655 jet fuel has a T10 value of the
distillation curve of less than 205.degree. C. In another
embodiment, the composition conforming to the specification of ASTM
1655 jet fuel has a final boiling point (FBP) of less than
300.degree. C. In another embodiment, the composition conforming to
the specification of ASTM 1655 jet fuel has a flash point of at
least 38.degree. C. In another embodiment, the composition
conforming to the specification of ASTM 1655 jet fuel has a density
between 775K/M.sup.3 and 840 K/M.sup.3. In yet another embodiment,
the composition conforming to the specification of ASTM 1655 jet
fuel has a freezing point that is below -47.degree. C. In another
embodiment, the composition conforming to the specification of ASTM
1655 jet fuel has a net Heat of Combustion that is at least 42.8
MJ/K. In another embodiment, the composition conforming to the
specification of ASTM 1655 jet fuel has a hydrogen content that is
at least 13.4 mass %. In another embodiment, the composition
conforming to the specification of ASTM 1655 jet fuel has a thermal
stability, as tested by quantitative gravimetric JFTOT at
260.degree. C., that is below 3 mm of Hg. In another embodiment,
the composition conforming to the specification of ASTM 1655 jet
fuel has an existent gum that is below 7 mg/dl.
[0418] Thus, the present invention discloses a variety of methods
in which chemical modification of microalgal lipid is undertaken to
yield products useful in a variety of industrial and other
applications. Examples of processes for modifying oil produced by
the methods disclosed herein include, but are not limited to,
hydrolysis of the oil, hydroprocessing of the oil, and
esterification of the oil. Other chemical modification of
microalgal lipid include, without limitation, epoxidation,
oxidation, hydrolysis, sulfations, sulfonation, ethoxylation,
propoxylation, amidation, and saponification. The modification of
the microalgal oil produces basic oleochemicals that can be further
modified into selected derivative oleochemicals for a desired
function. In a manner similar to that described above with
reference to fuel producing processes, these chemical modifications
can also be performed on oils generated from the microbial cultures
described herein. Examples of basic oleochemicals include, but are
not limited to, soaps, fatty acids, fatty esters, fatty alcohols,
fatty nitrogen compounds, fatty acid methyl esters, and glycerol.
Examples of derivative oleochemicals include, but are not limited
to, fatty nitriles, esters, dimer acids, quats, surfactants, fatty
alkanolamides, fatty alcohol sulfates, resins, emulsifiers, fatty
alcohols, olefins, drilling muds, polyols, polyurethanes,
polyacrylates, rubber, candles, cosmetics, metallic soaps, soaps,
alpha-sulphonated methyl esters, fatty alcohol sulfates, fatty
alcohol ethoxylates, fatty alcohol ether sulfates, imidazolines,
surfactants, detergents, esters, quats, ozonolysis products, fatty
amines, fatty alkanolamides, ethoxysulfates, monoglycerides,
diglycerides, triglycerides (including medium chain triglycerides),
lubricants, hydraulic fluids, greases, dielectric fluids, mold
release agents, metal working fluids, heat transfer fluids, other
functional fluids, industrial chemicals (e.g., cleaners, textile
processing aids, plasticizers, stabilizers, additives), surface
coatings, paints and lacquers, electrical wiring insulation, and
higher alkanes.
[0419] Hydrolysis of the fatty acid constituents from the
glycerolipids produced by the methods of the invention yields free
fatty acids that can be derivatized to produce other useful
chemicals. Hydrolysis occurs in the presence of water and a
catalyst which may be either an acid or a base. The liberated free
fatty acids can be derivatized to yield a variety of products, as
reported in the following: U.S. Pat. Nos. 5,304,664 (Highly
sulfated fatty acids); 7,262,158 (Cleansing compositions);
7,115,173 (Fabric softener compositions); 6,342,208 (Emulsions for
treating skin); 7,264,886 (Water repellant compositions); 6,924,333
(Paint additives); 6,596,768 (Lipid-enriched ruminant feedstock);
and 6,380,410 (Surfactants for detergents and cleaners).
[0420] With regard to hydrolysis, in one embodiment of the
invention, a triglyceride oil is optionally first hydrolyzed in a
liquid medium such as water or sodium hydroxide so as to obtain
glycerol and soaps. There are various suitable triglyceride
hydrolysis methods, including, but not limited to, saponification,
acid hydrolysis, alkaline hydrolysis, enzymatic hydrolysis
(referred herein as splitting), and hydrolysis using hot-compressed
water. One skilled in the art will recognize that a triglyceride
oil need not be hydrolyzed in order to produce an oleochemical;
rather, the oil may be converted directly to the desired
oleochemical by other known process. For example, the triglyceride
oil may be directly converted to a methyl ester fatty acid through
esterification.
[0421] In some embodiments, catalytic hydrolysis of the oil
produced by methods disclosed herein occurs by splitting the oil
into glycerol and fatty acids. As discussed above, the fatty acids
may then be further processed through several other modifications
to obtained derivative oleochemicals. For example, in one
embodiment the fatty acids may undergo an amination reaction to
produce fatty nitrogen compounds. In another embodiment, the fatty
acids may undergo ozonolysis to produce mono- and
dibasic-acids.
[0422] In other embodiments hydrolysis may occur via the, splitting
of oils produced herein to create oleochemicals. In some preferred
embodiments of the invention, a triglyceride oil may be split
before other processes is performed. One skilled in the art will
recognize that there are many suitable triglyceride splitting
methods, including, but not limited to, enzymatic splitting and
pressure splitting.
[0423] Generally, enzymatic oil splitting methods use enzymes,
lipases, as biocatalysts acting on a water/oil mixture. Enzymatic
splitting then slpits the oil or fat, respectively, is into
glycerol and free fatty acids. The glycerol may then migrates into
the water phase whereas the organic phase enriches with free fatty
acids.
[0424] The enzymatic splitting reactions generally take place at
the phase boundary between organic and aqueous phase, where the
enzyme is present only at the phase boundary. Triglycerides that
meet the phase boundary then contribute to or participate in the
splitting reaction. As the reaction proceeds, the occupation
density or concentration of fatty acids still chemically bonded as
glycerides, in comparison to free fatty acids, decreases at the
phase boundary so that the reaction is slowed down. In certain
embodiments, enzymatic splitting may occur at room temperature. One
of ordinary skill in the art would know the suitable conditions for
splitting oil into the desired fatty acids.
[0425] By way of example, the reaction speed can be accelerated by
increasing the interface boundary surface. Once the reaction is
complete, free fatty acids are then separated from the organic
phase freed from enzyme, and the residue which still contains fatty
acids chemically bonded as glycerides is fed back or recycled and
mixed with fresh oil or fat to be subjected to splitting. In this
manner, recycled glycerides are then subjected to a further
enzymatic splitting process. In some embodiments, the free fatty
acids are extracted from an oil or fat partially split in such a
manner. In that way, if the chemically bound fatty acids
(triglycerides) are returned or fed back into the splitting
process, the enzyme consumption can be drastically reduced.
[0426] The splitting degree is determined as the ratio of the
measured acid value divided by the theoretically possible acid
value which can be computed for a given oil or fat. Preferably, the
acid value is measured by means of titration according to standard
common methods. Alternatively, the density of the aqueous glycerol
phase can be taken as a measure for the splitting degree.
[0427] In one embodiment, the slitting process as described herein
is also suitable for splitting the mono-, di- and triglyceride that
are contained in the so-called soap-stock from the alkali refining
processes of the produced oils. In this manner, the soap-stock can
be quantitatively converted without prior saponification of the
neutral oils into the fatty acids. For this purpose, the fatty
acids being chemically bonded in the soaps are released, preferably
before splitting, through an addition of acid. In certain
embodiments, a buffer solution is used in addition to water and
enzyme for the splitting process.
[0428] In one embodiment, oils produced in accordance with the
methods of the invention can also be subjected to saponification as
a method of hydrolysis Animal and plant oils are typically made of
triacylglycerols (TAGs), which are esters of fatty acids with the
trihydric alcohol, glycerol. In an alkaline hydrolysis reaction,
the glycerol in a TAG is removed, leaving three carboxylic acid
anions that can associate with alkali metal cations such as sodium
or potassium to produce fatty acid salts. In this scheme, the
carboxylic acid constituents are cleaved from the glycerol moiety
and replaced with hydroxyl groups. The quantity of base (e.g., KOH)
that is used in the reaction is determined by the desired degree of
saponification. If the objective is, for example, to produce a soap
product that comprises some of the oils originally present in the
TAG composition, an amount of base insufficient to convert all of
the TAGs to fatty acid salts is introduced into the reaction
mixture. Normally, this reaction is performed in an aqueous
solution and proceeds slowly, but may be expedited by the addition
of heat. Precipitation of the fatty acid salts can be facilitated
by addition of salts, such as water-soluble alkali metal halides
(e.g., NaCl or KCl), to the reaction mixture. Preferably, the base
is an alkali metal hydroxide, such as NaOH or KOH. Alternatively,
other bases, such as alkanolamines, including for example
triethanolamine and aminomethylpropanol, can be used in the
reaction scheme. In some cases, these alternatives may be preferred
to produce a clear soap product. In one embodiment the lipid
composition subjected to saponification is a tallow mimetic (i.e.,
lipid composition similar to that of tallow) produced as described
herein, or a blend of a tallow mimetic with another triglyceride
oil.
[0429] In some methods, the first step of chemical modification may
be hydroprocessing to saturate double bonds, followed by
deoxygenation at elevated temperature in the presence of hydrogen
and a catalyst. In other methods, hydrogenation and deoxygenation
may occur in the same reaction. In still other methods
deoxygenation occurs before hydrogenation. Isomerization may then
be optionally performed, also in the presence of hydrogen and a
catalyst. Finally, gases and naphtha components can be removed if
desired. For example, see U.S. Pat. Nos. 5,475,160 (hydrogenation
of triglycerides); 5,091,116 (deoxygenation, hydrogenation and gas
removal); 6,391,815 (hydrogenation); and 5,888,947
(isomerization).
[0430] In some embodiments of the invention, the triglyceride oils
are partially or completely deoxygenated. The deoxygenation
reactions form desired products, including, but not limited to,
fatty acids, fatty alcohols, polyols, ketones, and aldehydes. In
general, without being limited by any particular theory, the
deoxygenation reactions involve a combination of various different
reaction pathways, including without limitation: hydrogenolysis,
hydrogenation, consecutive hydrogenation-hydrogenolysis,
consecutive hydrogenolysis-hydrogenation, and combined
hydrogenation-hydrogenolysis reactions, resulting in at least the
partial removal of oxygen from the fatty acid or fatty acid ester
to produce reaction products, such as fatty alcohols, that can be
easily converted to the desired chemicals by further processing.
For example, in one embodiment, a fatty alcohol may be converted to
olefins through FCC reaction or to higher alkanes through a
condensation reaction.
[0431] One such chemical modification is hydrogenation, which is
the addition of hydrogen to double bonds in the fatty acid
constituents of glycerolipids or of free fatty acids. The
hydrogenation process permits the transformation of liquid oils
into semi-solid or solid fats, which may be more suitable for
specific applications.
[0432] Hydrogenation of oil produced by the methods described
herein can be performed in conjunction with one or more of the
methods and/or materials provided herein, as reported in the
following: U.S. Pat. Nos. 7,288,278 (Food additives or
medicaments); 5,346,724 (Lubrication products); 5,475,160 (Fatty
alcohols); 5,091,116 (Edible oils); 6,808,737 (Structural fats for
margarine and spreads); 5,298,637 (Reduced-calorie fat
substitutes); 6,391,815 (Hydrogenation catalyst and sulfur
adsorbent); 5,233,099 and 5,233,100 (Fatty alcohols); 4,584,139
(Hydrogenation catalysts); 6,057,375 (Foam suppressing agents); and
7,118,773 (Edible emulsion spreads).
[0433] One skilled in the art will recognize that various processes
may be used to hydrogenate carbohydrates. One suitable method
includes contacting the carbohydrate with hydrogen or hydrogen
mixed with a suitable gas and a catalyst under conditions
sufficient in a hydrogenation reactor to form a hydrogenated
product. The hydrogenation catalyst generally can include Cu, Re,
Ni, Fe, Co, Ru, Pd, Rh, Pt, Os, Ir, and alloys or any combination
thereof, either alone or with promoters such as W, Mo, Au, Ag, Cr,
Zn, Mn, Sn, B, P, Bi, and alloys or any combination thereof. Other
effective hydrogenation catalyst materials include either supported
nickel or ruthenium modified with rhenium. In an embodiment, the
hydrogenation catalyst also includes any one of the supports,
depending on the desired functionality of the catalyst. The
hydrogenation catalysts may be prepared by methods known to those
of ordinary skill in the art.
[0434] In some embodiments the hydrogenation catalyst includes a
supported Group VIII metal catalyst and a metal sponge material
(e.g., a sponge nickel catalyst). Raney nickel provides an example
of an activated sponge nickel catalyst suitable for use in this
invention. In other embodiment, the hydrogenation reaction in the
invention is performed using a catalyst comprising a nickel-rhenium
catalyst or a tungsten-modified nickel catalyst. One example of a
suitable catalyst for the hydrogenation reaction of the invention
is a carbon-supported nickel-rhenium catalyst.
[0435] In an embodiment, a suitable Raney nickel catalyst may be
prepared by treating an alloy of approximately equal amounts by
weight of nickel and aluminum with an aqueous alkali solution,
e.g., containing about 25 weight % of sodium hydroxide. The
aluminum is selectively dissolved by the aqueous alkali solution
resulting in a sponge shaped material comprising mostly nickel with
minor amounts of aluminum. The initial alloy includes promoter
metals (i.e., molybdenum or chromium) in the amount such that about
1 to 2 weight % remains in the formed sponge nickel catalyst. In
another embodiment, the hydrogenation catalyst is prepared using a
solution of ruthenium(III) nitrosyInitrate, ruthenium (III)
chloride in water to impregnate a suitable support material. The
solution is then dried to form a solid having a water content of
less than about 1% by weight. The solid may then be reduced at
atmospheric pressure in a hydrogen stream at 300.degree. C.
(uncalcined) or 400.degree. C. (calcined) in a rotary ball furnace
for 4 hours. After cooling and rendering the catalyst inert with
nitrogen, 5% by volume of oxygen in nitrogen is passed over the
catalyst for 2 hours.
[0436] In certain embodiments, the catalyst described includes a
catalyst support. The catalyst support stabilizes and supports the
catalyst. The type of catalyst support used depends on the chosen
catalyst and the reaction conditions. Suitable supports for the
invention include, but are not limited to, carbon, silica,
silica-alumina, zirconia, titania, ceria, vanadia, nitride, boron
nitride, heteropolyacids, hydroxyapatite, zinc oxide, chromia,
zeolites, carbon nanotubes, carbon fullerene and any combination
thereof.
[0437] The catalysts used in this invention can be prepared using
conventional methods known to those in the art. Suitable methods
may include, but are not limited to, incipient wetting, evaporative
impregnation, chemical vapor deposition, wash-coating, magnetron
sputtering techniques, and the like.
[0438] The conditions for which to carry out the hydrogenation
reaction will vary based on the type of starting material and the
desired products. One of ordinary skill in the art, with the
benefit of this disclosure, will recognize the appropriate reaction
conditions. In general, the hydrogenation reaction is conducted at
temperatures of 80.degree. C. to 250.degree. C., and preferably at
90.degree. C. to 200.degree. C., and most preferably at 100.degree.
C. to 150.degree. C. In some embodiments, the hydrogenation
reaction is conducted at pressures from 500 KPa to 14000 KPa.
[0439] The hydrogen used in the hydrogenolysis reaction of the
current invention may include external hydrogen, recycled hydrogen,
in situ generated hydrogen, and any combination thereof. As used
herein, the term "external hydrogen" refers to hydrogen that does
not originate from the biomass reaction itself, but rather is added
to the system from another source.
[0440] In some embodiments of the invention, it is desirable to
convert the starting carbohydrate to a smaller molecule that will
be more readily converted to desired higher hydrocarbons. One
suitable method for this conversion is through a hydrogenolysis
reaction. Various processes are known for performing hydrogenolysis
of carbohydrates. One suitable method includes contacting a
carbohydrate with hydrogen or hydrogen mixed with a suitable gas
and a hydrogenolysis catalyst in a hydrogenolysis reactor under
conditions sufficient to form a reaction product comprising smaller
molecules or polyols. As used herein, the term "smaller molecules
or polyols" includes any molecule that has a smaller molecular
weight, which can include a smaller number of carbon atoms or
oxygen atoms than the starting carbohydrate. In an embodiment, the
reaction products include smaller molecules that include polyols
and alcohols. Someone of ordinary skill in the art would be able to
choose the appropriate method by which to carry out the
hydrogenolysis reaction.
[0441] In some embodiments, a 5 and/or 6 carbon sugar or sugar
alcohol may be converted to propylene glycol, ethylene glycol, and
glycerol using a hydrogenolysis catalyst. The hydrogenolysis
catalyst may include Cr, Mo, W, Re, Mn, Cu, Cd, Fe, Co, Ni, Pt, Pd,
Rh, Ru, Ir, Os, and alloys or any combination thereof, either alone
or with promoters such as Au, Ag, Cr, Zn, Mn, Sn, Bi, B, O, and
alloys or any combination thereof. The hydrogenolysis catalyst may
also include a carbonaceous pyropolymer catalyst containing
transition metals (e.g., chromium, molybdemum, tungsten, rhenium,
manganese, copper, cadmium) or Group VIII metals (e.g., iron,
cobalt, nickel, platinum, palladium, rhodium, ruthenium, iridium,
and osmium). In certain embodiments, the hydrogenolysis catalyst
may include any of the above metals combined with an alkaline earth
metal oxide or adhered to a catalytically active support. In
certain embodiments, the catalyst described in the hydrogenolysis
reaction may include a catalyst support as described above for the
hydrogenation reaction.
[0442] The conditions for which to carry out the hydrogenolysis
reaction will vary based on the type of starting material and the
desired products. One of ordinary skill in the art, with the
benefit of this disclosure, will recognize the appropriate
conditions to use to carry out the reaction. In general, they
hydrogenolysis reaction is conducted at temperatures of 110.degree.
C. to 300.degree. C., and preferably at 170.degree. C. to
220.degree. C., and most preferably at 200.degree. C. to
225.degree. C. In some embodiments, the hydrogenolysis reaction is
conducted under basic conditions, preferably at a pH of 8 to 13,
and even more preferably at a pH of 10 to 12. In some embodiments,
the hydrogenolysis reaction is conducted at pressures in a range
between 60 KPa and 16500 KPa, and preferably in a range between
1700 KPa and 14000 KPa, and even more preferably between 4800 KPa
and 11000 KPa.
[0443] The hydrogen used in the hydrogenolysis reaction of the
current invention can include external hydrogen, recycled hydrogen,
in situ generated hydrogen, and any combination thereof.
[0444] In some embodiments, the reaction products discussed above
may be converted into higher hydrocarbons through a condensation
reaction in a condensation reactor. In such embodiments,
condensation of the reaction products occurs in the presence of a
catalyst capable of forming higher hydrocarbons. While not
intending to be limited by theory, it is believed that the
production of higher hydrocarbons proceeds through a stepwise
addition reaction including the formation of carbon-carbon, or
carbon-oxygen bond. The resulting reaction products include any
number of compounds containing these moieties, as described in more
detail below.
[0445] In certain embodiments, suitable condensation catalysts
include an acid catalyst, a base catalyst, or an acid/base
catalyst. As used herein, the term "acid/base catalyst" refers to a
catalyst that has both an acid and a base functionality. In some
embodiments the condensation catalyst can include, without
limitation, zeolites, carbides, nitrides, zirconia, alumina,
silica, aluminosilicates, phosphates, titanium oxides, zinc oxides,
vanadium oxides, lanthanum oxides, yttrium oxides, scandium oxides,
magnesium oxides, cerium oxides, barium oxides, calcium oxides,
hydroxides, heteropolyacids, inorganic acids, acid modified resins,
base modified resins, and any combination thereof. In some
embodiments, the condensation catalyst can also include a modifier.
Suitable modifiers include La, Y, Sc, P, B, Bi, Li, Na, K, Rb, Cs,
Mg, Ca, Sr, Ba, and any combination thereof. In some embodiments,
the condensation catalyst can also include a metal. Suitable metals
include Cu, Ag, Au, Pt, Ni, Fe, Co, Ru, Zn, Cd, Ga, In, Rh, Pd, Ir,
Re, Mn, Cr, Mo, W, Sn, Os, alloys, and any combination thereof.
[0446] In certain embodiments, the catalyst described in the
condensation reaction may include a catalyst support as described
above for the hydrogenation reaction. In certain embodiments, the
condensation catalyst is self-supporting. As used herein, the term
"self-supporting" means that the catalyst does not need another
material to serve as support. In other embodiments, the
condensation catalyst in used in conjunction with a separate
support suitable for suspending the catalyst. In an embodiment, the
condensation catalyst support is silica.
[0447] The conditions under which the condensation reaction occurs
will vary based on the type of starting material and the desired
products. One of ordinary skill in the art, with the benefit of
this disclosure, will recognize the appropriate conditions to use
to carry out the reaction. In some embodiments, the condensation
reaction is carried out at a temperature at which the
thermodynamics for the proposed reaction are favorable. The
temperature for the condensation reaction will vary depending on
the specific starting polyol or alcohol. In some embodiments, the
temperature for the condensation reaction is in a range from
80.degree. C. to 500.degree. C., and preferably from 125.degree. C.
to 450.degree. C., and most preferably from 125.degree. C. to
250.degree. C. In some embodiments, the condensation reaction is
conducted at pressures in a range between 0 Kpa to 9000 KPa, and
preferably in a range between 0 KPa and 7000 KPa, and even more
preferably between 0 KPa and 5000 KPa.
[0448] The higher alkanes formed by the invention include, but are
not limited to, branched or straight chain alkanes that have from 4
to 30 carbon atoms, branched or straight chain alkenes that have
from 4 to 30 carbon atoms, cycloalkanes that have from 5 to 30
carbon atoms, cycloalkenes that have from 5 to 30 carbon atoms,
aryls, fused aryls, alcohols, and ketones. Suitable alkanes
include, but are not limited to, butane, pentane, pentene,
2-methylbutane, hexane, hexene, 2-methylpentane, 3-methylpentane,
2,2,-dimethylbutane, 2,3-dimethylbutane, heptane, heptene, octane,
octene, 2,2,4-trimethylpentane, 2,3-dimethyl hexane,
2,3,4-trimethylpentane, 2,3-dimethylpentane, nonane, nonene,
decane, decene, undecane, undecene, dodecane, dodecene, tridecane,
tridecene, tetradecane, tetradecene, pentadecane, pentadecene,
nonyldecane, nonyldecene, eicosane, eicosene, uneicosane,
uneicosene, doeicosane, doeicosene, trieicosane, trieicosene,
tetraeicosane, tetraeicosene, and isomers thereof. Some of these
products may be suitable for use as fuels.
[0449] In some embodiments, the cycloalkanes and the cycloalkenes
are unsubstituted. In other embodiments, the cycloalkanes and
cycloalkenes are mono-substituted. In still other embodiments, the
cycloalkanes and cycloalkenes are multi-substituted. In the
embodiments comprising the substituted cycloalkanes and
cycloalkenes, the substituted group includes, without limitation, a
branched or straight chain alkyl having 1 to 12 carbon atoms, a
branched or straight chain alkylene having 1 to 12 carbon atoms, a
phenyl, and any combination thereof. Suitable cycloalkanes and
cycloalkenes include, but are not limited to, cyclopentane,
cyclopentene, cyclohexane, cyclohexene, methyl-cyclopentane,
methyl-cyclopentene, ethyl-cyclopentane, ethyl-cyclopentene,
ethyl-cyclohexane, ethyl-cyclohexene, isomers and any combination
thereof.
[0450] In some embodiments, the aryls formed are unsubstituted. In
another embodiment, the aryls formed are mono-substituted. In the
embodiments comprising the substituted aryls, the substituted group
includes, without limitation, a branched or straight chain alkyl
having 1 to 12 carbon atoms, a branched or straight chain alkylene
having 1 to 12 carbon atoms, a phenyl, and any combination thereof.
Suitable aryls for the invention include, but are not limited to,
benzene, toluene, xylene, ethyl benzene, para xylene, meta xylene,
and any combination thereof.
[0451] The alcohols produced in the invention have from 4 to 30
carbon atoms. In some embodiments, the alcohols are cyclic. In
other embodiments, the alcohols are branched. In another
embodiment, the alcohols are straight chained. Suitable alcohols
for the invention include, but are not limited to, butanol,
pentanol, hexanol, heptanol, octanol, nonanol, decanol, undecanol,
dodecanol, tridecanol, tetradecanol, pentadecanol, hexadecanol,
heptyldecanol, octyldecanol, nonyldecanol, eicosanol, uneicosanol,
doeicosanol, trieicosanol, tetraeicosanol, and isomers thereof.
[0452] The ketones produced in the invention have from 4 to 30
carbon atoms. In an embodiment, the ketones are cyclic. In another
embodiment, the ketones are branched. In another embodiment, the
ketones are straight chained. Suitable ketones for the invention
include, but are not limited to, butanone, pentanone, hexanone,
heptanone, octanone, nonanone, decanone, undecanone, dodecanone,
tridecanone, tetradecanone, pentadecanone, hexadecanone,
heptyldecanone, octyldecanone, nonyldecanone, eicosanone,
uneicosanone, doeicosanone, trieicosanone, tetraeicosanone, and
isomers thereof.
[0453] Another such chemical modification is interesterification.
Naturally produced glycerolipids do not have a uniform distribution
of fatty acid constituents. In the context of oils,
interesterification refers to the exchange of acyl radicals between
two esters of different glycerolipids. The interesterification
process provides a mechanism by which the fatty acid constituents
of a mixture of glycerolipids can be rearranged to modify the
distribution pattern. Interesterification is a well-known chemical
process, and generally comprises heating (to about 200.degree. C.)
a mixture of oils for a period (e.g, 30 minutes) in the presence of
a catalyst, such as an alkali metal or alkali metal alkylate (e.g.,
sodium methoxide). This process can be used to randomize the
distribution pattern of the fatty acid constituents of an oil
mixture, or can be directed to produce a desired distribution
pattern. This method of chemical modification of lipids can be
performed on materials provided herein, such as microbial biomass
with a percentage of dry cell weight as lipid at least 20%.
[0454] Directed interesterification, in which a specific
distribution pattern of fatty acids is sought, can be performed by
maintaining the oil mixture at a temperature below the melting
point of some TAGs which might occur. This results in selective
crystallization of these TAGs, which effectively removes them from
the reaction mixture as they crystallize. The process can be
continued until most of the fatty acids in the oil have
precipitated, for example. A directed interesterification process
can be used, for example, to produce a product with a lower calorie
content via the substitution of longer-chain fatty acids with
shorter-chain counterparts. Directed interesterification can also
be used to produce a product with a mixture of fats that can
provide desired melting characteristics and structural features
sought in food additives or products (e.g., margarine) without
resorting to hydrogenation, which can produce unwanted trans
isomers.
[0455] Interesterification of oils produced by the methods
described herein can be performed in conjuction with one or more of
the methods and/or materials, or to produce products, as reported
in the following: U.S. Pat. Nos. 6,080,853 (Nondigestible fat
substitutes); 4,288,378 (Peanut butter stabilizer); 5,391,383
(Edible spray oil); 6,022,577 (Edible fats for food products);
5,434,278 (Edible fats for food products); 5,268,192 (Low calorie
nut products); 5,258,197 (Reduce calorie edible compositions);
4,335,156 (Edible fat product); 7,288,278 (Food additives or
medicaments); 7,115,760 (Fractionation process); 6,808,737
(Structural fats); 5,888,947 (Engine lubricants); 5,686,131 (Edible
oil mixtures); and 4,603,188 (Curable urethane compositions).
[0456] In one embodiment in accordance with the invention,
transesterification of the oil, as described above, is followed by
reaction of the transesterified product with polyol, as reported in
U.S. Pat. No. 6,465,642, to produce polyol fatty acid polyesters.
Such an esterification and separation process may comprise the
steps as follows: reacting a lower alkyl ester with polyol in the
presence of soap; removing residual soap from the product mixture;
water-washing and drying the product mixture to remove impurities;
bleaching the product mixture for refinement; separating at least a
portion of the unreacted lower alkyl ester from the polyol fatty
acid polyester in the product mixture; and recycling the separated
unreacted lower alkyl ester.
[0457] Transesterification can also be performed on microbial
biomass with short chain fatty acid esters, as reported in U.S.
Pat. No. 6,278,006. In general, transesterification may be
performed by adding a short chain fatty acid ester to an oil in the
presence of a suitable catalyst and heating the mixture. In some
embodiments, the oil comprises about 5% to about 90% of the
reaction mixture by weight. In some embodiments, the short chain
fatty acid esters can be about 10% to about 50% of the reaction
mixture by weight. Non-limiting examples of catalysts include base
catalysts, sodium methoxide, acid catalysts including inorganic
acids such as sulfuric acid and acidified clays, organic acids such
as methane sulfonic acid, benzenesulfonic acid, and toluenesulfonic
acid, and acidic resins such as Amberlyst 15. Metals such as sodium
and magnesium, and metal hydrides also are useful catalysts.
[0458] Another such chemical modification is hydroxylation, which
involves the addition of water to a double bond resulting in
saturation and the incorporation of a hydroxyl moiety. The
hydroxylation process provides a mechanism for converting one or
more fatty acid constituents of a glycerolipid to a hydroxy fatty
acid. Hydroxylation can be performed, for example, via the method
reported in U.S. Pat. No. 5,576,027. Hydroxylated fatty acids,
including castor oil and its derivatives, are useful as components
in several industrial applications, including food additives,
surfactants, pigment wetting agents, defoaming agents, water
proofing additives, plasticizing agents, cosmetic emulsifying
and/or deodorant agents, as well as in electronics,
pharmaceuticals, paints, inks, adhesives, and lubricants. One
example of how the hydroxylation of a glyceride may be performed is
as follows: fat may be heated, preferably to about 30-50.degree. C.
combined with heptane and maintained at temperature for thirty
minutes or more; acetic acid may then be added to the mixture
followed by an aqueous solution of sulfuric acid followed by an
aqueous hydrogen peroxide solution which is added in small
increments to the mixture over one hour; after the aqueous hydrogen
peroxide, the temperature may then be increased to at least about
60.degree. C. and stirred for at least six hours; after the
stirring, the mixture is allowed to settle and a lower aqueous
layer formed by the reaction may be removed while the upper heptane
layer formed by the reaction may be washed with hot water having a
temperature of about 60.degree. C.; the washed heptane layer may
then be neutralized with an aqueous potassium hydroxide solution to
a pH of about 5 to 7 and then removed by distillation under vacuum;
the reaction product may then be dried under vacuum at 100.degree.
C. and the dried product steam-deodorized under vacuum conditions
and filtered at about 50.degree. to 60.degree. C. using
diatomaceous earth.
[0459] Hydroxylation of microbial oils produced by the methods
described herein can be performed in conjuction with one or more of
the methods and/or materials, or to produce products, as reported
in the following: U.S. Pat. Nos. 6,590,113 (Oil-based coatings and
ink); 4,049,724 (Hydroxylation process); 6,113,971 (Olive oil
butter); 4,992,189 (Lubricants and lube additives); 5,576,027
(Hydroxylated milk); and 6,869,597 (Cosmetics).
[0460] Hydroxylated glycerolipids can be converted to estolides.
Estolides consist of a glycerolipid in which a hydroxylated fatty
acid constituent has been esterified to another fatty acid
molecule. Conversion of hydroxylated glycerolipids to estolides can
be carried out by warming a mixture of glycerolipids and fatty
acids and contacting the mixture with a mineral acid, as described
by Isbell et al., JAOCS 71(2):169-174 (1994). Estolides are useful
in a variety of applications, including without limitation those
reported in the following: U.S. Pat. Nos. 7,196,124 (Elastomeric
materials and floor coverings); 5,458,795 (Thickened oils for
high-temperature applications); 5,451,332 (Fluids for industrial
applications); 5,427,704 (Fuel additives); and 5,380,894
(Lubricants, greases, plasticizers, and printing inks).
[0461] Another such chemical modification is olefin metathesis. In
olefin metathesis, a catalyst severs the alkylidene carbons in an
alkene (olefin) and forms new alkenes by pairing each of them with
different alkylidine carbons. The olefin metathesis reaction
provides a mechanism for processes such as truncating unsaturated
fatty acid alkyl chains at alkenes by ethenolysis, cross-linking
fatty acids through alkene linkages by self-metathesis, and
incorporating new functional groups on fatty acids by
cross-metathesis with derivatized alkenes.
[0462] In conjunction with other reactions, such as
transesterification and hydrogenation, olefin metathesis can
transform unsaturated glycerolipids into diverse end products.
These products include glycerolipid oligomers for waxes;
short-chain glycerolipids for lubricants; homo- and
hetero-bifunctional alkyl chains for chemicals and polymers;
short-chain esters for biofuel; and short-chain hydrocarbons for
jet fuel. Olefin metathesis can be performed on triacylglycerols
and fatty acid derivatives, for example, using the catalysts and
methods reported in U.S. Pat. No. 7,119,216, US Patent Pub. No.
2010/0160506, and U.S. Patent Pub. No. 2010/0145086.
[0463] Olefin metathesis of bio-oils generally comprises adding a
solution of Ru catalyst at a loading of about 10 to 250 ppm under
inert conditions to unsaturated fatty acid esters in the presence
(cross-metathesis) or absence (self-metathesis) of other alkenes.
The reactions are typically allowed to proceed from hours to days
and ultimately yield a distribution of alkene products. One example
of how olefin metathesis may be performed on a fatty acid
derivative is as follows: A solution of the first generation Grubbs
Catalyst
(dichloro[2(1-methylethoxy-.alpha.-O)phenyl]methylene-.alpha.-C](tricyclo-
hexyl-phosphine) in toluene at a catalyst loading of 222 ppm may be
added to a vessel containing degassed and dried methyl oleate. Then
the vessel may be pressurized with about 60 psig of ethylene gas
and maintained at or below about 30.degree. C. for 3 hours, whereby
approximately a 50% yield of methyl 9-decenoate may be
produced.
[0464] Olefin metathesis of oils produced by the methods described
herein can be performed in conjunction with one or more of the
methods and/or materials, or to produce products, as reported in
the following: Patent App. PCT/US07/081,427 (.alpha.-olefin fatty
acids) and U.S. patent application Ser. Nos. 12/281,938 (petroleum
creams), 12/281,931 (paintball gun capsules), 12/653,742
(plasticizers and lubricants), 12/422,096 (bifunctional organic
compounds), and 11/795,052 (candle wax).
[0465] Other chemical reactions that can be performed on microbial
oils include reacting triacylglycerols with a cyclopropanating
agent to enhance fluidity and/or oxidative stability, as reported
in U.S. Pat. No. 6,051,539; manufacturing of waxes from
triacylglycerols, as reported in U.S. Pat. No. 6,770,104; and
epoxidation of triacylglycerols, as reported in "The effect of
fatty acid composition on the acrylation kinetics of epoxidized
triacylglycerols", Journal of the American Oil Chemists' Society,
79:1, 59-63, (2001) and Free Radical Biology and Medicine, 37:1,
104-114 (2004).
[0466] The generation of oil-bearing microbial biomass for fuel and
chemical products as described above results in the production of
delipidated biomass meal. Delipidated meal is a byproduct of
preparing algal oil and is useful as animal feed for farm animals,
e.g., ruminants, poultry, swine and aquaculture. The resulting
meal, although of reduced oil content, still contains high quality
proteins, carbohydrates, fiber, ash, residual oil and other
nutrients appropriate for an animal feed. Because the cells are
predominantly lysed by the oil separation process, the delipidated
meal is easily digestible by such animals. Delipidated meal can
optionally be combined with other ingredients, such as grain, in an
animal feed. Because delipidated meal has a powdery consistency, it
can be pressed into pellets using an extruder or expander or
another type of machine, which are commercially available.
[0467] The invention, having been described in detail above, is
exemplified in the following examples, which are offered to
illustrate, but not to limit, the claimed invention.
VII. METHODS FOR PREPARING RECOMBINANT MICROALGAL BIOMASS
[0468] The present invention provides recombinant microbial,
preferably algal, biomass suitable for human consumption that is
rich in nutrients, including lipid and/or protein constituents,
methods of combining the same with ingredients, including edible
ingredients and other ingredients and food compositions containing
the same. Although much of the following discussion is directed to
algal biomass or algal oil, it is intended to apply equally to
microbial biomass or microbial oil generally. The invention arose
in part from the discoveries that recombinant algal biomass can be
prepared with a high oil content and/or with excellent
functionality, and the resulting biomass incorporated into food
products in which the oil and/or protein content of the biomass can
substitute in whole or in part for oils and/or fats and/or proteins
present in conventional food products. Algal oil, which can
comprise predominantly monosaturated oil, provides health benefits
compared with saturated, hydrogenated (trans fats) and
polyunsaturated fats often found in conventional food products.
Algal oil also can be used as a healthy stable cooking oil free of
trans fats. The remainder of the algal biomass can encapsulate the
oil at least until a food product is cooked, thereby increasing
shelf-life of the oil. In uncooked products, in which cells remain
intact, the biomass, along with natural antioxidants found in the
oil, also protects the oil from oxidation, which would otherwise
create unpleasant odors, tastes, and textures. The biomass also
provides several beneficial micro-nutrients in addition to the oil
and/or protein, such as algal-derived dietary fibers (both soluble
and insoluble carbohydrates), phospholipids, glycoprotein,
phytosterols, tocopherols, tocotrieneols, and selenium.
1. Microalgae for Use in the Methods of the Invention
[0469] A variety species of microalgae that produce suitable oils
and/or lipids and/or protein can be used in accordance with the
methods of the present invention, although microalgae that
naturally produce high levels of suitable oils and/or lipids and/or
protein are preferred. Considerations affecting the selection of
microalgae for use in the invention include, in addition to
production of suitable oils, lipids, or protein for production of
food products: (1) high lipid (or protein) content as a percentage
of cell weight; (2) ease of growth; (3) ease of propagation; (4)
ease of biomass processing; (5) glycerolipid profile; and (6)
absence of algal toxins (Example 5 below demonstrates dried
recombinant microalgal biomass and oils or lipids extracted from
the biomass lacks algal toxins).
[0470] In some embodiments, the cell wall of the microalgae must be
disrupted during food processing (e.g., cooking) to release the
active components or for digestion, and, in these embodiments,
strains of microalgae with cell walls susceptible to digestion in
the gastrointestinal tract of an animal, e.g., a human or other
monogastrics, are preferred, especially if the algal biomass is to
be used in uncooked food products. Digestibility is generally
decreased for recombinant microalgal strains which have a high
content of cellulose/hemicellulose in the cell walls. Digestibility
can be evaluated using a standard pepsin digestibility assay.
2. Methods of Generating a Microalgae Strain Lacking or that has
Significantly Reduced Pigmentation
[0471] Microalgae, such as Chlorella, can be capable of either
photosynthetic or heterotrophic growth. Prototheca is an obligate
heterotroph. When grown in heterotrophic conditions where the
carbon source is a fixed carbon source and in the absence of light,
the normally green colored microalgae has a yellow color, lacking
or is significantly reduced in green pigmentation. Microalgae of
reduced (or lacking in) green pigmentation can be advantageous as a
food ingredient. One advantage of microalgae of reduced (or is
lacking) in green pigmentation is that the microalgae has a reduced
chlorophyll flavor. Another advantage of microalgae of reduced (or
is lacking in) green pigmentation is that as a food ingredient, the
addition of the microalgae to foodstuffs will not impart a green
color that can be unappealing to the consumer. The reduced green
pigmentation of microalgae grown under heterotrophic conditions is
transient. When switched back to phototrophic growth, microalgae
capable of both phototrophic and heterotrophic growth will regain
the green pigmentation. Additionally, even with reduced green
pigments, heterotrophically grown microalgae is a yellow color and
this may be unsuitable for some food applications where the
consumer expects the color of the foodstuff to be white or light in
color. Thus, it is advantageous to generate a microalgae strain
that is capable of heterotrophic growth (so it is reduced or
lacking in green pigmentation) and is also reduced in yellow
pigmentation (so that it is a neutral color for food
applications).
[0472] One method for generating such microalgae strain lacking in
or has significantly reduced pigmentation is through mutagenesis
and then screening for the desired phenotype. Several methods of
mutagenesis are known and practiced in the art. For example, Urano
et al., (Urano et al., J Bioscience Bioengineering (2000) v. 90(5):
pp. 567-569) describes yellow and white color mutants of Chlorella
ellipsoidea generated using UV irradiation. Kamiya (Kamiya, Plant
Cell Physiol. (1989) v. 30(4): 513-521) describes a colorless
strain of Chlorella vulgaris, 11 h (M125).
[0473] In addition to mutagenesis by UV irradiation, chemical
mutagenesis can also be employed in order to generate microalgae
with reduced (or lacking in) pigmentation. Chemical mutagens such
as ethyl methanesulfonate (EMS) or N-methyl-N'
nitro-N-nitroguanidine (NTG) have been shown to be effective
chemical mutagens on a variety of microbes including yeast, fungi,
mycobacterium and microalgae. Mutagenesis can also be carried out
in several rounds, where the microalgae is exposed to the mutagen
(either UV or chemical or both) and then screened for the desired
reduced pigmentation phenotype. Colonies with the desired phenotype
are then streaked out on plates and reisolated to ensure that the
mutation is stable from one generation to the next and that the
colony is pure and not of a mixed population.
[0474] In a particular example, Chlorella protothecoides was used
to generate strains lacking in or with reduced pigmentation using a
combination of UV and chemical mutagenesis. Chlorella
protothecoides was exposed to a round of chemical mutagenesis with
NTG and colonies were screened for color mutants. Colonies not
exhibiting color mutations were then subjected to a round of UV
irradiation and were again screened for color mutants. In one
embodiment, a Chlorella protothecoides strain lacking in
pigmentation was isolated and is Chlorella protothecoides 33-55,
deposited on Oct. 13, 2009 at the American Type Culture Collection
at 10801 University Boulevard, Manassas, Va. 20110-2209, in
accordance with the Budapest Treaty, with a Patent Deposit
Designation of PTA-XXXX. In another embodiment, a Chlorella
protothecoides strain with reduced pigmentation was isolated and is
Chlorella protothecoides 25-32, deposited on Oct. 13, 2009 at the
American Type Culture Collection at 10801 University Boulevard,
Manassas, Va. 20110-2209, in accordance with the Budapest Treaty,
with a Patent Deposit Designation of PTA-XXXX.
[0475] High lipid biomass from microalgae is an advantageous
material for inclusion in food products compared to low lipid
biomass, because it allows for the addition of less recombinant
microalgal biomass to incorporate the same amount of lipid into a
food composition. This is advantageous, because healthy oils from
high lipid microalgae can be added to food products without
altering other attributes such as texture and taste compared with
low lipid biomass. The lipid-rich biomass provided by the methods
of the invention typically has at least 25% lipid by dry cell
weight. Process conditions can be adjusted to increase the
percentage weight of cells that is lipid. For example, in certain
embodiments, a microalgae is cultured in the presence of a limiting
concentration of one or more nutrients, such as, for example,
nitrogen, phosphorous, or sulfur, while providing an excess of a
fixed carbon source, such as glucose. Nitrogen limitation tends to
increase microbial lipid yield over microbial lipid yield in a
culture in which nitrogen is provided in excess. In particular
embodiments, the increase in lipid yield is at least about 10%,
50%, 100%, 200%, or 500%. The microbe can be cultured in the
presence of a limiting amount of a nutrient for a portion of the
total culture period or for the entire period. In some embodiments,
the nutrient concentration is cycled between a limiting
concentration and a non-limiting concentration at least twice
during the total culture period.
[0476] High protein biomass from algae is another advantageous
material for inclusion in food products. The methods of the
invention can also provide biomass that has at least 20%, 30%, 40%
or 50% of its dry cell weight as protein. Growth conditions can be
adjusted to increase the percentage weight of cells that is
protein. In a preferred embodiment, a microalgae is cultured in a
nitrogen rich environment and an excess of fixed carbon energy such
as glucose or any of the other carbon sources discussed above.
Conditions in which nitrogen is in excess tends to increase
microbial protein yield over microbial protein yield in a culture
in which nitrogen is not provided in excess. For maximal protein
production, the microbe is preferably cultured in the presence of
excess nitrogen for the total culture period. Suitable nitrogen
sources for microalgae may come from organic nitrogen sources
and/or inorganic nitrogen sources.
[0477] Recombinant microalgal cultures generated according to the
methods described herein yield recombinant microalgal biomass in
fermentation media. To prepare the biomass for use as a food
composition, the biomass is concentrated, or harvested, from the
fermentation medium. At the point of harvesting the recombinant
microalgal biomass from the fermentation medium, the biomass
comprises predominantly intact cells suspended in an aqueous
culture medium. To concentrate the biomass, a dewatering step is
performed. Dewatering or concentrating refers to the separation of
the biomass from fermentation broth or other liquid medium and so
is solid-liquid separation. Thus, during dewatering, the culture
medium is removed from the biomass (for example, by draining the
fermentation broth through a filter that retains the biomass), or
the biomass is otherwise removed from the culture medium. Common
processes for dewatering include centrifugation, filtration, and
the use of mechanical pressure. These processes can be used
individually or in any combination.
[0478] After concentration, recombinant microalgal biomass can be
processed, as described herein, to produce vacuum-packed cake,
algal flakes, algal homogenate, algal powder, algal flour, or algal
oil.
3. Chemical Composition of Recombinant Microalgal Biomass
[0479] The recombinant microalgal biomass generated by the culture
methods described herein comprises recombinant microalgal oil
and/or protein as well as other constituents generated by the
microorganisms or incorporated by the microorganisms from the
culture medium during fermentation.
[0480] Heterotrophic growth results in relatively low chlorophyll
content (as compared to phototrophic systems such as open ponds or
closed photobioreactor systems). Reduced chlorophyll content
generally improves organoleptic properties of microalgae and
therefore allows more algal biomass (or oil prepared therefrom) to
be incorporated into a food product. The reduced chlorophyll
content found in heterotrophically grown microalgae (e.g.,
Chlorella) also reduces the green color in the biomass as compared
to phototrophically grown microalgae. Thus, the reduced chlorophyll
content avoids an often undesired green coloring associated with
food products containing phototrophically grown microalgae and
allows for the incorporation or an increased incorporation of algal
biomass into a food product. In at least one embodiment, the food
product contains heterotrophically grown microalgae of reduced
chlorophyll content compared to phototrophically grown
microalgae.
[0481] The recombinant microalgal oil of the biomass described
herein (or extracted from the biomass) can comprise glycerolipids
with one or more distinct fatty acid ester side chains.
Glycerolipids are comprised of a glycerol molecule esterified to
one, two, or three fatty acid molecules, which can be of varying
lengths and have varying degrees of saturation. Specific blends of
algal oil can be prepared either within a single species of algae,
or by mixing together the biomass (or algal oil) from two or more
species of microalgae.
[0482] Thus, the oil composition, i.e., the properties and
proportions of the fatty acid constituents of the glycerolipids,
can also be manipulated by combining biomass (or oil) from at least
two distinct species of microalgae. In some embodiments, at least
two of the distinct species of microalgae have different
glycerolipid profiles. The distinct species of microalgae can be
cultured together or separately as described herein, preferably
under heterotrophic conditions, to generate the respective oils.
Different species of microalgae can contain different percentages
of distinct fatty acid constituents in the cell's
glycerolipids.
[0483] In some embodiments, the recombinant microalgal oil is
primarily comprised of monounsaturated oil. In some cases, the
algal oil is at least 20% monounsaturated oil by weight. In various
embodiments, the algal oil is at least 25%, 50%, 75% or more
monounsaturated oil by weight or by volume. In some embodiments,
the monounsaturated oil is 18:1, 16:1, 14:1 or 12:1. In some
embodiments, the recombinant microalgal oil comprises at least 10%,
20%, 25%, or 50% or more esterified oleic acid or esterified
alpha-linolenic acid by weight of by volume. In at least one
embodiment, the algal oil comprises less than 10%, less than 5%,
less than 3%, less than 2%, or less than 1% by weight or by volume,
or is substantially free of, esterified docosahexanoic acid (DHA
(22:6)). For examples of production of high DHA-containing
microalgae, such as in Crypthecodinium cohnii, see U.S. Pat. Nos.
7,252,979, 6,812,009 and 6,372,460.
[0484] High protein recombinant microalgal biomass has been
generated using different methods of culture. Recombinant
microalgal biomass with a higher percentage of protein content is
useful in accordance with the present invention. For example, the
protein content of various species of microalgae has been reported
(see Table 1 of Becker, Biotechnology Advances (2007) 25:207-210).
Controlling the renewal rate in a semi-continous photoautotrophic
culture of Tetraselmis suecica has been reported to affect the
protein content per cell, the highest being approximately 22.8%
protein (Fabregas, et al., Marine Biotechnology (2001)
3:256-263).
[0485] Recombinant microalgal biomass generated by culture methods
described herein and useful in accordance to those embodiments of
the present invention relating to high protein typically comprises
at least 30% protein by dry cell weight. In some embodiments, the
recombinant microalgal biomass comprises at least 40%, 50%, 75% or
more protein by dry cell weight. In some embodiments, the
recombinant microalgal biomass comprises from 30-75% protein by dry
cell weight or from 40-60% protein by dry cell weight. In some
embodiments, the protein in the recombinant microalgal biomass
comprises at least 40% digestible crude protein. In other
embodiments, the protein in the recombinant microalgal biomass
comprises at least 50%, 60%, 70%, 80%, or at least 90% digestible
crude protein. In some embodiments, the protein in the recombinant
microalgal biomass comprises from 40-90% digestible crude protein,
from 50-80% digestible crude protein, or from 60-75% digestible
crude protein.
[0486] Recombinant microalgal biomass (and oil extracted
therefrom), can also include other constituents produced by the
microalgae, or incorporated into the biomass from the culture
medium. These other constituents can be present in varying amounts
depending on the culture conditions used and the species of
microalgae (and, if applicable, the extraction method used to
recover recombinant microalgal oil from the biomass). The other
constituents can include, without limitation, phospholipids (e.g.,
algal lecithin), carbohydrates, soluble and insoluble fiber,
glycoproteins, phytosterols (e.g., .beta.-sitosterol, campesterol,
stigmasterol, ergosterol, and brassicasterol), tocopherols,
tocotrienols, carotenoids (e.g., .alpha.-carotene,
.beta.-carotene,and lycopene), xanthophylls (e.g., lutein,
zeaxanthin, .alpha.-cryptoxanthin, and
.beta.-cryptoxanthin),proteins, polysaccharides (e.g., arabinose,
mannose, galactose, 6-methyl galactose and glucose) and various
organic or inorganic compounds (e.g., selenium).
[0487] In some cases, the recombinant microalgal biomass comprises
at least 10% soluble fiber. In other embodiments, the recombinant
microalgal biomass comprises at least 20% to 25% soluble fiber. In
some embodiments, the recombinant microalgal biomass comprises at
least 30% insoluble fiber. In other embodiments, the recombinant
microalgal biomass comprises at least 50% to at least 70% insoluble
fiber. Total dietary fiber is the sum of soluble fiber and
insoluble fiber. In some embodiments, the recombinant microalgal
biomass comprises at least 40% total dietary fiber. In other
embodiments, the recombinant microalgal biomass comprises at least
50%, 55%, 60%, 75%, 80%, 90%, to 95% total dietary fiber.
VIII. PROCESSING RECOMBINANT MICROALGAL BIOMASS INTO FINISHED FOOD
INGREDIENTS
[0488] The concentrated recombinant microalgal biomass produced in
accordance with the methods of the invention is itself a finished
food ingredient and may be used in foodstuffs without further, or
with only minimal, modification. For example, the cake can be
vacuum-packed or frozen. Alternatively, the biomass may be dried
via lyophilization, a "freeze-drying" process, in which the biomass
is frozen in a freeze-drying chamber to which a vacuum is applied.
The application of a vacuum to the freeze-drying chamber results in
sublimation (primary drying) and desorption (secondary drying) of
the water from the biomass. However, the present invention provides
a variety of recombinant microalgal derived finished food
ingredients with enhanced properties resulting from processing
methods of the invention that can be applied to the concentrated
recombinant microalgal biomass.
[0489] Drying the recombinant microalgal biomass, either
predominantly intact or in homogenate form, is advantageous to
facilitate further processing or for use of the biomass in the
methods and compositions described herein. Drying refers to the
removal of free or surface moisture/water from predominantly intact
biomass or the removal of surface water from a slurry of
homogenized (e.g., by micronization)biomass. Different textures and
flavors can be conferred on food products depending on whether the
algal biomass is dried, and if so, the drying method. Drying the
biomass generated from the cultured microalgae described herein
removes water that may be an undesirable component of finished food
products or food ingredients. In some cases, drying the biomass may
facilitate a more efficient recombinant microalgal oil extraction
process.
[0490] In one embodiment, the concentrated recombinant microalgal
biomass is drum dried to a flake form to produce algal flake, as
described in part A of this section. In another embodiment, the
concentrated micralgal biomass is spray or flash dried (i.e.,
subjected to a pneumatic drying process) to form a powder
containing predominantly intact cells to produce algal powder, as
described in part B of this section. In another embodiment, the
concentrated recombinant microalgal biomass is micronized
(homogenized) to form a homogenate of predominantly lysed cells
that is then spray or flash dried to produce algal flour, as
described in part C of this section. In another embodiment, oil is
extracted from the concentrated recombinant microalgal biomass to
form algal oil, as described in part D of this section.
1. Algal Flake
[0491] Algal flake of the invention is prepared from concentrated
recombinant microalgal biomass that is applied as a film to the
surface of a rolling, heated drum. The dried solids are then
scraped off with a knife or blade, resulting in a small flakes.
U.S. Pat. No. 6,607,900 describes drying recombinant microalgal
biomass using a drum dryer without a prior centrifugation
(concentration) step, and such a process may be used in accordance
with the methods of the invention.
[0492] Because the biomass may be exposed to high heat during the
drying process, it may be advantageous to add an antioxidant to the
biomass prior to drying. The addition of an antioxidant will not
only protect the biomass during drying, but also extend the
shelf-life of the dried recombinant microalgal biomass when stored.
In a preferred embodiment, an antioxidant is added to the
recombinant microalgal biomass prior to subsequent processing such
as drying or homogenization. Antioxidants that are suitable for use
are discussed in detail below.
[0493] Additionally, if there is significant time between the
production of the dewatered recombinant microalgal biomass and
subsequent processing steps, it may be advantageous to pasteurize
the biomass prior to drying. Free fatty acids from lipases may form
if there is significant time between producing and drying the
biomass. Pasteurization of the biomass inactivates these lipases
and prevents the formation of a "soapy" flavor in the resulting
dried biomass product. Thus, in one embodiment, the invention
provides pasteurized recombinant microalgal biomass. In another
embodiment, the pasteurized recombinant microalgal biomass is an
algal flake.
2. Algal Powder
[0494] Algal powder of the invention is prepared from concentrated
recombinant microalgal biomass using a pneumatic or spray dryer
(see for example U.S. Pat. No. 6,372,460). In a spray dryer,
material in a liquid suspension is sprayed in a fine droplet
dispersion into a current of heated air. The entrained material is
rapidly dried and forms a dry powder. In some cases, a pulse
combustion dryer can also be used to achieve a powdery texture in
the final dried material. In other cases, a combination of spray
drying followed by the use of a fluid bed dryer is used to achieve
the optimal conditions for dried microbial biomass (see, for
example, U.S. Pat. No. 6,255,505). As an alternative, pneumatic
dryers can also be used in the production of algal powder.
Pneumatic dryers draw or entrain the material that is to be dried
in a stream of hot air. While the material is entrained in the hot
air, the moisture is rapidly removed. The dried material is then
separated from the moist air and the moist air is then recirculated
for further drying.
3. Algal Flour
[0495] Algal flour of the invention is prepared from concentrated
recombinant microalgal biomass that has been mechanically lysed and
homogenized and the homogenate spray or flash dried (or dried using
another pneumatic drying system). The production of algal flour
requires that cells be lysed to release their oil and that cell
wall and intracellular components be micronized or reduced in
particle size to an average size of no more than 20 .mu.m,
preferably 10 .mu.m. The lysed microbial cells can agglomerate to
form bigger particles of up to 1,000 .mu.m. The resulting oil,
water, and micronized particles are emulsified such that the oil
does not separate from the dispersion prior to drying. For example,
a pressure disrupter can be used to pump a cell containing slurry
through a restricted orifice valve to lyse the cells. High pressure
(up to 1500 bar) is applied, followed by an instant expansion
through an exiting nozzle. Cell disruption is accomplished by three
different mechanisms: impingement on the valve, high liquid shear
in the orifice, and sudden pressure drop upon discharge, causing an
explosion of the cell. The method releases intracellular molecules.
A Niro (Niro Soavi GEA) homogenizer (or any other high pressure
homogenizer) can be used to process cells to particles
predominantly 0.2 to 5 microns in length. Processing of algal
biomass under high pressure (approximately 1000 bar) typically
lyses over 90% of the cells and reduces particle size to less than
5 microns.
[0496] Alternatively, a ball mill can be used. In a ball mill,
cells are agitated in suspension with small abrasive particles,
such as beads. Cells break because of shear forces, grinding
between beads, and collisions with beads. The beads disrupt the
cells to release cellular contents. In one embodiment, algal
biomass is disrupted and formed into a stable emulsion using a
Dyno-mill ECM Ultra (CB Mills) ball mill Cells can also be
disrupted by shear forces, such as with the use of blending (such
as with a high speed or Waring blender as examples), the french
press, or even centrifugation in case of weak cell walls, to
disrupt cells. A suitable ball mill including specifics of ball
size and blade is described in U.S. Pat. No. 5,330,913.
[0497] The immediate product of homogenization is a slurry of
particles smaller in size than the original cells that is suspended
in in oil and water. The particles represent cellular debris. The
oil and water are released by the cells. Additional water may be
contributed by aqueous media containing the cells before
homogenization. The particles are preferably in the form of a
micronized homogenate. If left to stand, some of the smaller
particles may coalesce. However, an even dispersion of small
particles can be preserved by seeding with a microcrystalline
stabilizer, such as microcrystalline cellulose.
[0498] To form the algal flour, the slurry is spray or flash dried,
removing water and leaving a dry power containing cellular debris
and oil. Although the oil content of the powder can be at least 10,
25 or 50% by weight of the dry powder, the powder can have a dry
rather than greasy feel and appearance (e.g., lacking visible oil)
and can also flow freely when shaken. Various flow agents
(including silica-derived products) can also be added. After
drying, the water or moisture content of the powder is typically
less than 10%, 5%, 3% or 1% by weight. Other dryers such as
pneumatic dryers or pulse combustion dryers can also be used to
produce algal flour.
[0499] The oil content of algal flour can vary depending on the
percent oil of the algal biomass. Algal flour can be produced from
algal biomass of varying oil content. In certain embodiments, the
algal flour is produced from algal biomass of the same oil content.
In other embodiments, the algal flour is produced from alglal
biomass of different oil content. In the latter case, algal biomass
of varying oil content can be combined and then the homogenization
step performed. In other embodiments, algal flour of varying oil
content is produced first and then blended together in various
proportions in order to achieve an algal flour product that
contains the final desired oil content. In a further embodiment,
algal biomass of different lipid profiles can be combined together
and then homogenized to produce algal flour. In another embodiment,
algal flour of different lipid profiles is produced first and then
blended together in various proportions in order to achieve an
algal flour product that contains the final desired lipid
profile.
[0500] The algal flour of the invention is useful for a wide range
of food preparations. Because of the oil content, fiber content and
the micronized particles, algal flour is a multifunctional food
ingredient. Algal flour can be used in baked goods, quick breads,
yeast dough products, egg products, dressing, sauces, nutritional
beverages, algal milk, pasta and gluten free products. Additional
details of formulating these food products and more with algal
flour is described in the Examples below.
[0501] Algal flour can be used in baked goods in place of
convention fat sources (e.g., oil, butter or margarine) and eggs.
Baked goods and gluten free products have superior moisture content
and a cumb structure that is indistinguishable from conventional
baked goods made with butter and eggs. Because of the superior
moisture content, these baked goods have a longer shelf life and
retain their original texture longer than conventional baked goods
that are produced without algal flour.
[0502] Algal flour can also act as a fat extender with used in
smoothies, sauces, or dressings. The composition of algal flour is
unique in its ability to convey organoleptic qualities and
mouth-feel comparable to a food product with a higher fat content.
Dressings, sauces and beverages made with algal flour have a
rheology and opacity that is close to conventional higher fat
recipes although these food products contains about half the
fat/oil levels. Algal flour is also a superior emulsifier and is
suitable in use in food preparation that requires thickness,
opacity and viscosity, such as, sauces, dressings and soups.
Additionally the lipid profile found in algal flour of the
inventions described herein does not contain trans-fat and have a
higher level of healthy, unsaturated fats as compared to butter or
margarine (or other animal fats). Thus, products made with algal
flour can have a lower fat content (with healthier fats) without
sacrificing the mouthfeel and organoleptic qualities of the same
food product that is made using a conventional recipe using a
conventional fat source.
[0503] Algal flour can also be added to powdered or liquid eggs,
which are typically served in a food service setting. The addition
of algal flour improves the appearance, texture and mouthfeel of
powdered and liquid eggs and also extends improved appearance,
texture and mouthfeel over time, even when the prepared eggs are
held on a steam table. Specific formulations and sensory panel
results are described below in the Examples.
4. Algal Oil
[0504] In one aspect, the present invention is directed to a method
of preparing algal oil by harvesting algal oil from an algal
biomass comprising at least 15% oil by dry weight under GMP
conditions, in which the algal oil is greater than 50% 18:1 lipid.
In some cases, the algal biomass comprises a mixture of at least
two distinct species of microalgae. In some cases, at least two of
the distinct species of microalgae have been separately cultured.
In at least one embodiment, at least two of the distinct species of
microalgae have different glycerolipid profiles. In some cases, the
algal biomass is derived from algae grown heterotrophically. In
some cases, all of the at least two distinct species of microalgae
contain at least 15% oil by dry weight.
[0505] In one aspect, the present invention is directed to a method
of making a food composition comprising combining algal oil
obtained from algal cells containing at least 10%, or at least 15%
oil by dry weight with one or more other edible ingredients to form
the food composition. In some cases, the method further comprises
preparing the algal oil under GMP conditions.
[0506] Algal oil can be separated from lysed biomass for use in
food product (among other applications). The algal biomass
remaining after oil extraction is referred to as delipidated meal.
Delipidated meal contains less oil by dry weight or volume than the
microalgae contained before extraction. Typically 50-90% of oil is
extracted so that delipidated meal contains, for example, 10-50% of
the oil content of biomass before extraction. However, the biomass
still has a high nutrient value in content of protein and other
constituents discussed above. Thus, the delipidated meal can be
used in animal feed or in human food applications.
[0507] In some embodiments of the method, the algal oil is at least
50% w/w oleic acid and contains less than 5% DHA. In some
embodiments of the method, the algal oil is at least 50% w/w oleic
acid and contains less than 0.5% DHA. In some embodiments of the
method, the algal oil is at least 50% w/w oleic acid and contains
less than 5% glycerolipid containing carbon chain length greater
than 18. In some cases, the algal cells from which the algal oil is
obtained comprise a mixture of cells from at least two distinct
species of microalgae. In some cases, at least two of the distinct
species of microalgae have been separately cultured. In at least
one embodiment, at least two of the distinct species of microalgae
have different glycerolipid profiles. In some cases, the algal
cells are cultured under heterotrophic conditions. In some cases,
all of the at least two distinct species of microalgae contain at
least 10%, or at least 15% oil by dry weight.
[0508] In one aspect, the present invention is directed to algal
oil containing at least 50% monounsaturated oil and containing less
than 1% DHA prepared under GMP conditions. In some cases, the
monounsaturated oil is 18:1 lipid. In some cases, the algal oil is
packaged in a capsule for delivery of a unit dose of oil. In some
cases, the algal oil is derived from a mixture of at least two
distinct species of microalgae. In some cases, at least two of the
distinct species of microalgae have been separately cultured. In at
least one embodiment, at least two of the distinct species of
microalgae have different glycerolipid profiles. In some cases, the
algal oil is derived from algal cells cultured under heterotrophic
conditions.
[0509] In one aspect, the present invention is directed to oil
comprising greater than 60% 18:1, and at least 0.20 mg/g
tocotrienol.
[0510] In one aspect, the present invention is directed to a fatty
acid alkyl ester composition comprising greater than 60% 18:1
ester, and at least 0.20 mg/g tocotrienol.
[0511] Algal oil of the invention is prepared from concentrated,
washed recombinant microalgal biomass by extraction. The cells in
the biomass are lysed prior to extraction. Optionally, the
microbial biomass may also be dried (oven dried, lyophilized, etc.)
prior to lysis (cell disruption). Alternatively, cells can be lysed
without separation from some or all of the fermentation broth when
the fermentation is complete. For example, the cells can be at a
ratio of less than 1:1 v:v cells to extracellular liquid when the
cells are lysed.
[0512] Microalgae containing lipids can be lysed to produce a
lysate. As detailed herein, the step of lysing a microorganism
(also referred to as cell lysis) can be achieved by any convenient
means, including heat-induced lysis, adding a base, adding an acid,
using enzymes such as proteases and polysaccharide degradation
enzymes such as amylases, using ultrasound, mechanical
pressure-based lysis, and lysis using osmotic shock. Each of these
methods for lysing a microorganism can be used as a single method
or in combination simultaneously or sequentially. The extent of
cell disruption can be observed by microscopic analysis. Using one
or more of the methods above, typically more than 70% cell breakage
is observed. Preferably, cell breakage is more than 80%, more
preferably more than 90% and most preferred about 100%.
[0513] Lipids and oils generated by the microalgae in accordance
with the present invention can be recovered by extraction. In some
cases, extraction can be performed using an organic solvent or an
oil, or can be performed using a solventless-extraction
procedure.
[0514] For organic solvent extraction of the recombinant microalgal
oil, the preferred organic solvent is hexane. Typically, the
organic solvent is added directly to the lysate without prior
separation of the lysate components. In one embodiment, the lysate
generated by one or more of the methods described above is
contacted with an organic solvent for a period of time sufficient
to allow the lipid components to form a solution with the organic
solvent. In some cases, the solution can then be further refined to
recover specific desired lipid components. The mixture can then be
filtered and the hexane removed by, for example, rotoevaporation.
Hexane extraction methods are well known in the art. See, e.g.,
Frenz et al., Enzyme Microb. Technol., 11:717 (1989).
[0515] Miao and Wu describe a protocol of the recovery of
recombinant microalgal lipid from a culture of Chlorella
protothecoides in which the cells were harvested by centrifugation,
washed with distilled water and dried by freeze drying. The
resulting cell powder was pulverized in a mortar and then extracted
with n-hexane. Miao and Wu, Biosource Technology 97:841-846
(2006).
[0516] In some cases, recombinant microalgal oils can be extracted
using liquefaction (see for example Sawayama et al., Biomass and
Bioenergy 17:33-39 (1999) and Inoue et al., Biomass Bioenergy
6(4):269-274 (1993)); oil liquefaction (see for example Minowa et
al., Fuel 74(12):1735-1738 (1995)); or supercritical CO.sub.2
extraction (see for example Mendes et al., Inorganica Chimica Acta
356:328-334 (2003)).
[0517] Oil extraction includes the addition of an oil directly to a
lysate without prior separation of the lysate components. After
addition of the oil, the lysate separates either of its own accord
or as a result of centrifugation or the like into different layers.
The layers can include in order of decreasing density: a pellet of
heavy solids, an aqueous phase, an emulsion phase, and an oil
phase. The emulsion phase is an emulsion of lipids and aqueous
phase. Depending on the percentage of oil added with respect to the
lysate (w/w or v/v), the force of centrifugation if any, volume of
aqueous media and other factors, either or both of the emulsion and
oil phases can be present. Incubation or treatment of the cell
lysate or the emulsion phase with the oil is performed for a time
sufficient to allow the lipid produced by the microorganism to
become solubilized in the oil to form a heterogeneous mixture.
[0518] In various embodiments, the oil used in the extraction
process is selected from the group consisting of oil from soy,
rapeseed, canola, palm, palm kernel, coconut, corn, waste vegetable
oil, Chinese tallow, olive, sunflower, cotton seed, chicken fat,
beef tallow, porcine tallow, microalgae, macroalgae, Cuphea, flax,
peanut, choice white grease (lard), Camelina sativa mustard
seedcashew nut, oats, lupine, kenaf, calendula, hemp, coffee,
linseed, hazelnut, euphorbia, pumpkin seed, coriander, camellia,
sesame, safflower, rice, tung oil tree, cocoa, copra, pium poppy,
castor beans, pecan, jojoba, jatropha, macadamia, Brazil nuts, and
avocado. The amount of oil added to the lysate is typically greater
than 5% (measured by v/v and/or w/w) of the lysate with which the
oil is being combined. Thus, a preferred v/v or w/w of the oil is
greater than 5%, 10%, 20%, 25%, 50%, 70%, 90%, or at least 95% of
the cell lysate.
[0519] Lipids can also be extracted from a lysate via a solventless
extraction procedure without substantial or any use of organic
solvents or oils by cooling the lysate. Sonication can also be
used, particularly if the temperature is between room temperature
and 65.degree. C. Such a lysate on centrifugation or settling can
be separated into layers, one of which is an aqueous:lipid layer.
Other layers can include a solid pellet, an aqueous layer, and a
lipid layer. Lipid can be extracted from the emulsion layer by
freeze thawing or otherwise cooling the emulsion. In such methods,
it is not necessary to add any organic solvent or oil. If any
solvent or oil is added, it can be below 5% v/v or w/w of the
lysate.
IX. COMBINING RECOMBINANT MICROALGAL BIOMASS OR MATERIALS DERIVED
THEREFROM WITH OTHER FOOD INGREDIENTS
[0520] In one aspect, the present invention is directed to a food
composition comprising at least 0.1% w/w algal biomass and one or
more other edible ingredients, wherein the algal biomass comprises
at least 10% triglyceride by dry weight, optionally wherein at
least 90% of the oil is glycerolipid. The algal cells are
cultivated heterotrophically and optionally in the absence of
light. In some embodiments, the algal biomass contains at least
25%, 40%, 50% or 60% oil by dry weight. In some cases, the algal
biomass contains 10-90%, 25-75%, 40-75% or 50-70% oil by dry
weight, optionally wherein at least 90% of the oil is glycerolipid.
In at least one embodiment, at least 50% by weight of the oil is
monounsaturated glycerolipid oil. In some cases, at least 50%, 60%,
70% 80% or 90% by weight of the oil is a C18:1 lipid. In some
embodiments, the lipid profile of the algal triglyceride oil is
similar to a naturally occurring oil. Some of the naturally
occurring oils are provided in table 5. In one embodiment, the
algal triglycerides produced by the invention are similar to cocoa
butter, coconut oil, palm oil, beef tallow or lard. In some cases,
less than 5% by weight of the oil is docosahexanoic acid (DHA)
(22:6). In at least one embodiment, less than 1% by weight of the
oil is DHA. An algal lipid content with low levels of
polyunsaturated fatty acids (PUFA) is preferred to ensure chemical
stability of the biomass. In preferred embodiments, the algal
biomass is grown under heterotrophic conditions and has reduced
green pigmentation. In other embodiments, the microalgae is a color
mutant that lacks or is reduced in pigmentation.
[0521] This invention also provide a food composition comprising at
least 0.1% w/w algal triglyceride oil isolated from recombinant
algal cells cultivated under heterotrophic conditions and one or
more other ingredients. The recombinant algal cells can be
optionally cultivated in the dark. In some embodiments, the
triglyceride profile of the algal triglycerol oil is similar to the
triglyceride profile of a naturally occurring oil. Some of the
naturally occurring oils are provided in table 5. In an embodiment
of the invention, the algal triglycerides produced by the invention
are similar to cocoa butter, coconut oil, palm oil, beef tallow or
lard. In at least one embodiment, at least 50% by weight of the oil
is monounsaturated glycerolipid oil. In some cases, at least 50%,
60%, 70% 80% or 90% by weight of the oil is a C18:1 lipid.
[0522] In another aspect, the present invention is directed to a
food composisiton comprising at least 0.1% w/w algal biomass and
one or more other edible ingredients, wherein the algal biomass
comprises at least 30% protein by dry weight, at least 40% protein
by dry weight, at least 45% protein by dry weight, at least 50%
protein by dry weight, at least 55% protein by dry weight, at least
60% protein by dry weight or at least 75% protein by dry weight. In
some cases, the algal biomass contains 30-75% or 40-60% protein by
dry weight. In some embodiments, at least 40% of the crude protein
is digestible, at least 50% of the crude protein is digestible, at
least 60% of the crude protein is digestible, at least 70% of the
crude protein is digestible, at least 80% of the crude protein is
digestible, or at least 90% of the crude protein is digestible. In
some cases, the algal biomass is grown under heterotrophic
conditions. In at least one embodiment, the algal biomass is grown
under nitrogen-replete conditions. In other embodiments, the
microalgae is a color mutant that lacks or is reduced in
pigmentation.
[0523] In some cases, the algal biomass comprises predominantly
intact cells. In some embodiments, the food composition comprises
oil which is predominantly or completely encapsulated inside cells
of the biomass. In some cases, the food composition comprises
predominantly intact recombinant microalgal cells. In some cases,
the algal oil is predominantly encapsulated in cells of the
biomass. In other cases, the biomass comprises predominantly lysed
cells (e.g., a homogenate). As discussed above, such a homogenate
can be provided as a slurry, flake, powder, or flour.
[0524] In some embodiments of the food composition, the algal
biomass further comprises at least 10 ppm selenium. In some cases,
the biomass further comprises at least 15% w/w algal
polysaccharide. In some cases, the biomass further comprises at
least 5% w/w algal glycoprotein. In some cases, the biomass
comprises between 0 and 115 mcg/g total carotenoids. In some cases,
the biomass comprises at least 0.5% w/w algal phospholipids. In all
cases, as just noted, these components are true cellular components
and not extracellular.
[0525] In some cases, the algal biomass of the food composition
contains components that have antioxidant qualities. The strong
antioxidant qualities can be attributed to the multiple
antioxidants present in the algal biomass, which include, but are
not limited to carotenoids, essential minerals such as zinc,
copper, magnesium, calcium, and manganese. Algal biomass has also
been shown to contain other antioxidants such as tocotrienols and
tocopherols. These members of the vitamin E family are important
antioxidants and have other health benefits such as protective
effects against stroke-induced injuries, reversal of arterial
blockage, growth inhibition of breast and prostate cancer cells,
reduction in cholesterol levels, a reduced-risk of type II diabetes
and protective effects against glaucomatous damage. Natural sources
of tocotrienols and tocopherols can be found in oils produced from
palm, sunflower, corn, soybean and olive oil, however compositions
provided herein have significantly greater levels of tocotrienols
than heretofore known materials.
[0526] In some cases, food compositions of the present invention
contain algal oil comprising at least 0.05 mg/g, at least 0.07 mg/g
or at least 0.08 mg/g total tocopherol. In some cases, food
compositions of the present invention contain algal oil comprising
at least 0.15 mg/g, at least 0.20 mg/g or at least 0.25 mg/g total
tocotrienol.
[0527] In particular embodiments of the compositions and/or methods
described above, the microalgae can produce carotenoids. In some
embodiments, the carotenoids produced by the microalgae can be
co-extracted with the lipids or oil produced by the microalgae
(i.e., the oil or lipid will contain the carotenoids). In some
embodiments, the carotenoids produced by the microalgae are
xanthophylls. In some embodiments, the carotenoids produced by the
microalgae are carotenes. In some embodiments, the carotenoids
produced by the microalgae are a mixture of carotenes and
xanthophylls. In various embodiments, the carotenoids produced by
the microalgae comprise at least one carotenoid selected from the
group consisting of astaxanthin, lutein, zeaxanthin,
alpha-carotene, trans-beta carotene, cis-beta carotene, lycopene
and any combination thereof.
[0528] In some embodiments of the food composition, the algal
biomass is derived from algae cultured and dried under good
manufacturing practice (GMP) conditions. In some cases, the algal
biomass is combined with one or more other edible ingredients,
including without limitation, grain, fruit, vegetable, protein,
lipid, herb and/or spice ingredients. In some cases, the food
composition is a salad dressing, egg product, baked good, bread,
bar, pasta, sauce, soup drink, beverage, frozen dessert, butter or
spread. In particular embodiments, the food composition is not a
pill or powder. In some cases, the food composition in accordance
with the present invention weighs at least 50 g, or at least 100
g.
[0529] Biomass can be combined with one or more other edible
ingredients to make a food product. The biomass can be from a
single algal source (e.g., strain) or algal biomass from multiple
sources (e.g., different strains). The biomass can also be from a
single algal species, but with different composition profile. For
example, a manufacturer can blend microalgae that is high in oil
content with microalgae that is high in protein content to the
exact oil and protein content that is desired in the finished food
product. The combination can be performed by a food manufacturer to
make a finished product for retail sale or food service use.
Alternatively, a manufacturer can sell algal biomass as a product,
and a consumer can incorporate the algal biomass into a food
product, for example, by modification of a conventional recipe. In
either case, the algal biomass is typically used to replace all or
part of the oil, fat, eggs, or the like used in many conventional
food products.
[0530] In one aspect, the present invention is directed to a food
composition comprising at lest 0.1% w/w algal biomass and one or
more other edible ingredients, wherein the algal biomass is
formulated thorugh blending of algal biomass that contains at least
40% protein by dry weight with algal biomass that contains 40%
lipid by dry weight to obtain a blend of a desired percent protein
and lipid by dry weight. In some embodiments, the biomass is from
the same strain of algae. Alternatively, algal biomass that
contains at least 40% lipid by dry weight containing less than 1%
of its lipid as DHA is blended with algal biomass that contains at
lest 20% lipid by dry weight containing at least 5% of its lipid as
DHA to obtain a blend of dry biomass that contains in the aggregate
at least 10% lipid and 1% DHA by dry weight.
[0531] In one aspect, the present invention is directed to a method
of preparing algal biomass by drying an algal culture to provide
algal biomass comprising at least 15% oil by dry weight under GMP
conditions, in which the algal oil is greater than 50%
monounsaturated lipid.
[0532] In one aspect, the present invention is directed to algal
biomass containing at least 15% oil by dry weight manufactured
under GMP conditions, in which the algal oil is greater than 50%,
60%, 70%, 80% or 90% C18:1 lipid. In one aspect, the present
invention is directed to algal biomass containing at least 40% oil
by dry weight manufactured under GMP conditions. In one aspect, the
present invention is directed to algal biomass containing at least
55% oil by dry weight manufactured under GMP conditions. In some
cases, the algal biomass is packaged as a tablet for delivery of a
unit dose of biomass. In some cases, the algal biomass is packaged
with or otherwise bears a label providing directions for combining
the algal biomass with other edible ingredients.
[0533] In one aspect, the present invention is directed to methods
of combining recombinant microalgal biomass and/or materials
derived therefrom, as described above, with at least one other
finished food ingredient, as described below, to form a food
composition or foodstuff. In various embodiments, the food
composition formed by the methods of the invention comprises an egg
product (powdered or liquid), a pasta product, a dressing product,
a mayonnaise product, a cake product, a bread product, an energy
bar, a milk product, a juice product, a spread, or a smoothie. In
some cases, the food composition is not a pill or powder. In
various embodiments, the food composition weighs at least 10 g, at
least 25 g, at least 50 g, at least 100 g, at least 250 g, or at
least 500 g or more. In some embodiments, the food composition
formed by the combination of recombinant microalgal biomass and/or
product derived therefrom is an uncooked product. In other cases,
the food composition is a cooked product.
[0534] In other cases, the food composition is a cooked product. In
some cases, the food composition contains less than 25% oil or fat
by weight excluding oil contributed by the algal biomass. Fat, in
the form of saturated triglycerides (TAGs or trans fats), is made
when hydrogenating vegetable oils, as is practiced when making
spreads such as margarines. The fat contained in algal biomass has
no trans fats present. In some cases, the food composition contains
less than 10% oil or fat by weight excluding oil contributed by the
biomass. In at least one embodiment, the food composition is free
of oil or fat excluding oil contributed by the biomass. In some
cases, the food composition is free of oil other than oil
contributed by the biomass. In some cases, the food composition is
free of egg or egg products.
[0535] In one aspect, the present invention is directed to a method
of making a food composition in which the fat or oil in a
conventional food product is fully or partially substituted with
algal biomass containing at least 10% by weight oil. In one
embodiment, the method comprises determining an amount of the algal
biomass for substitution using the proportion of algal oil in the
biomass and the amount of oil or fat in the conventional food
product, and combining the algal biomass with at least one other
edible ingredient and less than the amount of oil or fat contained
in the conventional food product to form a food composition. In
some cases, the amount of algal biomass combined with the at least
one other ingredient is 1-4 times the mass or volume of oil and/or
fat in the conventional food product.
[0536] In some embodiments, the method described above further
includes providing a recipe for a conventional food product
containing the at least one other edible ingredient combined with
an oil or fat, and combining 1-4 times the mass or volume of the
algal biomass with the at least one other edible ingredient as the
mass or volume of fat or oil in the conventional food product. In
some cases, the method further includes preparing the algal biomass
under GMP conditions.
[0537] In some cases, the food composition formed by the
combination of recombinant microalgal biomass and/or product
derived therefrom comprises at least 0.1%, at least 0.5%, at least
1%, at least 5%, at least 10%, at least 25%, or at least 50% w/w or
v/v recombinant microalgal biomass or recombinant microalgal oil.
In some embodiments, food compositions formed as described herein
comprise at least 2%, at least 5%, at least 10%, at least 25%, at
least 50%, at least 75%, at least 90%, or at least 95% w/w
recombinant microalgal biomass or product derived therefrom. In
some cases, the food composition comprises 5-50%, 10-40%, or 15-35%
algal biomass or product derived therefrom by weight or by
volume.
[0538] As described above, recombinant microalgal biomass can be
substituted for other components that would otherwise be
conventionally included in a food product. In some embodiments, the
food composition contains less than 50%, less than 40%, or less
than 30% oil or fat by weight excluding recombinant microalgal oil
contributed by the biomass or from recombinant microalgal sources.
In some cases, the food composition contains less than 25%, less
than 20%, less than 15%, less than 10%, or less than 5% oil or fat
by weight excluding recombinant microalgal oil contributed by the
biomass or from recombinant microalgal sources. In at least one
embodiment, the food composition is free of oil or fat excluding
recombinant microalgal oil contributed by the biomass or from
recombinant microalgal sources. In some cases, the food composition
is free of eggs, butter, or other fats/oils or at least one other
ingredient that would ordinarily be included in a comparable
conventional food product. Some food products are free of dairy
products (e.g., butter, cream and/or cheese).
[0539] The amount of algal biomass used to prepare a food
composition depends on the amount of non-algal oil, fat, eggs, or
the like to be replaced in a conventional food product and the
percentage of oil in the algal biomass. Thus, in at least one
embodiment, the methods of the invention include determining an
amount of the algal biomass to combine with at least one other
edible ingredient from a proportion of oil in the biomass and a
proportion of oil and/or fat that is ordinarily combined with the
at least one other edible ingredient in a conventional food
product. For example, if the algal biomass is 50% w/w recombinant
microalgal oil, and complete replacement of oil or fat in a
conventional recipe is desired, then the oil can for example be
replaced in a 2:1 ratio. The ratio can be measured by mass, but for
practical purposes, it is often easier to measure volume using a
measuring cup or spoon, and the replacement can be by volume. In a
general case, the volume or mass of oil or fat to be replaced is
replaced by (100/100-X) volume or mass of algal biomass, where X is
the percentage of recombinant microalgal oil in the biomass. In
general, oil and fats to be replaced in conventional recipes can be
replaced in total by algal biomass, although total replacement is
not necessary and any desired proportion of oil and/or fats can be
retained and the remainder replaced according to taste and
nutritional needs. Because the algal biomass contains proteins and
phospholipids, which function as emulsifiers, items such as eggs
can be replaced in total or in part with algal biomass. If an egg
is replaced in total with biomass, it is sometimes desirable or
necessary to augment the emulsifying properties in the food
composition with an additional emulsifying agent(s) and/or add
additional water or other liquid(s) to compensate for the loss of
these components that would otherwise be provided by the egg.
Because an egg is not all fat, the amount of biomass used to
replace an egg may be less than that used to replace pure oil or
fat. An average egg weighs about 58 g and comprises about 11.2%
fat. Thus, about 13 g of algal biomass comprising 50% recombinant
microalgal oil by weight can be used to replace the total fat
portion of an egg in total. Replacing all or part of the eggs in a
food product has the additional benefit of reducing
cholesterol.
[0540] For simplicity, substitution ratios can also be provided in
terms of mass or volume of oil, fat and/or eggs replaced with mass
or volume of biomass. In some methods, the mass or volume of oil,
fat and/or eggs in a conventional recipe is replaced with 5-150%,
25-100% or 25-75% of the mass or volume of oil, fat and/or eggs.
The replacement ratio depends on factors such as the food product,
desired nutritional profile of the food product, overall texture
and appearance of the food product, and oil content of the
biomass.
[0541] In cooked foods, the determination of percentages (i.e.,
weight or volume) can be made before or after cooking. The
percentage of algal biomass can increase during the cooking process
because of loss of liquids. Because some algal biomass cells may
lyse in the course of the cooking process, it can be difficult to
measure the content of algal biomass directly in a cooked product.
However, the content can be determined indirectly from the mass or
volume of biomass that went into the raw product as a percentage of
the weight or volume of the finished product (on a biomass dry
solids basis), as well as by methods of analyzing components that
are unique to the algal biomass such as genomic sequences or
compounds that are delivered solely by the algal biomass, such as
certain carotenoids.
[0542] In some cases, it may be desirable to combine algal biomass
with the at least one other edible ingredient in an amount that
exceeds the proportional amount of oil, fat, eggs, or the like that
is present in a conventional food product. For example, one may
replace the mass or volume of oil and/or fat in a conventional food
product with 1, 2, 3, 4, or more times that amount of algal
biomass. Some embodiments of the methods of the invention include
providing a recipe for a conventional food product containing the
at least one other edible ingredient combined with an oil or fat,
and combining 1-4 times the mass or volume of algal biomass with
the at least one other edible ingredient as the mass or volume of
fat or oil in the conventional food product.
[0543] Algal biomass (predominantly intact or homogenized or
micronized) and/or algal oil are combined with at least one other
edible ingredient to form a food product. In some food products,
the algal biomass and/or algal oil is combined with 1-20, 2-10, or
4-8 other edible ingredients. The edible ingredients can be
selected from all the major food groups, including without
limitation, fruits, vegetables, legumes, meats, fish, grains (e.g.,
wheat, rice, oats, cornmeal, barley), herbs, spices, water,
vegetable broth, juice, wine, and vinegar. In some food
compositions, at least 2, 3, 4, or 5 food groups are represented as
well as the algal biomass or algal oil.
[0544] Oils, fats, eggs and the like can also be combined into food
compositions, but, as has been discussed above, are usually present
in reduced amounts (e.g., less than 50%, 25%, or 10% of the mass or
volume of oil, fat or eggs compared with conventional food
products. Some food products of the invention are free of oil other
than that provided by algal biomass and/or algal oil. Some food
products are free of oil other than that provided by algal biomass.
Some food products are free of fats other than that provided by
algal biomass or algal oil. Some food products are free of fats
other than that provided by algal biomass. Some food products are
free of both oil and fats other than that provided by algal biomass
or algal oil. Some food products are free of both oil and fats
other than that provided by algal biomass. Some food products are
free of eggs. In some embodiments, the oils produced by the
microalgae can be tailored by culture conditions or strain
selection to comprise a particular fatty acid component(s) or
levels.
[0545] In some cases, the algal biomass used in making the food
composition comprises a mixture of at least two distinct species of
microalgae. In some cases, at least two of the distinct species of
microalgae have been separately cultured. In at least one
embodiment, at least two of the distinct species of microalgae have
different glycerolipid profiles. In some cases, the method
described above further comprises culturing algae under
heterotrophic conditions and preparing the biomass from the algae.
In some cases, all of the at least two distinct species of
microalgae contain at least 10%, or at least 15% oil by dry weight.
In some cases, a food composition contains a blend of two distinct
preparations of biomass of the same species, wherein one of the
preparations contains at least 30% oil by dry weight and the second
contains less than 15% oil by dry weight. In some cases, a food
composition contains a blend of two distinct preparations of
biomass of the same species, wherein one of the preparations
contains at least 50% oil by dry weight and the second contains
less than 15% oil by dry weight, and further wherein the species is
Chlorella protothecoides.
[0546] As well as using algal biomass as an oil, fat or egg
replacement in otherwise conventional foods, algal biomass can be
used as a supplement in foods that do not normally contain oil,
such as a smoothie. The combination of oil with products that are
mainly carbohydrate can have benefits associated with the oil, and
from the combination of oil and carbohydrate by reducing the
glycemic index of the carbohydrate. The provision of oil
encapsulated in biomass is advantageous in protecting the oil from
oxidation and can also improve the taste and texture of the
smoothie.
[0547] Oil extracted from algal biomass can be used in the same way
as the biomass itself, that is, as a replacement for oil, fat,
eggs, or the like in conventional recipes. The oil can be used to
replace conventional oil and/or fat on about a 1:1 weight/weight or
volume/volume basis. The oil can be used to replace eggs by
substitution of about 1 teaspoon of algal oil per egg optionally in
combination with additional water and/or an emulsifier (an average
58 g egg is about 11.2% fat, algal oil has a density of about 0.915
g/ml, and a teaspoon has a volume of about 5 ml=1.2 teaspoons of
algal oil/egg). The oil can also be incorporated into dressings,
sauces, soups, margarines, creamers, shortenings and the like. The
oil is particularly useful for food products in which combination
of the oil with other food ingredients is needed to give a desired
taste, texture and/or appearance. The content of oil by weight or
volume in food products can be at least 5, 10, 25, 40 or 50%.
[0548] In at least one embodiment, oil extracted from algal biomass
can also be used as a cooking oil by food manufacturers,
restaurants and/or consumers. In such cases, algal oil can replace
conventional cooking oils such as safflower oil, canola oil, olive
oil, grape seed oil, corn oil, sunflower oil, coconut oil, palm
oil, or any other conventionally used cooking oil. The oil obtained
from algal biomass as with other types of oil can be subjected to
further refinement to increase its suitability for cooking (e.g.,
increased smoke point). Oil can be neutralized with caustic soda to
remove free fatty acids. The free fatty acids form a removable soap
stock. The color of oil can be removed by bleaching with chemicals
such as carbon black and bleaching earth. The bleaching earth and
chemicals can be separated from the oil by filtration. Oil can also
be deodorized by treating with steam.
[0549] Predominantly intact biomass, homogenized or micronized
biomass (as a slurry, flake, powder or flour) and purified algal
oil can all be combined with other food ingredients to form food
products. All are a source of oil with a favorable nutritional
profile (relatively high monounsaturated content). Predominantly
intact, homogenized, and micronized biomass also supply high
quality protein (balanced amino acid composition), carbohydrates,
fiber and other nutrients as discussed above. Foods incorporating
any of these products can be made in vegan or vegetarian form.
Another advantage in using recombinant microalgal biomass (either
predominantly intact or homogenized (or micronized) or both) as a
protein source is that it is a vegan/vegetarian protein source that
is not from a major allergen source, such as soy, eggs or
dairy.
[0550] Other edible ingredients with which algal biomass and/or
algal oil can be combined in accordance with the present invention
include, without limitation, grains, fruits, vegetables, proteins,
meats, herbs, spices, carbohydrates, and fats. The other edible
ingredients with which the algal biomass and/or algal oil is
combined to form food compositions depend on the food product to be
produced and the desired taste, texture and other properties of the
food product.
[0551] Although in general any of these sources of algal oil can be
used in any food product, the preferred source depends in part
whether the oil is primarily present for nutritional or caloric
purposes rather than for texture, appearance or taste of food, or
alternatively whether the oil in combination with other food
ingredients is intended to contribute a desired taste, texture or
appearance of the food as well as or instead of improving its
nutritional or caloric profile.
[0552] The food products can be cooked by conventional procedures
as desired. Depending on the length and temperature, the cooking
process may break down some cell walls, releasing oil such that it
combines with other ingredients in the mixture. However, at least
some algal cells often survive cooking intact. Alternatively, food
products can be used without cooking. In this case, the algal wall
remains intact, protecting the oil from oxidation.
[0553] The algal biomass, if provided in a form with cells
predominantly intact, or as a homogenate powder, differs from oil,
fat or eggs in that it can be provided as a dry ingredient,
facilitating mixing with other dry ingredients, such as flour. In
one embodiment the algal biomass is provided as a dry homogenate
that contains between 25 and 40% oil by dry weight. A biomass
homogenate can also be provided as slurry. After mixing of dry
ingredients (and biomass homogenate slurry, if used), liquids such
as water can be added. In some food products, the amount of liquid
required is somewhat higher than in a conventional food product
because of the non-oil component of the biomass and/or because
water is not being supplied by other ingredients, such as eggs.
However, the amount of water can readily be determined as in
conventional cooking.
[0554] In one aspect, the present invention is directed to a food
ingredient composition comprising at least 0.5% w/w algal biomass
containing at least 10% algal oil by dry weight and at least one
other edible ingredient, in which the food ingredient can be
converted into a reconstituted food product by addition of a liquid
to the food ingredient composition. In one embodiment, the liquid
is water.
[0555] Homogenized or micronized high-oil biomass is particularly
advantageous in liquid, and/or emulsified food products (water in
oil and oil in water emulsions), such as sauces, soups, drinks,
salad dressings, butters, spreads and the like in which oil
contributed by the biomass forms an emulsion with other liquids.
Products that benefit from improved rheology, such as dressings,
sauces and spreads are described below in the Examples. Using
homogenized biomass an emulsion with desired texture (e.g.,
mouth-feel), taste and appearance (e.g., opacity) can form at a
lower oil content (by weight or volume of overall product) than is
the case with conventional products employing conventional oils,
thus can be used as a fat extender. Such is useful for low-calorie
(i.e., diet) products. Purified algal oil is also advantageous for
such liquid and/or emulsified products. Both homogenized or
micronized high-oil biomass and purified algal oil combine well
with other edible ingredients in baked goods achieving similar or
better taste, appearance and texture to otherwise similar products
made with conventional oils, fats and/or eggs but with improved
nutritional profile (e.g., higher content of monosaturated oil,
and/or higher content or quality of protein, and/or higher content
of fiber and/or other nutrients).
[0556] Predominantly intact biomass is particularly useful in
situations in which it is desired to change or increase the
nutritional profile of a food (e.g., higher oil content, different
oil content (e.g., more monounsaturated oil), higher protein
content, higher calorie content, higher content of other
nutrients). Such foods can be useful for example, for athletes or
patients suffering from wasting disorders. Predominantly intact
biomass can be used as a bulking agent. Bulking agents can be used,
for example, to augment the amount of a more expensive food (e.g.,
meat helper and the like) or in simulated or imitation foods, such
as vegetarian meat substitutes. Simulated or imitation foods differ
from natural foods in that the flavor and bulk are usually provided
by different sources. For example, flavors of natural foods, such
as meat, can be imparted into a bulking agent holding the flavor.
Predominantly intact biomass can be used as a bulking agent in such
foods. Predominantly intact biomass is also particularly useful in
dried food, such as pasta because it has good water binding
properties, and can thus facilitate rehydration of such foods.
Predominantly intact biomass is also useful as a preservative, for
example, in baked goods. The predominantly intact biomass can
improve water retention and thus shelf-life.
[0557] Algal biomass that has been disrupted or micronized can also
improve water retention and thus shelf-life. Increased moisture
retention is especially desirable in gluten-free products, such as
gluten-free baked goods. A detailed description of formulation of a
gluten-free cookie using disrupted algal biomass and subsequent
shelf-life study is described in the Examples below.
[0558] In some cases, the algal biomass can be used in egg
preparations. In some embodiments, algal biomass (e.g., algal
flour) added to a conventional dry powder egg preparation to create
scrambled eggs that are creamier, have more moisture and a better
texture than dry powdered eggs prepared without the algal biomass.
In other embodiments, algal biomass is added to whole liquid eggs
in order to improve the overall texture and moisture of eggs that
are prepared and then held on a steam table. Specific examples of
the foregoing preparations are described in the Examples below.
[0559] Algal biomass (predominantly intact and/or homogenized or
micronized) and/or algal oil can be incorporated into virtually any
food composition. Some examples include baked goods, such as cakes,
brownies, yellow cake, bread including brioche, cookies including
sugar cookies, biscuits, and pies. Other examples include products
often provided in dried form, such as pastas or powdered dressing,
dried creamers, commuted meats and meat substitutes. Incorporation
of predominantly intact biomass into such products as a binding
and/or bulking agent can improve hydration and increase yield due
to the water binding capacity of predominantly intact biomass.
Re-hydrated foods, such as scrambled eggs made from dried powdered
eggs, may also have improved texture and nutritional profile. Other
examples include liquid food products, such as sauces, soups,
dressings (ready to eat), creamers, milk drinks, juice drinks,
smoothies, creamers. Other liquid food products include nutritional
beverages that serve as a meal replacement or algal milk. Other
food products include butters or cheeses and the like including
shortening, margarine/spreads, nut butters, and cheese products,
such as nacho sauce. Other food products include energy bars,
chocolate confections-lecithin replacement, meal replacement bars,
granola bar-type products. Another type of food product is batters
and coatings. By providing a layer of oil surrounding a food,
predominantly intact biomass or a homogenate repel additional oil
from a cooking medium from penetrating a food. Thus, the food can
retain the benefits of high monounsaturated oil content of coating
without picking up less desirable oils (e.g., trans fats, saturated
fats, and by products from the cooking oil). The coating of biomass
can also provide a desirable (e.g., crunchy) texture to the food
and a cleaner flavor due to less absorption of cooking oil and its
byproducts.
[0560] In uncooked foods, most algal cells in the biomass remain
intact. This has the advantage of protecting the algal oil from
oxidation, which confers a long shelf-life and minimizes adverse
interaction with other ingredients. Depending on the nature of the
food products, the protection conferred by the cells may reduce or
avoid the need for refrigeration, vacuum packaging or the like.
Retaining cells intact also prevents direct contact between the oil
and the mouth of a consumer, which reduces the oily or fatty
sensation that may be undesirable. In food products in which oil is
used more as nutritional supplement, such can be an advantage in
improving the organoleptic properties of the product. Thus,
predominantly intact biomass is suitable for use in such products.
However, in uncooked products, such as a salad dressing, in which
oil imparts a desired mouth feeling (e.g., as an emulsion with an
aqueous solution such as vinegar), use of purified algal oil or
micronized biomass is preferred. In cooked foods, some algal cells
of original intact biomass may be lysed but other algal cells may
remain intact. The ratio of lysed to intact cells depends on the
temperature and duration of the cooking process. In cooked foods in
which dispersion of oil in a uniform way with other ingredients is
desired for taste, texture and/or appearance (e.g., baked goods),
use of micronized biomass or purified algal oil is preferred. In
cooked foods, in which algal biomass is used to supply oil and/or
protein and other nutrients, primarily for their nutritional or
caloric value rather than texture.
[0561] Algal biomass can also be useful in increasing the satiety
index of a food product (e.g., a meal-replacement drink or
smoothie) relative to an otherwise similar conventional product
made without the algal biomass. The satiety index is a measure of
the extent to which the same number of calories of different foods
satisfy appetite. Such an index can be measured by feeding a food
being tested and measuring appetite for other foods at a fixed
interval thereafter. The less appetite for other foods thereafter,
the higher the satiety index. Values of satiety index can be
expressed on a scale in which white bread is assigned a value of
100. Foods with a higher satiety index are useful for dieting.
Although not dependent on an understanding of mechanism, algal
biomass is believed to increase the satiety index of a food by
increasing the protein and/or fiber content of the food for a given
amount of calories.
[0562] Algal biomass (predominantly intact and homogenized or
micronized) and/or algal oil can also be manufactured into
nutritional or dietary supplements. For example, algal oil can be
encapsulated into digestible capsules in a manner similar to fish
oil. Such capsules can be packaged in a bottle and taken on a daily
basis (e.g., 1-4 capsules or tablets per day). A capsule can
contain a unit dose of algal biomass or algal oil. Likewise,
biomass can be optionally compressed with pharmaceutical or other
excipients into tablets. The tablets can be packaged, for example,
in a bottle or blister pack, and taken daily at a dose of, e.g.,
1-4 tablets per day. In some cases, the tablet or other dosage
formulation comprises a unit dose of biomass or algal oil.
Manufacturing of capsule and tablet products and other supplements
is preferably performed under GMP conditions appropriate for
nutritional supplements as codified at 21 C.F.R. 111, or comparable
regulations established by foreign jurisdictions. The algal biomass
can be mixed with other powders and be presented in sachets as a
ready-to-mix material (e.g., with water, juice, milk or other
liquids). The algal biomass can also be mixed into products such as
yogurts.
[0563] Although algal biomass and/or algal oil can be incorporated
into nutritional supplements, the functional food products
discussed above have distinctions from typical nutritional
supplements, which are in the form of pills, capsules, or powders.
The serving size of such food products is typically much larger
than a nutritional supplement both in terms of weight and in terms
of calories supplied. For example, food products often have a
weight of over 100 g and/or supply at least 100 calories when
packaged or consumed at one time. Typically food products contain
at least one ingredient that is either a protein, a carbohydrate or
a liquid and often contain two or three such other ingredients. The
protein or carbohydrate in a food product often supplies at least
30%, 50%, or 60% of the calories of the food product.
[0564] As discussed above, algal biomass can be made by a
manufacturer and sold to a consumer, such as a restaurant or
individual, for use in a commercial setting or in the home. Such
algal biomass is preferably manufactured and packaged under Good
Manufacturing Practice (GMP) conditions for food products. The
algal biomass in predominantly intact form or homogenized or
micronized form as a powder is often packaged dry in an airtight
container, such as a sealed bag. Homogenized or micronized biomass
in slurry form can be conveniently packaged in a tub among other
containers. Optionally, the algal biomass can be packaged under
vacuum to enhance shelf life. Refrigeration of packaged algal
biomass is not required. The packaged algal biomass can contain
instructions for use including directions for how much of the algal
biomass to use to replace a given amount of oil, fat or eggs in a
conventional recipe, as discussed above. For simplicity, the
directions can state that oil or fat are to be replaced on a 2:1
ratio by mass or volume of biomass, and eggs on a ratio of 11 g
biomass or 1 teaspoon of algal oil per egg. As discussed above,
other ratios are possible, for example, using a ratio of 10-175%
mass or volume of biomass to mass or volume of oil and/or fat
and/or eggs in a conventional recipe. Upon opening a sealed
package, the instructions may direct the user to keep the algal
biomass in an airtight container, such as those widely commercially
available (e.g., Glad), optionally with refrigeration.
[0565] Algal biomass (predominantly intact or homogenized or
micronized powder) can also be packaged in a form combined with
other dry ingredients (e.g., sugar, flour, dry fruits, flavorings)
and portioned packed to ensure uniformity in the final product. The
mixture can then be converted into a food product by a consumer or
food service company simply by adding a liquid, such as water or
milk, and optionally mixing, and/or cooking without adding oils or
fats. In some cases, the liquid is added to reconstitute a dried
algal biomass composition. Cooking can optionally be performed
using a microwave oven, convection oven, conventional oven, or on a
cooktop. Such mixtures can be used for making cakes, breads,
pancakes, waffles, drinks, sauces and the like. Such mixtures have
advantages of convenience for the consumer as well as long shelf
life without refrigeration. Such mixtures are typically packaged in
a sealed container bearing instructions for adding liquid to
convert the mixture into a food product.
[0566] Algal oil for use as a food ingredient is likewise
preferably manufactured and packaged under GMP conditions for a
food. The algal oil is typically packaged in a bottle or other
container in a similar fashion to conventionally used oils. The
container can include an affixed label with directions for using
the oil in replacement of conventional oils, fats or eggs in food
products, and as a cooking oil. When packaged in a sealed
container, the oil has a long shelf-life (at least one year)
without substantial deterioration. After opening, algal oil
comprised primarily of monounsaturated oils is not acutely
sensitive to oxidation. However, unused portions of the oil can be
kept longer and with less oxidation if kept cold and/or out of
direct sunlight (e.g., within an enclosed space, such as a
cupboard). The directions included with the oil can contain such
preferred storage information.
[0567] Optionally, the algal biomass and/or the algal oil may
contain a food approved preservative/antioxidant to maximize
shelf-life, including but not limited to, carotenoids (e.g.,
astaxanthin, lutein, zeaxanthin, alpha-carotene, beta-carotene and
lycopene), phospholipids (e.g., N-acylphosphatidylethanolamine,
phosphatidic acid, phosphatidylethanolamine, phosphatidylcholine,
phosphatidylinositol and lysophosphatidylcholine), tocopherols
(e.g., alpha tocopherol, beta tocopherol, gamma tocopherol and
delta tocopherol), tocotrienols (e.g., alpha tocotrienol, beta
tocotrienol, gamma tocotrienol and delta tocotrienol), Butylated
hydroxytoluene, Butylated hydroxyanisole, polyphenols, rosmarinic
acid, propyl gallate, ascorbic acid, sodium ascorbate, sorbic acid,
benzoic acid, methyl parabens, levulinic acid, anisic acid, acetic
acid, citric acid, and bioflavonoids.
[0568] The description of incorporation of predominantly intact
biomass, homogenized, or micronized biomass (slurry, flake, powder,
or flour) or algal oil into food for human nutrition is in general
also applicable to food products for non-human animals.
[0569] The biomass imparts high quality oil or proteins or both in
such foods. The content of algal oil is preferably at least 10 or
20% by weight as is the content of algal protein. Obtaining at
least some of the algal oil and/or protein from predominantly
intact biomass is sometimes advantageous for food for high
performance animals, such as sport dogs or horses. Predominantly
intact biomass is also useful as a preservative. Algal biomass or
oil is combined with other ingredients typically found in animal
foods (e.g., a meat, meat flavor, fatty acid, vegetable, fruit,
starch, vitamin, mineral, antioxidant, probiotic) and any
combination thereof. Such foods are also suitable for companion
animals, particularly those having an active life style. Inclusion
of taurine is recommended for cat foods. As with conventional
animal foods, the food can be provided in bite-size particles
appropriate for the intended animal.
[0570] Delipidated meal is useful as animal feed for farm animals,
e.g., ruminants, poultry, swine, and aquaculture. Delipidated meal
is a byproduct of preparing purified algal oil either for food or
other purposes. The resulting meal although of reduced oil content
still contains high quality proteins, carbohydrates, fiber, ash and
other nutrients appropriate for an animal feed. Because the cells
are predominantly lysed, delipidated meal is easily digestible by
such animals. Delipidated meal can optionally be combined with
other ingredients, such as grain, in an animal feed. Because
delipidated meal has a powdery consistency, it can be pressed into
pellets using an extruder or expanders, which are commercially
available.
[0571] The tailored oils of the present invention can be used in
place of conventional oils such as palm oil, palm kernel oil,
coconut oil, cocoa butter, tallow, or lard.
[0572] Palm Oil: Palm oil is used around the world in such foods as
margarine, shortening, baked goods, and confections. Palm oil is
comprised of approximately 50% saturated fat and 50% unsaturated
fat, and can therefore be separated into (solid) palm stearin
containing C18:0 and lower chain saturated fatty acids and (liquid)
palm olein containing C18:1 and higher chain unsaturated fatty
acids. Palm stearin can be used to form solid trans-free fats. A
microbial triglyceride composition of the present invention in
which the oil comprises higher amounts of C18:1 is an excellent
healthier substitute for partially hydrogenated vegetable oils that
are high in trans-fats that are commonly used today. Foods
containing trans-fats, including hydrogenated vegetable oils, are
widely believed to be an unhealthy food. The invention provides a
tailored oil, higher in C18:1, that is healthier than the partially
hydrogenated vegetable oils. Thus, the present invention provides a
healthier oil and meets the demands placed by the public on the
food industry to supply healthier choices. The tailored oils of the
present invention can be used as a replacement of the unhealthy
partially hydrogenated vegetable oils.
[0573] In addition to food products, palm oil, with its moderate
linoleic acid content and high level of natural antioxidants, is
suitable for direct use in most cooking ad frying applications. The
use of palm oil as a frying oil is a major use of palm oil
worldwide. Potato chips, French fries, doughnuts, ramen noodles,
nuts, etc. are typically fried in palm oil.
[0574] For the large scale frying of potato chips, palm olein or a
blend of palm olein with soya or rapeseed oil is preferred. This is
because the surface appearance of the finished product is improved.
French fries are often purchased as part fried and deep frozen
products.
[0575] In addition to its use in baking and frying, palm oil is
also extensively used as an ingredient in numerous types of foods,
including biscuits, crackers, bread, cereals, chips, chocolate, ice
cream, soup, sauces, mayonnaise and many others.
[0576] The palm oil mimetic of the present invention are a healthy
replacement of palm oil in the human food supply.
[0577] Palm Kernel Oil & Coconut Oil: Whole palm kernel oil and
whole coconut oil as well as fractionated parts are used alone or
in blends with other oils for the manufacture of cocoa butter
substitutes and other confectionary fats (toffees and caramels),
biscuit dough and filling creams, cake icings, ice cream, imitation
whipping cream, non-dairy creamers (coffee whiteners), filled milk
and table margarines and spreads. These oils are also used widely
in making bar and liquid soap. Palm kernel oil and coconut oil are
high in C12:0 and C14:0. Table 5 discloses that the total amount of
C12:0 and C14:0 of coconut oil is approximately 50%-75%. Similarly,
the total amount of C12:0 and C14:0 of palm kerne oil is
approximately 50%-70%. The present invention provides a palm oil
mimetic, a microbial oil comprising about 50%-75% C12:0 and
C14:0.
[0578] Cocoa Butter: Cocoa butter, is a pale-yellow, pure edible
vegetable fat extracted from the cocoa bean. It is used to make
chocolate, biscuits, baked goods, pharmaceuticals, ointments and
toiletries. Cocoa butter historically has served as a major
ingredient in the commercial production of both white chocolate and
milk chocolate.
[0579] Additionally, pharmaceutical companies have made use of
cocoa butter's specific physical properties. As an edible oil,
solid at room temperature, but melts at body temperature, it is
considered an ideal base for delivering medicinal ingredients, for
example as a suppository.
[0580] Cocoa butter is also one of the most stable fats known, a
quality that coupled with natural antioxidant that prevents
rancidity, grants it a storage life of two to five years. The
velvety texture, pleasant fragrance and emollient properties of
cocoa butter have made it a popular ingredient in products for the
skin, such as cosmetics, soaps and lotions.
[0581] The moisturizing abilities of cocoa butter are frequently
recommended for prevention of stretch marks in pregnant women,
treatment of chapped skin and lips, and as a daily moisturizer to
prevent dry, itchy skin.
[0582] Example 14 provides a microbial triglyceride composition
that is very similar to cocoa butter. The cocoa butter mimetic of
the invention is useful in all applications that use cocoa
butter.
[0583] Tallow: The USA is by far the biggest producer and exporter
of beef tallow, with production accounting for approx. 25 to 30% of
global oil and fat production. In the past, beef tallow was used in
early cultures for lighting (woodchips soaked in beef tallow) and
used for making soaps and ointments. Today, beef tallow is a major
raw material used in the production of chemical intermediate
products, such as fatty acids and fat alcohols. In addition to its
principal uses in edible fats and oils, beef tallow is also used as
baking and cooking fat, as well as in margarine production. With
its similar fatty acid spectrum, beef tallow was formerly used to
stretch cocoa butter.
[0584] In food and cooking, tallow may be used as oil for frying
and as ingredient for making pemmican, a Native American dish.
Tallow may also be used as shortening for breads and pastries and
as part of the ingredients for margarine. Aside from beef fat,
tallow may also be sourced from horses, sheep, and pigs. People who
don't eat meat and are vegetarians have also their own version of
tallow using wax isolated from the seeds of the tallow tree,
Triadica sebiferum. Tallow is also used as part of the ingredients
of various animal feeds like those for chickens and pigs.
[0585] The tallow mimetic as described herein is useful as a
replacement of tallow.
[0586] Lard: Lard is isolated from pigs and is one of the few
edible oils with a relatively high smoke point, attributable to its
high saturated fatty acids content. Pure lard is especially useful
for cooking since it produces little smoke when heated and has a
distinct taste when combined with other foods. Many chefs and
bakers deem lard a superior cooking fat over shortening because of
lards range of applications and taste.
[0587] Because of the relatively large fat crystals found in lard,
it is extremely effective as a shortening in baking. Pie crusts
made with lard tend to be more flaky than those made with butter.
Many cooks employ both types of fat in their pastries to combine
the shortening properties of lard with the flavor of butter.
[0588] Example 14 provides a microbial triglyceride composition
that is similar lard. The lard mimetic of the invention is useful
in all applications that use lard.
X. EXAMPLES
Example 1
Methods for Culturing Prototheca
[0589] Prototheca strains were cultivated to achieve a high
percentage of oil by dry cell weight. Cryopreserved cells were
thawed at room temperature and 500 ul of cells were added to 4.5 ml
of medium (4.2 g/L K.sub.2HPO.sub.4, 3.1 g/L NaH.sub.2PO.sub.4,
0.24 g/L MgSO.sub.4.7H.sub.2O, 0.25 g/L Citric Acid monohydrate,
0.025 g/L CaCl.sub.2 2H.sub.2O, 2 g/L yeast extract) plus 2%
glucose and grown for 7 days at 28.degree. C. with agitation (200
rpm) in a 6-well plate. Dry cell weights were determined by
centrifuging 1 ml of culture at 14,000 rpm for 5 mM in a
pre-weighed Eppendorf tube. The culture supernatant was discarded
and the resulting cell pellet washed with 1 ml of deionized water.
The culture was again centrifuged, the supernatant discarded, and
the cell pellets placed at -80.degree. C. until frozen. Samples
were then lyophilized for 24 hrs and dry cell weights calculated.
For determination of total lipid in cultures, 3 ml of culture was
removed and subjected to analysis using an Ankom system (Ankom
Inc., Macedon, N.Y.) according to the manufacturer's protocol.
Samples were subjected to solvent extraction with an Amkom XT10
extractor according to the manufacturer's protocol. Total lipid was
determined as the difference in mass between acid hydrolyzed dried
samples and solvent extracted, dried samples. Percent oil dry cell
weight measurements are shown in Table 10.
TABLE-US-00016 TABLE 10 Percent oil by dry cell weight Species
Strain % Oil Prototheca stagnora UTEX 327 13.14 Prototheca
moriformis UTEX 1441 18.02 Prototheca moriformis UTEX 1435
27.17
[0590] Microalgae samples from multiple strains from the genus
Prototheca were genotyped. Genomic DNA was isolated from algal
biomass as follows. Cells (approximately 200 mg) were centifuged
from liquid cultures 5 minutes at 14,000.times.g. Cells were then
resuspended in sterile distilled water, centrifuged 5 minutes at
14,000.times.g and the supernatant discarded. A single glass bead
.about.2 mm in diameter was added to the biomass and tubes were
placed at -80.degree. C. for at least 15 minutes. Samples were
removed and 150 .mu.l of grinding buffer (1% Sarkosyl, 0.25 M
Sucrose, 50 mM NaCl, 20 mM EDTA, 100 mM Tris-HCl, pH 8.0, RNase A
0.5 ug/ul) was added. Pellets were resuspended by vortexing
briefly, followed by the addition of 40 ul of 5M NaCl. Samples were
vortexed briefly, followed by the addition of 66 .mu.l of 5% CTAB
(Cetyl trimethylammonium bromide) and a final brief vortex. Samples
were next incubated at 65.degree. C. for 10 minutes after which
they were centrifuged at 14,000.times.g for 10 minutes. The
supernatant was transferred to a fresh tube and extracted once with
300 .mu.l of Phenol:Chloroform:Isoamyl alcohol 12:12:1, followed by
centrifugation for 5 minutes at 14,000.times.g. The resulting
aqueous phase was transferred to a fresh tube containing 0.7 vol of
isopropanol (.about.190 .mu.l), mixed by inversion and incubated at
room temperature for 30 minutes or overnight at 4.degree. C. DNA
was recovered via centrifugation at 14,000.times.g for 10 minutes.
The resulting pellet was then washed twice with 70% ethanol,
followed by a final wash with 100% ethanol. Pellets were air dried
for 20-30 minutes at room temperature followed by resuspension in
50 .mu.l of 10 mM TrisCl, 1 mM EDTA (pH 8.0).
[0591] Five .mu.l of total algal DNA, prepared as described above,
was diluted 1:50 in 10 mM Tris, pH 8.0. PCR reactions, final volume
20 .mu.l, were set up as follows. Ten .mu.l of 2.times.iProof HF
master mix (BIO-RAD) was added to 0.4 .mu.l primer SZ02613
(5'-TGTTGAAGAATGAGCCGGCGAC-3' (SEQ ID NO:9) at 10 mM stock
concentration). This primer sequence runs from position 567-588 in
Gen Bank accession no. L43357 and is highly conserved in higher
plants and algal plastid genomes. This was followed by the addition
of 0.4 .mu.l primer SZ02615 (5'-CAGTGAGCTATTACGCACTC-3' (SEQ ID
NO:10) at 10 mM stock concentration). This primer sequence is
complementary to position 1112-1093 in Gen Bank accession no.
L43357 and is highly conserved in higher plants and algal plastid
genomes. Next, 5 .mu.l of diluted total DNA and 3.2 .mu.l dH.sub.2O
were added. PCR reactions were run as follows: 98.degree. C., 45'';
98.degree. C., 8''; 53.degree. C., 12''; 72.degree. C., 20'' for 35
cycles followed by 72.degree. C. for 1 min and holding at
25.degree. C. For purification of PCR products, 20 .mu.l of 10 mM
Tris, pH 8.0, was added to each reaction, followed by extraction
with 40 .mu.l of Phenol:Chloroform:isoamyl alcohol 12:12:1,
vortexing and centrifuging at 14,000.times.g for 5 minutes. PCR
reactions were applied to S-400 columns (GE Healthcare) and
centrifuged for 2 minutes at 3,000.times.g. Purified PCR products
were subsequently TOPO cloned into PCR8/GW/TOPO and positive clones
selected for on LB/Spec plates. Purified plasmid DNA was sequenced
in both directions using M13 forward and reverse primers. In total,
twelve Prototheca strains were selected to have their 23S rRNA DNA
sequenced and the sequences are listed in the Sequence Listing. A
summary of the strains and Sequence Listing Numbers is included
below. The sequences were analyzed for overall divergence from the
UTEX 1435 (SEQ ID NO: 15) sequence. Two pairs emerged (UTEX
329/UTEX 1533 and UTEX 329/UTEX 1440) as the most divergent. In
both cases, pairwise alignment resulted in 75.0% pairwise sequence
identity. The percent sequence identity to UTEX 1435 is also
included below:
TABLE-US-00017 % nt Species Strain identity SEQ ID NO. Prototheca
kruegani UTEX 329 75.2 SEQ ID NO: 11 Prototheca wickerhamii UTEX
1440 99 SEQ ID NO: 12 Prototheca stagnora UTEX 1442 75.7 SEQ ID NO:
13 Prototheca moriformis UTEX 288 75.4 SEQ ID NO: 14 Prototheca
moriformis UTEX 1439; 100 SEQ ID NO: 15 1441; 1435; 1437 Prototheca
wikerhamii UTEX 1533 99.8 SEQ ID NO: 16 Prototheca moriformis UTEX
1434 75.9 SEQ ID NO: 17 Prototheca zopfii UTEX 1438 75.7 SEQ ID NO:
18 Prototheca moriformis UTEX 1436 88.9 SEQ ID NO: 19
[0592] Lipid samples from a subset of the above-listed strains were
analyzed for lipid profile using HPLC. Results are shown below in
Table 11.
TABLE-US-00018 TABLE 11 Diversity of lipid chains in Prototheca
species Strain C14:0 C16:0 C16:1 C18:0 C18:1 C18:2 C18:3 C20:0
C20:1 UTEX 0 12.01 0 0 50.33 17.14 0 0 0 327 UTEX 1.41 29.44 0.70
3.05 57.72 12.37 0.97 0.33 0 1441 UTEX 1.09 25.77 0 2.75 54.01
11.90 2.44 0 0 1435
[0593] Oil extracted from Prototheca moriformis UTEX 1435 (via
solvent extraction or using an expeller press was analyzed for
carotenoids, chlorophyll, tocopherols, other sterols and
tocotrienols. The results are summarized below in Table 12.
TABLE-US-00019 TABLE 12 Carotenoid, chlorophyll, tocopherol/sterols
and tocotrienol analysis in oil extracted from Prototheca
moriformis (UTEX 1435). Pressed oil Solvent extracted oil (mcg/ml)
(mcg/ml) cis-Lutein 0.041 0.042 trans-Lutein 0.140 0.112
trans-Zeaxanthin 0.045 0.039 cis-Zeaxanthin 0.007 0.013
t-alpha-Crytoxanthin 0.007 0.010 t-beta-Crytoxanthin 0.009 0.010
t-alpha-Carotene 0.003 0.001 c-alpha-Carotene none detected none
detected t-beta-Carotene 0.010 0.009 9-cis-beta-Carotene 0.004
0.002 Lycopene none detected none detected Total Carotenoids 0.267
0.238 Chlorophyll <0.01 mg/kg <0.01 mg/kg Tocopherols and
Sterols Pressed oil Solvent extracted oil (mg/100 g) (mg/100 g)
gamma Tocopherol 0.49 0.49 Campesterol 6.09 6.05 Stigmasterol 47.6
47.8 Beta-sitosterol 11.6 11.5 Other sterols 445 446 Tocotrienols
Pressed oil Solvent extracted oil (mg/g) (mg/g) alpha Tocotrienol
0.26 0.26 beta Tocotrienol <0.01 <0.01 gamma Tocotrienol 0.10
0.10 detal Tocotrienol <0.01 <0.01 Total Tocotrienols 0.36
0.36
[0594] Oil extracted from Prototheca moriformis, from four separate
lots, were refined and bleached using standard vegetable oil
processing methods. Briefly, crude oil extracted from Prototheca
moriformis was clarified in a horizontal decanter, where the solids
were separated from the oil. The clarified oil was then transferred
to a tank with citric acid and water and left to settle for
approximately 24 hours. After 24 hours, the mixture in the tank
formed 2 separate layers. The bottom layer was composed of water
and gums that were then removed by decantation prior to
transferring the degummed oil into a bleaching tank. The oil was
then heated along with another dose of citric acid. Bleaching clay
was then added to the bleaching tank and the mixture was further
heated under vacuum in order to evaporate off any water that was
present. The mixture was then pumped through a leaf filter in order
to remove the bleaching clay. The filtered oil was then passed
through a final 5 .mu.m polishing filter and then collected for
storage until use. The refined and bleached (RB) oil was then
analyzed for carotenoids, chlorophyll, sterols, tocotrienols and
tocopherols. The results of these analyses are summarized in Table
13 below. "Nd" denotes none detected and the sensitivity of
detection is listed below:
[0595] Sensitivity of Detection
[0596] Carotenoids (mcg/g) nd=<0.003 mcg/g
[0597] Chlorophyll (mcg/g) nd=<0.03 mcg/g
[0598] Sterols (%) nd=0.25%
[0599] Tocopherols (mcg/g); nd=3 mcg/g
TABLE-US-00020 TABLE 13 Carotenoid, chlorophyll, sterols,
tocotrienols and tocopherol analysis from refined and bleached
Prototheca moriformis oil. Lot A Lot B Lot C Lot D Carotenoids
(mcg/g) Lutein 0.025 0.003 nd 0.039 Zeaxanthin nd nd nd nd
cis-Lutein/Zeaxanthin nd nd nd nd trans-alpha-Cryptoxanthin nd nd
nd nd trans-beta-Cryptoxanthin nd nd nd nd trans-alpha-Carotene nd
nd nd nd cis-alpha-Carotene nd nd nd nd trans-beta-Carotene nd nd
nd nd cis-beta-Carotene nd nd nd nd Lycopene nd nd nd nd
Unidentified 0.219 0.066 0.050 0.026 Total Carotenoids 0.244 0.069
0.050 0.065 Chlorophyll (mcg/g) Chlorophyll A 0.268 0.136 0.045
0.166 Chlorophyll B nd nd nd nd Total Chlorophyll 0.268 0.136 0.045
0.166 Sterols (%) Brassicasterol nd nd nd nd Campesterol nd nd nd
nd Stigmasterol nd nd nd nd beta-Sitosterol nd nd nd nd Total
Sterols nd nd nd nd Tocopherols (mcg/g) alpha-Tocopherol 23.9 22.8
12.5 8.2 beta-Tocopherol 3.72 nd nd nd gamma-Tocopherol 164 85.3
43.1 38.3 delta-Tocopherol 70.1 31.1 18.1 14.3 Total Tocopherols
262 139.2 73.7 60.8 Tocotrienols (mcg/g) alpha-Tocotrienol 190 225
253 239 beta-Tocotrienol nd nd nd nd gamma-Tocotrienol 47.3 60.4
54.8 60.9 delta-Tocotrienol 12.3 16.1 17.5 15.2 Total Tocotrienols
250 302 325 315
[0600] The same four lots of Prototheca moriformis oil was also
analyzed for trace elements and the results are summarized below in
Table 14.
TABLE-US-00021 TABLE 14 Elemental analysis of refined and bleached
Prototheca moriformis oil. Lot A Lot B Lot C Lot D Elemental
Analysis (ppm) Calcium 0.08 0.07 <0.04 0.07 Phosphorous <0.2
0.38 <0.2 0.33 Sodium <0.5 0.55 <0.5 <0.5 Potassium
1.02 1.68 <0.5 0.94 Magnesium <0.04 <0.04 <0.04 0.07
Manganese <0.05 <0.05 <0.05 <0.05 Iron <0.02
<0.02 <0.02 <0.02 Zinc <0.02 <0.02 <0.02 <0.02
Copper <0.05 <0.05 <0.05 <0.05 Sulfur 2.55 4.45 2.36
4.55 Lead <0.2 <0.2 <0.2 <0.2 Silicon 0.37 0.41 0.26
0.26 Nickel <0.2 <0.2 <0.2 <0.2 Organic chloride
<1.0 <1.0 <1.0 2.2 Inorganic chloride <1.0 <1.0
<1.0 <1.0 Nitrogen 4.4 7.8 4.2 6.9 Lithium <0.02 <0.02
<0.02 <0.02 Boron 0.07 0.36 0.09 0.38 Aluminum -- <0.2
<0.2 <0.2 Vanadium <0.05 <0.05 <0.05 <0.05
Lovibond Color (.degree.L) Red 5.0 4.3 3.2 5.0 Yellow 70.0 70.0
50.0 70.0 Mono & Diglycerides by HPLC (%) Diglycerides 1.68
2.23 1.25 1.61 Monoglycerides 0.03 0.04 0.02 0.03 Free fatty acids
(FFA) 1.02 1.72 0.86 0.83 Soaps 0 0 0 Oxidized and Polymerized
Triglycerides Oxidized Triglycerides (%) 3.41 2.41 4.11 1.00
Polymerized Triglycerides 1.19 0.45 0.66 0.31 (%) Peroxide Value
(meg/kg) 0.75 0.80 0.60 1.20 p-Anisidine value 5.03 9.03 5.44 20.1
(dimensionless) Water and Other Impurities (%) Karl Fisher Moisture
0.8 0.12 0.07 0.18 Total polar compounds 5.02 6.28 4.54 5.23
Unsaponificable matter 0.92 1.07 0.72 1.04 Insoluble impurities
<0.01 <0.01 0.01 <0.01 Total oil (%) Neutral oil 98.8 98.2
99.0 98.9
Example 2
General Methods for Biolistic Transforation of Prototheca
[0601] Seashell Gold Microcarriers 550 nanometers were prepared
according to the protocol from manufacturer. Plasmid (20 .mu.g) was
mixed with 50 .mu.l of binding buffer and 60 .mu.l (30 mg) of S550d
gold carriers and incubated in ice for 1 min. Precipitation buffer
(100 .mu.l) was added, and the mixture was incubated in ice for
another 1 min After vortexing, DNA-coated particles were pelleted
by spinning at 10,000 rpm in an Eppendorf 5415C microfuge for 10
seconds. The gold pellet was washed once with 500 .mu.l of cold
100% ethanol, pelleted by brief spinning in the microfuge, and
resuspended with 50 .mu.l of ice-cold ethanol. After a brief (1-2
sec) sonication, 10 .mu.l of DNA-coated particles were immediately
transferred to the carrier membrane.
[0602] Prototheca strains were grown in proteose medium (2 g/L
yeast extract, 2.94 mM NaNO3, 0.17 mM CaCl2.2H2O, 0.3 mM
MgSO4.7H2O, 0.4 mM K2HPO4, 1.28 mM KH2PO4, 0.43 mM NaCl) with 2%
glucose on a gyratory shaker until it reaches a cell density of
2.times.10.sup.6 cells/ml. The cells were harvested, washed once
with sterile distilled water, and resuspended in 50 .mu.l of
medium. 1.times.10.sup.7 cells were spread in the center third of a
non-selective proteose media plate. The cells were bombarded with
the PDS-1000/He Biolistic Particle Delivery system (Bio-Rad).
Rupture disks (1350 psi) were used, and the plates are placed 6 cm
below the screen/macrocarrier assembly. The cells were allowed to
recover at 25.degree. C. for 12-24 h. Upon recovery, the cells were
scraped from the plates with a rubber spatula, mixed with 100 .mu.l
of medium and spread on plates containing the appropriate
antibiotic selection. After 7-10 days of incubation at 25.degree.
C., colonies representing transformed cells were visible on the
plates. Colonies were picked and spotted on selective (either
antibiotic or carbon source) agar plates for a second round of
selection.
Example 3
Transformation of Chlorella
Vector Construction
[0603] A BamHI-SacII fragment containing the CMV promoter, a
hygromycin resistance cDNA, and a CMV 3' UTR (SEQ ID NO: 152, a
subsequence of the pCAMBIA1380 vector, Cambia, Can berra,
Australia) was cloned into the BamHI and SacII sites of pBluescript
and is referred to herein as pHyg.
Biolistic Transformation of Chlorella
[0604] S550d gold carriers from Seashell Technology were prepared
according to the protocol from manufacturer. Linearized pHyg
plasmid (20 .mu.g) was mixed with 50 .mu.l of binding buffer and 60
.mu.l (30 mg) of S550d gold carriers and incubated in ice for 1
min. Precipitation buffer (100 .mu.l) was added, and the mixture
was incubated in ice for another 1 min. After vortexing, DNA-coated
particles were pelleted by spinning at 10,000 rpm in an Eppendorf
5415C microfuge for 10 seconds. The gold pellet was washed once
with 500 .mu.l of cold 100% ethanol, pelleted by brief spinning in
the microfuge, and resuspended with 50 .mu.l of ice-cold ethanol.
After a brief (1-2 sec) sonication, 10 .mu.l of DNA-coated
particles were immediately transferred to the carrier membrane.
[0605] Chlorella protothecoides culture (Univeristy of Texas
Culture Collection 250) was grown in proteose medium (2 g/L yeast
extract, 2.94 mM NaNO3, 0.17 mM CaCl2.2H.sub.2O, 0.3 mM MgSO4.7H2O,
0.4 mM K2HPO4, 1.28 mM KH2PO4, 0.43 mM NaCl) on a gyratory shaker
under continuous light at 75 .mu.mol photons m.sup.-2 sec.sup.-1
until it reached a cell density of 2.times.10.sup.6 cells/ml. The
cells were harvested, washed once with sterile distilled water, and
resuspended in 50 .mu.l of medium. 1.times.10.sup.7 cells were
spread in the center third of a non-selective proteose media plate.
The cells were bombarded with the PDS-1000/He Biolistic Particle
Delivery system (Bio-Rad). Rupture disks (1100 and 1350 psi) were
used, and the plates were placed 9 and 12 cm below the
screen/macrocarrier assembly. The cells were allowed to recover at
25.degree. C. for 12-24 h. Upon recovery, the cells were scraped
from the plates with a rubber spatula, mixed with 100 .mu.l of
medium and spread on hygromycin contained plates (200 .mu.g/ml).
After 7-10 days of incubation at 25.degree. C., colonies
representing transformed cells were visible on the plates from 1100
and 1350 psi rupture discs and from 9 and 12 cm distances. Colonies
were picked and spotted on selective agar plates for a second round
of selection.
Transformation of Chlorella by Electroporation
[0606] Chlorella protothecoides culture was grown in proteose
medium on a gyratory shaker under continuous light at 75 .mu.mol
photons m.sup.-2 sec.sup.-1 until it reached a cell density of
2.times.10.sup.6 cells/ml. The cells were harvested, washed once
with sterile distilled water, and resuspended in a tris-phosphate
buffer (20m M Tris-HCl, pH 7.0; 1 mM potassium phosphate)
containing 50 mM sucrose to a density of 4.times.10.sup.8 cells/ml.
About 250 .mu.l cell suspension (1.times.10.sup.8 cells) was placed
in a disposable electroporation cuvette of 4 mm gap. To the cell
suspension, 5 .mu.g of linearized pHyg plasmid DNA and 200 .mu.g of
carrier DNA (sheared salmon sperm DNA) was added. The
electroporation cuvette was then incubated in a water bath at
16.degree. C. for 10 minutes. An electrical pulse (1100 V/cm) was
then applied to the cuvette at a capacitance of 25 .mu.F (no shunt
resistor was used for the electroporation) using a Gene Pulser II
(Bio-Rad Labs, Hercules, Calif.) electroporation apparatus. The
cuvette was then incubated at room temperature for 5 minutes,
following which the cell suspension was transferred to 50 ml of
proteose media, and shaken on a gyratory shaker for 2 days.
Following recovery, the cells were harvested by centrifugation at
low speed, resuspended in proteose media, and plated at low density
on plates supplemented with 200 .mu.g/ml hygromycin. The plates
were incubated under continuous light at 75 .mu.mol photons
m.sup.-2 sec.sup.-1. Transformants appeared as colonies in 1-2
weeks. Colonies were picked and spotted on selective agar plates
for a second round of selection.
Genotyping
[0607] A subset of colonies that survived a second round of
selection were cultured in small volume and harvested. Pellets of
approximately 5-10 uL volume were resuspended in 50 uL of 10 mM
NaEDTA by vortexing and then incubated at 100.degree. C. for 10.
The tubes were then vortexed briefly and sonicated for 10 seconds,
then centifuged at 12,000.times.g for 1 minute. 2 uL of supernatant
as template was used in a 50 uL PCR reaction. Primers used for
genotyping were SEQ ID NO: 153 and SEQ ID NO: 154. PCR conditions
were as follows: 95.degree. C. 5 mM.times.1 cycle; 95.degree. C. 30
sec-58.degree. C. 30 sec-72.degree. C. 1 mM 30 sec.times.35 cycles;
72.degree. C. 10 min.times.1 cycle. The expected 992 bp fragment
was found in 6 of 10 colonies from the biolistic method and from a
single electroporation colony. A lower sized, nonspecific band was
present in all lanes. To confirm the identity of the amplified 992
bp fragment, two biolistic bands and the electroporation band were
excised from the gel and individually sequenced. The sequence of
all three bands corresponded to the expected 992 bp fragment. (DNA
ladder: Bionexus.RTM. All Purpose Hi-Lo.RTM. DNA ladder catalog
#BN2050).
Example 4
Algal-Derived Promoters and Genes for Use in Microalgae
[0608] A. 5'UTR and Promoter Sequences from Chlorella
protothecoides
[0609] A cDNA library was generated from mixotrophically grown
Chlorella protothecoides (UTEX 250) using standard techniques.
Based upon the cDNA sequences, primers were designed in certain
known housekeeping genes to "walk" upstream of the coding regions
using Seegene's DNA Walking kit (Rockville, Md.). Sequences
isolated include an actin (SEQ ID NO: 155) and elongation factor-1a
(EF1a) (SEQ ID NO: 156) promoter/UTR, both of which contain introns
(as shown in the lower case) and exons (upper case italicized) and
the predicted start site (in bold) and two beta-tubulin
promoter/UTR elements: Isoform A (SEQ ID NO: 157) and Isoform B
(SEQ ID NO: 158).
[0610] B. Lipid Biosynthesis Enzyme and Plastid Targeting Sequences
from C. protothecoides
[0611] From the cDNA library described above, three cDNAs encoding
proteins functional in lipid metabolism in Chlorella protothecoides
(UTEX 250) were cloned using the same methods as described above.
The nucleotide and amino acid sequences for an acyl ACP desaturase
(SEQ ID NOs: 159 and 160) and two geranyl geranyl diphosphate
synthases (SEQ ID NOs: 161-164) are included in the Sequence
Listing below. Additionally, three cDNAs with putative signal
sequences targeting to the plastid were also cloned. The nucleotide
and amino acid sequences for a glyceraldehyde-3-phosphate
dehydrogenase (SEQ ID NOs: 165 and 166), an oxygen evolving complex
protein OEE33 (SEQ ID NOs: 167 and 168) and a Clp protease (SEQ ID
NOs: 169 and 170) are included in the Sequence Listing below. The
putative plastid targeting sequence has been underlined in both the
nucleotide and amino acid sequence. The plastid targeting sequences
can be used to target the producs of transgenes to the plastid of
microbes, such as lipid modification enzymes.
Example 5
Genetic Engineering of Chlorella protothecoides to Express an
Exogenous Sucrose Invertase
[0612] Strains and Media: Chlorella protothecoides (UTEX 250) was
obtained from the Culture Collection of Alga at the University of
Texas (Austin, Tex., USA). The stock cultures were maintained on
modified Proteose medium. Modified Proteose medium consists of 0.25
g NaNO.sub.3, 0.09 g K.sub.2HPO.sub.4, 0.175 g KH.sub.2PO.sub.4
0.025 g, 0.025 g CaCl.sub.2.2H.sub.2O, 0.075 g
MgSO.sub.4.7H.sub.2O, and 2 g yeast extract per liter (g/L).
[0613] Plasmid Construction: To express the secreted form of
invertase in Chlorella protothecoides, a Saccharomyces cerevisiae
SUC2 gene was placed under the control of three different
promoters: Cauliflower mosaic virus 35S promoter (CMV), Chlorella
virus promoter (NC-1A), and Chlorella HUP1 promoter. A yeast SUC2
gene was synthesized to accommodate codon usage optimized for C.
protothecoides and includes a signal sequence required for
directing extracellular secretion of invertase. Each construct was
built in pBluescript KS+, and EcoRI/AscI, AscI/XhoI, and XhoI/BamHI
sites were introduced to each promoter, invertase gene, and CMV
3'UTR, respectively, by PCR ampilication using specific primers.
Purified PCR products were cloned sequentially.
[0614] Transformation of Chlorella protothecoides: A Chlorella
protothecoides culture was grown in modified Proteose medium on a
gyratory shaker under continuous light at 75 .mu.mol photons
m.sup.-2 sec.sup.-1 till it reached a cell density of
6.times.10.sup.6 cells/ml.
[0615] For biolistic transformation, S550d gold carriers from
Seashell Technology were prepared according to the protocol from
the manufacturer. Briefly, a linearized construct (20 .mu.g) by
BsaI was mixed with 50 .mu.l of binding buffer and 60 .mu.l (3 mg)
of S550d gold carriers and incubated in ice for 1 min.
Precipitation buffer (100 .mu.l) was added, and the mixture was
incubated in ice for another 1 min. After mild vortexing,
DNA-coated particles were pelleted by spinning at 10,000 rpm in an
Eppendorf microfuge for 10 seconds. The gold pellet was washed once
with 500 .mu.l of cold 100% ethanol, pelleted by brief spinning in
the microfuge, and resuspended with 50 .mu.l of ice-cold ethanol.
After a brief (1-2 sec) sonication, 10 .mu.l of DNA-coated
particles were immediately transferred to the carrier membrane. The
cells were harvested, washed once with sterile distilled water,
resuspended in 50 .mu.l of medium (1.times.10.sup.7 cells), and
were spread in the center third of a non-selective Proteous plate.
The cells were bombarded with the PDS-1000/He Biolistic Particle
Delivery system (Bio-Rad). Rupture disks (1100 and 1350 psi) were
used, and the plates were placed 9-12 cm below the
screen/macrocarrier assembly. The cells were allowed to recover at
25.degree. C. for 12-24 hours. Upon recovery, the cells were
scraped from the plates with a rubber spatula, mixed with 100 .mu.l
of medium and spread on modified Proteose plates with 1% sucrose.
After 7-10 days of incubation at 25.degree. C. in the dark,
colonies representing transformed cells were visible on the
plates.
[0616] For transformation with electroporation, cells were
harvested, washed once with sterile distilled water, and
resuspended in a Tris-phosphate buffer (20m M Tris-HCl, pH 7.0; 1
mM potassium phosphate) containing 50 mM sucrose to a density of
4.times.10.sup.8 cells/ml. About 250 .mu.l cell suspension
(1.times.10.sup.8 cells) was placed in a disposable electroporation
cuvette of 4 mm gap. To the cell suspension, 5 .mu.g of linearized
plasmid DNA and 200 .mu.g of carrier DNA (sheared salmon sperm DNA)
were added. The electroporation cuvette was then incubated in an
ice water bath at 16.degree. C. for 10 min. An electrical pulse
(1100 V/cm) was then applied to the cuvette at a capacitance of 25
.mu.F (no shunt resistor was used for the electroporation) using a
Gene Pulser II (Bio-Rad Labs, Hercules, Calif.) electroporation
apparatus. The cuvette was then incubated at room temperature for 5
minutes, following which the cell suspension was transferred to 50
ml of modified Proteose media, and shaken on a gyratory shaker for
2 days. Following recovery, the cells were harvested at low speed
(4000 rpm), resuspended in modified Proteose media, and plated out
at low density on modified Proteose plates with 1% sucrose. After
7-10 days of incubation at 25.degree. C. in the dark, colonies
representing transformed cells were visible on the plates.
[0617] Screening Transformants and Genotyping: The colonies were
picked from dark grown-modified Proteose plates with 1% sucrose,
and approximately the same amount of cells were transferred to 24
well-plates containing 1 ml of modified Proteose liquid media with
1% sucrose. The cultures were kept in dark and agitated by orbital
shaker from Labnet (Berkshire, UK) at 430 rpm for 5 days.
[0618] To verify the presence of the invertase gene introduced in
Chlorella transformants, DNA of each transformant was isolated and
amplified with a set of gene-specific primers (CMV construct:
forward primer (CAACCACGTCTTCAAAGCAA) (SEQ ID NO: 153)/reverse
primer (TCCGGTGTGTTGTAAGTCCA) (SEQ ID NO: 171), CV constructs:
forward primer (TTGTCGGAATGTCATATCAA) (SEQ ID NO: 172)/reverse
primer (TCCGGTGTGTTGTAAGTCCA) (SEQ ID NO: 171), and HUP1 construct:
forward primer (AACGCCTTTGTACAACTGCA) (SEQ ID NO: 173)/reverse
primer (TCCGGTGTGTTGTAAGTCCA) (SEQ ID NO: 171)). For quick DNA
isolation, a volume of cells (approximately 5-10 uL in size) were
resuspended in 50 uL of 10 mM Na-EDTA. The cell suspension was
incubated at 100.degree. C. for 10 mM and sonicated for 10 sec.
After centrifugation at 12000 g for 1 mM, 3 uL of supernatant was
used for the PCR reaction. PCR amplification was performed in the
DNA thermal cycler (Perkin-Elmer GeneAmp 9600). The reaction
mixture (50 uL) contained 3 uL extracted DNA, 100 pmol each of the
respective primers described above, 200 uM dNTP, 0.5 units of Taq
DNA polymerase (NEB), and Taq DNA polymerase buffer according to
the manufacturer's instructions. Denaturation of DNA was carried
out at 95.degree. C. for 5 min for the first cycle, and then for 30
sec. Primer annealing and extension reactions were carried out at
58.degree. C. for 30 sec and 72.degree. C. for 1 min respectively.
The PCR products were then visualized on 1% agarose gels stained
with ethidium bromide.
[0619] Growth in Liquid Culture: After five days growth in
darkness, the genotype-positive transformants showed growth on
minimal liquid Proteose media+1% sucrose in darkness, while
wild-type cells showed no growth in the same media in darkness.
Example 6
Transformation of Algal Strains with a Secreted Invertase Derived
from S. cerevisiae
[0620] Secreted Invertase: A gene encoding a secreted sucrose
invertase (Gen Bank Accession no. NP.sub.--012104 from
Saccharomyces cerevisiae) was synthesized de-novo as a 1599 bp Asc
I-Xho fragment that was subsequently sub-cloned into a pUC19
derivative possessing the Cauliflower Mosaic Virus 35S promoter and
3' UTR as EcoR I/Asc I and Xho/Sac I cassettes, respectively.
[0621] Growth of Algal Cells: Media used in these experiments was
liquid base media (2 g/L yeast extract, 2.94 mM NaNO.sub.3, 0.17 mM
CaCl.sub.2.2H.sub.2O, 0.3 mM MgDO.sub.4.7H.sub.2O, 0.4 mM
K.sub.2HPO.sub.4, 1.28 mM KH.sub.2PO.sub.4, 0.43 mM NaCl) and solid
base media (+1.5% agarose) containing fixed carbon in the form of
sucrose or glucose (as designated) at 1% final concentration. The
strains used in this experiment did not grow in the dark on base
media in the absence of an additional fixed carbon source. Species
were struck out on plates, and grown in the dark at 28.degree. C.
Single colonies were picked and used to inoculate 500 mL of liquid
base media containing 1% glucose and allowed to grow in the dark
until mid-log phase, measuring cell counts each day. Each of the
following strains had been previously tested for growth on sucrose
in the dark as a sole carbon source and exhibited no growth, and
were thus chosen for transformation with a secreted invertase: (1)
Chlorella protothecoides (UTEX 31); (2) Chlorella minutissima (UTEX
2341); and (3) Chlorella emersonii (CCAP 211/15).
[0622] Transformation of Algal Cells via Particle Bombardment:
Sufficient culture was centrifuged to give approximately
1-5.times.10.sup.8 total cells. The resulting pellet was washed
with base media with no added fixed carbon source. Cells were
centrifuged again and the pellet was resuspended in a volume of
base media sufficient to give 5.times.10.sup.7 to 2.times.10.sup.8
cells/ml. 250-1000 .mu.l of cells were then plated on solid base
media supplemented with 1% sucrose and allowed to dry onto the
plate in a sterile hood. Plasmid DNA was precipitated onto gold
particles according to the manufacturer's recommendations (Seashell
Technology, La Jolla, Calif.). Transformations were carried out
using a BioRad PDS He-1000 particle delivery system using 1350 psi
rupture disks with the macrocarrier assembly set at 9 cm from the
rupture disk holder. Following transformations, plates were
incubated in the dark at 28.degree. C. All strains generated
multiple transformant colonies. Control plates transformed with no
invertase insert, but otherwise prepared in an identical fashion,
contained no colonies.
[0623] Analysis of Chlorella protothecoides transformants: Genomic
DNA was extracted from Chlorella protothecoides wild type cells and
transformant colonies as follows: Cells were resuspended in 100 ul
extraction buffer (87.5 mM Tris Cl, pH 8.0, 50 mM NaCl, 5 mM EDTA,
pH 8.0, 0.25% SDS) and incubated at 60.degree. C., with occasional
mixing via inversion, for 30 minutes. For PCR, samples were diluted
1:100 in 20 mM Tris Cl, pH 8.0.
[0624] Genotyping was done on genomic DNA extracted from WT, the
transformants and plasmid DNA. The samples were genotyped for the
marker gene. Primers 2383 (5' CTGACCCGACCTATGGGAGCGCTCTTGGC 3')
(SEQ ID NO: 174) and 2279 (5' CTTGACTTCCCTCACCTGGAATTTGTCG 3') (SEQ
ID NO: 175) were used in this genotyping PCR. The PCR profile used
was as follows: 94.degree. C. denaturation for 5 min; 35 cycles of
94.degree. C.-30 sec, 60.degree. C.-30 sec, 72.degree. C.-3 min;
72.degree. C.-5 min. A band of identical size was amplified from
the positive controls (plasmid) and two transformants of Chlorella
protothecoides (UTEX 31).
[0625] Analysis of Chlorella minutissima and Chlorella emersonii
transformants: Genomic DNA was extracted from Chlorella WT and the
tranformants as follows: Cells were resuspended in 100 ul
extraction buffer (87.5 mM Tris Cl, pH 8.0, 50 mM NaCl, 5 mM EDTA,
pH 8.0, 0.25% SDS) and incubated at 60.degree. C., with occasional
mixing via inversion, for 30 minutes. For PCR, samples were diluted
1:100 in 20 mM Tris Cl, pH 8.0. Genotyping was done on genomic DNA
extracted from WT, the transformants and plasmid DNA. The samples
were genotyped for the marker gene. Primers 2336 (5'
GTGGCCATATGGACTTACAA 3') (SEQ ID NO: 176) and 2279 (5'
CTTGACTTCCCTCACCTGGAATTTGTCG 3') (SEQ ID NO: 175) were designated
primer set 2 (1215 bp expected product), while primers 2465 (5'
CAAGGGCTGGATGAATGACCCCAATGGACTGTGGTACGACG 3') (SEQ ID NO: 177) and
2470 (5' CACCCGTCGTCATGTTCACGGAGCCCAGTGCG 3') (SEQ ID NO: 178) were
designated primer set 4 (1442 bp expected product). The PCR profile
used was as follows: 94.degree. C. denaturation for 2 min; 29
cycles of 94.degree. C.-30 sec, 60.degree. C.-30 sec, 72.degree.
C.-1 min, 30 sec; 72.degree. C.-5 min. A plasmid control containing
the secreted invertase was used as a PCR control.
[0626] The sequence of the invertase construct corresponds to SEQ
ID NO: 8.
Example 7
Homologous Recombination in Prototheca Species
[0627] Homologous recombination of transgenes has several
advantages. First, the introduction of transgenes without
homologous recombination can be unpredictable because there is no
control over the number of copies of the plasmid that gets
introduced into the cell. Also, the introduction of transgenes
without homologous recombination can be unstable because the
plasmid may remain episomal and is lost over subsequent cell
divisions. Another advantage of homologous recombination is the
ability to "knock-out" gene targets, introduce epitope tags, switch
promoters of endogenous genes and otherwise alter gene targets
(e.g., the introduction of point mutations.
[0628] Two vectors were constructed using a specific region of the
Prototheca moriformis (UTEX 1435) genome, designated KE858. KE858
is a 1.3 kb, genomic fragment that encompasses part of the coding
region for a protein that shares homology with the transfer RNA
(tRNA) family of proteins. Southern blots have shown that the KE858
sequence is present in a single copy in the Prototheca moriformis
(UTEX 1435) genome. The first type of vector that was constructed,
designated SZ725 (SEQ ID NO: 179), consisted of the entire 1.3 kb
KE858 fragment cloned into a pUC19 vector backbone that also
contains the optimized yeast invertase (suc2) gene. The KE858
fragment contains a unique SnaB1 site that does not occur anywhere
else in the targeting construct. The second type of vector that was
constructed, designated SZ726 (SEQ ID NO: 180), consisted of the
KE858 sequence that had been disrupted by the insertion of the
yeast invertase gene (suc2) at the SnaB1 site within the KE858
genomic sequence. The entire DNA fragment containing the KE858
sequences flanking the yeast invertase gene can be excised from the
vector backbone by digestion with EcoRI, which cuts at either end
of the KE858 region.
[0629] Both vectors were used to direct homologous recombination of
the yeast invertase gene (suc2) into the corresponding KE858 region
of the Prototheca moriformis (UTEX 1435) genome. The linear DNA
ends homologous to the genomic region that was being targeted for
homologous recombination were exposed by digesting the vector
construct SZ725 with SnaB1 and vector construct SZ726 with EcoRI.
The digested vector constructs were then introduced into Prototheca
moriformis cultures using methods described above. Transformants
from each vector construct were then selected using sucrose plates.
Ten independent, clonally pure transformants from each vector
transformation were analyzed for successful recombination of the
yeast invertase gene into the desired genomic location (using
Southern blots) and for transgene stability.
[0630] Southern blot analysis of the SZ725 transformants showed
that 4 out of the 10 transformants picked for analysis contained
the predicted recombinant bands, indicating that a single crossover
event had occurred between the KE858 sequences on the vector and
the KE858 sequences in the genome. In contrast, all ten of the
SZ726 transformants contained the predicted recombinant bands,
indicating that double crossover events had occurred between the
EcoRI fragment of pSZ726 carrying KE858 sequence flanking the yeast
invertase transgene and the corresponding KE858 region of the
genome.
[0631] Sucrose invertase expression and transgene stability were
assessed by growing the transformants for over 15 generations in
the absence of selection. The four SZ725 transformants and the ten
SZ276 transformants that were positive for the transgene by
Southern blotting were selected and 48 single colonies from each of
the transformants were grown serially: first without selection in
glucose containing media and then with selection in media
containing sucrose as the sole carbon source. All ten SZ276
transformants (100%) retained their ability to grow on sucrose
after 15 generations, whereas about 97% of the SZ725 transformants
retained their ability to grow on sucrose after 15 generations.
Transgenes introduced by a double crossover event (SZ726 vector)
have extremely high stability over generation doublings. In
contrast, transgenes introduced by a single cross over event (SZ725
vector) can result in some instability over generation doublings
because is tandem copies of the transgenes were introduced, the
repeated homologous regions flanking the transgenes may recombine
and excise the transgenic DNA located between them.
[0632] These experiments demonstrate the successful use of
homologous recombination to generate Prototheca transformants
containing a heterologous sucrose invertase gene that is stably
integrated into the nuclear chromosomes of the organism. The
success of the homologous recombination enables other genomic
alterations in Prototheca, including gene deletions, point
mutations and epitope tagging a desired gene product. These
experiments also demonstrate the first documented system for
homologous recombination in the nuclear genome of a eukaryotic
microalgae.
[0633] Use of Homologous Recombination to Knock-out an Endogenous
Prototheca moriformis gene: In a Prototheca moriformis cDNA/genomic
screen, like that described above in Example 4, an endogenous
stearoyl ACP desaturase (SAPD) cDNA was identified. Stearoyl ACP
desaturase enzymes are part of the lipid synthesis pathway and they
function to introduce double bonds into the fatty acyl chains. In
some cases, it may be advantages to knock-out or reduce the
expression of lipid pathway enzymes in order to alter a fatty acid
profile. A homologous recombination construct was created to assess
whether the expression of an endogenous stearoyl ACP desaturase
enzyme can be reduced (or knocked out) and if a corresponding
reduction in unsaturated fatty acids can be observed in the lipid
profile of the host cell. An approximately 1.5 kb coding sequence
of a stearoyl ACP desaturase gene from Prototheca moriformis (UTEX
1435) was identified and cloned (SEQ ID NO: 181). The homologous
recombination construct was constructed using 0.5 kb of the SAPD
coding sequence at the 5' end (5' targeting site), followed by the
Chlamydomonas reinhardtii .beta.-tublin promoter driving a
codon-optimized yeast sucrose invertase suc2 gene with the
Chlorella vulgaris 3'UTR. The rest (.about.1 kb) of the Prototheca
moriformis SAPD coding sequence was then inserted after the C.
vulgaris 3'UTR to make up the 3' targeting site. The sequence for
this homologous recombination cassette is listed in SEQ ID NO: 182.
As shown above, the success-rate for integration of the homologous
recombination cassette into the nuclear genome can be increased by
linearizing the cassette before transforming the microalgae,
leaving exposed ends. The homologous recombination cassette
targeting an endogenous SAPD enzyme in Prototheca moriformis is
linearized and then transformed into the host cell (Prototheca
moriformis, UTEX 1435). A successful integration will eliminate the
endogenous SAPD enzyme coding region from the host genome via a
double reciprocal recombination event, while expression of the
newly inserted suc2 gene will be regulated by the C. reinhardtii
.beta.-tubulin promoter. The resulting clones can be screened using
plates/media containing sucrose as the sole carbon source. Clones
containing a successful integration of the homologous recombination
cassette will have the ability to grow on sucrose as the sole
carbon source and changes in overall saturation of the fatty acids
in the lipid profile will serve as a secondary confirmation factor.
Additionally, Southern blotting assays using a probe specific for
the yeast sucrose invertase suc2 gene and RT-PCR can also confirm
the presence and expression of the invertase gene in positive
clones. As an alternative, the same construct without the
.beta.-tubulin promoter can be used to excise the endogenous SAPD
enzyme coding region. In this case, the newly inserted yeast
sucrose invertase suc2 gene will be regulated by the endogenous
SAPD promoter/5'UTR.
Example 8
Expression of Various Thioesterases in Prototheca
[0634] Methods and effects of expressing a heterologous
thioesterase gene in Prototheca species have been previously
described in PCT Application No. PCT/US2009/66142, hereby
incorporated by reference. The effect of other thioesterase
genes/gene products from higher plants species was further
investigated. These thioesterases include thioesterases from the
following higher plants:
TABLE-US-00022 GenBank Species Accession No. Specificity SEQ ID NO:
Cinnamomum Q39473 C14 SEQ ID NOs: 30-31 camphora Umbellularia
Q41635 C10-C12 SEQ ID NOs: 34-35 californica Cuphea hookeriana
AAC49269 C8-C10 SEQ ID NOs: 32-33 Cuphea palustris AAC49179 C8 SEQ
ID NOs: 36-37 Cuphea lanceolata CAB60830 C10 SEQ ID NOs: 38-39 Iris
germanica AAG43858.1 C14 SEQ ID NOs: 40-41 Myristica fragrans
AAB717291.1 C14 SEQ ID NOs: 42-43 Cuphea palustris AAC49180 C14 SEQ
ID NOs: 44-45 Ulmus americana AAB71731 broad SEQ ID NOs: 46-47
[0635] In all cases, each of the above thioesterase constructs was
transformed in to Prototheca moriformis (UTEX 1435) using biolistic
particle bombardment. Other transformation methods including
homologous recombination as disclosed in PCT Application No.
PCT/US2009/66142, would also be suitable for heterologous
expression of genes of interest. Transformation of Prototheca
moriformis (UTEX 1435) with each of the above thioesterase
constructs was performed using the methods described in Example 2.
Each of the constructs contained a NeoR gene and selection for
positive clones was carried out using 100 .mu.g/ml G418. All coding
regions were codon optimized to reflect the codon bias inherent in
Prototheca moriformis UTEX 1435 (see Table 2) nuclear genes. Both
amino acid sequences and the cDNA sequences for the construct used
are listed in the sequence identity listing. The transit peptide
for each of the higher plant thioesterase was replaced with an
algal codon optimized transit peptide from Prototheca moriformis
delta 12 fatty acid desaturase (SEQ ID NO: 48)) or from Chlorella
protothecoides stearoyl ACP desaturase (SEQ ID NO: 49). All
thioesterase constructs were driven by the Chlamydomanas
reinhardtii beta-tubulin promoter/5'UTR. Growth and lipid
production of selected positive clones were compared to wildtype
(untransformed) Prototheca moriformis (UTEX 1435). Wildtype and
selected positive clones were grown on 2% glucose G418 plates.
Lipid profiles analysis on selected positive clones for each
construct is summarized below (expressed in Area %) in Table
15.
TABLE-US-00023 TABLE 15 Lipid profiles of Prototheca moriformis
expressing various heterologous thioesterases. Thioesterase C. C.
Fatty UTEX U. C. I. M. palustris C. C. palustris U. Acid 1435 wt
californica camphora germanica fragrans C8:0 hookeriana lanceolata
C14:0 americana C8:0 0 0 0 0 3.1 1.8 0 0 .09 C10:0 0.02 .07 .02 .01
.09 .56 6.85 1.91 .01 2.85 C12:0 0.05 14 1.82 .09 .05 .25 .2 .29
.06 .74 C14:0 1.65 3 17.3 2.59 5.31 1.45 1.8 1.83 2.87 10.45 C16:0
28.0 21.4 24.3 26.52 31.08 22.84 23.9 25.55 27.23 33.3 C18:0 2.9
2.9 2.7 3.11 2.71 3.24 2.8 3.26 3.62 3.47 C18:l 53.8 45.2 41.3
49.96 39.77 56.62 49.8 55.43 51.04 38.71 C18:2 10.95 10 9.7 11.86
14.17 8.24 9.7 8.17 10.81 7.38 C18:3 .alpha. 0.8 .86 .8 .40 .64 .61
.9 .58 .97 .52 Total 32.62 44.97 46.14 32.32 39.24 31.44 37.35
32.84 33.79 50.9 saturates (area %)
[0636] The results show that all of the thioesterases expressed
impacted fatty acid profiles to some level. Looking at the "Total
saturates" row, the degree of saturation was profoundly impacted by
the expression of several of the thioesterases, including those
from U. californica, C. camphora, and most notably, U. americana.
These changes in the percentage of total saturates were unexpected
in that the heterologous expression of thioesterases from higher
plants can apparently impact more than just lipid chain lengths; it
can also impact other attributes of lipid profiles produced by
microalgae, namely the degree of saturation of the fatty acids.
[0637] Selected clones transformed with C. palustris C8
thioesterase, C. hookeriana thioesterase, U. californica and C.
camphora thioesterase were further grown in varing amounts of G418
(from 25 mg/L to 50 mg/L) and at varying temperatures (from
22.degree. C. to 25.degree. C.) and the lipid profile was
determined for these clones. Table 16 summarizes the lipid profile
(in Area %) of representative clones containing each thioesterase.
A second construct containing the U. americana thioesterase was
constructed and transformed into Prototheca moriformis (UTEX 1435)
using the biolistic methods described above. This second construct
was introduced into the cell via homologous recombination. Methods
of homologous recombination in Prototheca species were described
previously in PCT Application No. PCT/US2009/66142. The homologous
DNA that was used was from genomic DNA sequence of 6S rRNA from
Prototheca moriformis UTEX 1435. The selection agent was the
ability to grow on sucrose, using a codon optimized suc2 gene from
S. cereveisiae driven by the C. reinhardtii beta tubulin promoter.
The native U. americana transit peptide was replaced by the
Chlorella protothecoides (UTEX 250) stearoyl ACP desaturase transit
peptide. The cDNA of this construct is listed in the Sequence
Listing as SEQ ID NO: 50. Selection of positive clones was
performed on 2% sucrose plates and the resulting cultures for lipid
profile determination was also grown on 2% sucrose containing
medium. A representative lipid profile for this Prototheca
moriformis strain containing a homologously recombined heterologous
U. americana thioesterase is summarized in Table 16.
TABLE-US-00024 TABLE 16 Lipid profiles of Prototheca moriformis
strains containing heterologous thioesterase genes. C. palustris U.
americana C8 C. hookeriana C. camphora 2 C8:0 12.28 2.37 0 0 C10:0
2.17 12.09 0.02 4.69 C12:0 0.34 0.33 3.81 1.02 C14:0 1.59 2.08
32.73 16.21 C16:0 15.91 20.07 24.03 38.39 C18:0 1.59 1.57 1.21 2.83
C18:1 50.64 41.80 18.64 27.22 C18:2 13.02 16.37 16.57 7.65 C18:3
.alpha. 1.52 1.75 1.66 0.74 Total 33.88 38.51 61.80 63.14
saturates
[0638] As with the clones described above, all transformants
containing a heterologous thioesterase gene showed impacted fatty
acid profiles to some level, and the total percent of saturated
fatty acids were also changed, as compared to wildtype
(untransformed) Prototheca moriformis. The Prototheca moriformis
containing the U. americana thioesterase introduced by homologous
recombination had the greatest increase in total saturates.
[0639] Additionally, transgenic clones containing the exogenous C.
hookeriana, C. camphora, U. californica or U. americana
thioesterase were assessed for novel lipid profiles. The C.
hookeriana thioesterase containing clone achieved the following
lipid profile when grown in 2% glucose, 25 mg/ml G418 at 22.degree.
C.: 5.10% C8:0; 18.28% C10:0; 0.41% C12:0; 1.76% C14:0; 16.31%
C16:0; 1.40% C18:0; 40.49% C18:1; and 13.16% C18:2. The C. camphora
thioesterase-containing clone (also containing an exogenous sucrose
invertase) achieved the following lipid profile when grown in 2%
sucrose at 25.degree. C.: 0.04% C10:0; 6.01% C12:0; 35.98% C14:0;
19.42 C16:0; 1.48% C18:0; 25.44% C18:1; and 9.34% C18:2. The U.
calformica thioesterase containing clone achieved the following
lipid profile when grown in 2% glucose, 25-100 mg/ml G418 at
22.degree. C.: 0% C8:0; 0.11% C10:0; 34.01% C12:0; 5.75% C14:0;
14.02% C16:0; 1.10% C18:0; 28.93% C18:1; and 13.01% C18:2. The U.
americana thioesterase containing clone achieved the following
lipid profile when grown in 2% glucose at 28.degree. C.: 1.54%
C10:0; 0.43% C12:0; 7.56% C14:0; 39.45% C16:0; 2.49% C18:0; 38.49%
C18:1; and 7.88% C18:2.
Example 9
Transformation of Prototheca with Multiple Exogenous Heterologous
Thioesterase Genes
[0640] Microalgae strain Prototheca moriformis (UTEX 1435) was
transformed using the above disclosed methods to express multiple
thioesterases in a single clone. The expression of multiple
thioesterases in a single clone allows the microaglae to produce
oils with fatty acid profiles completely different from those
elaborated when any single thioesterase is expressed alone (as
demonstrated in the preceding Examples). Prototheca moriformis
(UTEX 1435) was first transformed with the Cinnamomum camphora
thioesterase (a C14 preferring thioesterase) along with a sucrose
invertase gene, the suc2 from S. cerevisiae (selection was the
ability to grow on sucrose) using homologous recombination. The DNA
used for this homologous recombination construct is from the KE858
region of Prototheca moriformis genomic DNA as described in the
Section III above. The relevant portion of this construct is listed
in the Sequence Listing as SEQ ID NO: 51. Positive clones were
screened on sucrose-containing plates. A positive clone was then
re-transformed with one of three cassettes, each encoding
resistance to the antibiotic G418 as well as an additional
thioesterase: (1) thioesterase gene from Cuphea hookeriana (C8-10
preferring), SEQ ID NO: 52; (2) thioesterase gene from Umbellularia
californica (C12 preferring), SEQ ID NO: 53; or thioesterase from
Ulmus americana (broad; C10-C16 preferring), SEQ ID NO: 54.
Included in the Sequence Listing is the sequence of the relevant
portion of each construct. Clones expressing both thioesterase
genes were screened on sucrose containing medium with 50 .mu.g/ml
G418. Positive clones were selected and growth and lipid profile
were assayed. Table 17 summarizes the lipid profile of
representative positive clones (expressed in Area %).
TABLE-US-00025 TABLE 17 Lipid profiles of Prototheca moriformis
transformed with multiple thioesterases. UTEX 1435 + C. camphora TE
genetic background Fatty UTEX UTEX 1435 + +C. hookeriana +U.
californica +U. americana Acid 1435 C. camphora TE TE TE TE C8:0 0
0 0.19 0 0.06 C10:0 0.02 0.02 2.16 0.07 1.87 C12:0 0.05 0.66 0.53
13.55 1.61 C14:0 1.65 10.52 7.64 8.0 14.58 C16:0 28.0 22.56 22.31
19.98 29.53 C18:0 2.9 6.67 3.23 2.24 2.93 C18:1 53.8 47.78 48.54
42.55 37.3 C18:2 10.95 12.3 11.76 10.13 8.9 C18:3 .alpha. 0.8 0.93
0.91 0.91 0.76 Total 32.62 40.43 36.06 43.84 50.58 saturates (Area
%)
[0641] Additionally, a double thioesterase clone with C. camphora
and U. californica thioesterases was grown in 2% sucrose containing
medium with 50 mg/L G418 at 22.degree. C. The fatty acid profile
obtained from this strain under these growth conditions was: C8:0
(0); C10:0 (0.10); C12:0 (31.03); C14:0 (7.47); C16:0 (15.20);
C18:0 (0.90); C18:1 (30.60); C18:2 (12.44); and C18:3a (1.38), with
a total saturates of 54.7.
[0642] Double thioesterase clones with two homologous recombination
constructs (one targeting the 6S region and the other targeting the
KE858 region) containing the C. camphora thioestease were produced.
A positive representative clone had a fatty acid profile of: 0%
C8:0; 0.06% C10:0; 5.91% C12:0; 43.27% C14:0; 19.63% C16:0; 0.87%
C18:0; 13.96% C18:1; and 13.78% C18:2, with a total saturates at
69.74%. This clone had a C12-C14 level at over 49%, which is over
37 times the C12-C14 level in wildtype cells.
[0643] The above data shows that multiple thioesterases can be
successfully co-expressed in microalgae. The co-expression of
multiple thioesterases results in altered fatty acid profiles that
differ significantly not only from the wild type strain, but also
from the fatty acid profile obtained by the expression of any one
of the individual thioesterases. The expression of multiple
thioesterases with overlapping chain length specificity can result
in cumulative increases in those specific fatty acids.
[0644] The expression of heterologous thioesterases (either alone
or in combination) in Prototheca moriformis not only alters the
fatty acid/lipid profiles in the host strain, but when compared to
oils currently available from a variety of seed crops (Table 5),
these profiles are of truly unique oils found in no other currently
available system. Not only do the transgenic strains show
significant differences from the untransformed wildtype strain,
they have remarkably different profiles from any of the commercial
oils that are shown in Table 5. As an example, both coconut and
palm kernel oils have levels of C8-C10 fatty acids ranging from
5.5-17%. Transgenic strain expressing the C. palustris
C8-preferring thioesterase or the C. hookeriana C10-preferring
thioesterase accumulates anywhere from 3.66 to 8.65%, respectively.
These C8-C10 fatty acid levels are similar to coconut oil and palm
kernel, however, the transgenic algal strains lack the
significantly higher C12:0 fatty acids, and they have extremely
high C16:0 (23% in transgenics versus 11-16% in coconut or palm
kernel oil, respectively and/or 18:1 (50-57% in transgenics versus
8-19% in coconut or palm kernel oil, respectively.
Example 10
Identification of Endogenous Nitrogen-Dependent Prototheca
Promoters
[0645] A. Identification and Characterization of Endogenous
Nitrogen-Dependent Promoters.
[0646] A cDNA library was generated from Prototheca moriformis
(UTEX 1435) using standard techniques. The Prototheca moriformis
cells were grown for 48 hours under nitrogen replete conditions.
Then a 5% innoculum (v/v) was then transferred to low nitrogen and
the cells were harvested every 24 hours for seven days. After about
24 hours in culture, the nitrogen supply in the media was
completely depleted. The collected samples were immediately frozen
using dry ice and isopropanol. Total RNA was subsequently isolated
from the frozen cell pellet samples and a portion from each sample
was held in reserve for RT-PCR studies. The rest of the total RNA
harvested from the samples was subjected to polyA selection.
Equimolar amounts of polyA selected RNA from each condition was
then pooled and used to generate a cDNA library in vector pcDNA 3.0
(Invitrogen). Roughly 1200 clones were randomly picked from the
resulting pooled cDNA libray and subjected to sequencing on both
strands. Approximately 68 different cDNAs were selected from among
these 1200 sequences and used to design cDNA-specific primers for
use in real-time RT-PCR studies.
[0647] RNA isolated from the cell pellet samples that were held in
reserve was used as substrate in the real time RT-PCR studies using
the cDNA-specific primer sets generated above. This reserved RNA
was converted into cDNA and used as substrate for RT-PCR for each
of the 68 gene specific primer sets. Threshold cylcle or C.sub.T
numbers were used to indicate relative transcript abundance for
each of the 68 cDNAs within each RNA sample collected throughout
the time course. cDNAs showing significant increase (greater than
three fold) between nitrogen replete and nitrogen-depleted
conditions were flagged as potential genes whose expression was
up-regulated by nitrogen depletion. As discussed in the
specification, nitrogen depletion/limitation is a known inducer of
lipogenesis in oleaginous microorganisms.
[0648] In order to identify putative promoters/5'UTR sequences from
the cDNAs whose expression was upregulated during nitrogen
depletion/limitation, total DNA was isolated from Prototheca
moriformis (UTEX 1435) grown under nitrogen replete conditions and
were then subjected to sequencing using 454 sequencing technology
(Roche). cDNAs flagged as being up-regulated by the RT-PCR results
above were compared using BLAST against assembled contigs arising
from the 454 genomic sequencing reads. The 5' ends of cDNAs were
mapped to specific contigs, and where possible, greater than 500 bp
of 5' flanking DNA was used to putatively identify promoters/UTRs.
The presence of promoters/5'UTR were subsequently confirmed and
cloned using PCR amplification of genomic DNA. Individual cDNA 5'
ends were used to design 3' primers and 5' end of the 454 contig
assemblies were used to design 5' gene-specific primers.
[0649] As a first screen, one of the putative promoters, the
5'UTR/promoter isolated from Aat2 (Ammonium transporter, SEQ ID NO:
63), was cloned into the Cinnamomum camphora C14 thioesterase
construct with the Chlorella protothecoides stearoyl ACP desaturase
transit peptide, replacing the C. sorokinana glutamate
dehydrogenase promoter. This construct is listed as SEQ ID NO: 81.
To test the putative promoter, the thioesterase construct is
transformed into Prototheca moriformis cells to confirm actual
promoter activity by screening for an increase in C14/C12 fatty
acids under low/no nitrogen conditions, using the methods described
above. Similar testing of the putative nitrogen-regulated promoters
isolated from the cDNA/genomic screen can be done using the same
methods.
[0650] Other putative nitrogen-regulated promoters/5'UTRs that were
isolated from the cDNA/genomic screen were:
TABLE-US-00026 Fold Promoter/5'UTR SEQ ID NO. increased FatB/A
promoter/5'UTR SEQ ID NO: 55 n/a NRAMP metal transporter SEQ ID NO:
56 9.65 promoter/5'UTR Flap Flagellar-associated protein SEQ ID NO:
57 4.92 promoter/5'UTR SulfRed Sulfite reductase promoter/5'UTR SEQ
ID NO: 58 10.91 SugT Sugar transporter promoter/5'UTR SEQ ID NO: 59
17.35 Amt03-Ammonium transporter 03 SEQ ID NO: 60 10.1
promoter/5'UTR Amt02-Ammonium transporter 02 SEQ ID NO: 61 10.76
promoter/5'UTR Aat01-Amino acid transporter 01 SEQ ID NO: 62 6.21
promoter/5'UTR Aat02-Amino acid transporter 02 SEQ ID NO: 63 6.5
promoter/5'UTR Aat03-Amino acid transporter 03 SEQ ID NO: 64 7.87
promoter/5'UTR Aat04-Amino acid transporter 04 SEQ ID NO: 65 10.95
promoter/5'UTR Aat05-Amino acid transporter 05 SEQ ID NO: 66 6.71
promoter/5'UTR
[0651] Fold increase refers to the fold increase in cDNA abundance
after 24 hours of culture in low nitrogen medium.
[0652] To gain further insight into potential regulation of these
putative promoter/5'UTRs, eight of the sequences were selected for
further testing: (1) FatB/A; (2) SulfRed Sulfite reductase; (3)
SugT Sugar transporter; (4) Amt02-Ammonium transporter O.sub.2; (5)
Aat01-Amino acid transporter 01; (6) Aat03-Amino acid transporter
03; (7) Aat04-Amino acid transporter 04; and (8) Aat05-Amino acid
transporter 05. Higher resolution transcriptome analysis utilizing
Illumina sequencing reads were carried out on RNA isolated from
Prototheca moriformis cells various time points: T0 (seed); 20
hours; 32 hours; 48 hours; 62 hours; and 114 hours post inoculation
from seed. The medium at TO (seed) was nitrogen replete, while at
the time points 20 hours and longer, the medium contained little to
no nitrogen. Assembled transcript contigs generated from RNA
isolated from each of the time points were then blasted
independently with each of the eight previously identified
transcripts. The results are summarized in Table 18 below.
TABLE-US-00027 TABLE 18 Transcriptome expression profiles for eight
putative promoters/5'UTRs. cDNA TS T20 T32 T48 T62 T114 aa trans_01
absolute 98 96 321 745 927 1300 relative 1 0.98 3.28 7.61 9.47
13.28 aa trans_03 absolute 7 21 51 137 102 109 relative 1 2.95 7.2
19.42 14.47 15.45 aa trans_04 absolute 1 6 25 90 131 160 relative 1
5.16 21.29 74.97 109.35 133.31 aa trans_05 absolute 109 88 123 210
214 273 relative 1 0.81 1.13 1.93 1.97 2.51 ammon trans_02 absolute
683 173 402 991 1413 1397 relative 1 0.25 0.59 1.45 2.07 2.04
fatA/B-1_cDNA absolute 13 36 654 617 544 749 relative 1 2.8 51.57
48.65 42.9 59.1 sug trans_01 absolute 25 25 106 261 266 251
relative 1 1 4.22 10.4 10.63 10 sulfite reductase_01 absolute 634
238 138 145 163 155 relative 1 0.38 0.22 0.22 0.26 0.24
[0653] From the above-summarized results, several of the
transcripts show increased accumulation over time, although
interestingly, the sulfite reductase mRNA shows a distinct decrease
in mRNA accumulation over time.
[0654] These eight putative promoter/5'UTR regions were cloned
upstream of the C. camphora thioesterase coding region with its
native transit peptide taken out and substituted with the transit
peptide from Chlorella protothecoides (UTEX 250) stearoyl ACP
desaturase. Each putative promoter/5'UTR region construct was
introduced into Prototheca moriformis UTEX 1435 via homologous
recombination using DNA from the genomic sequence of 6S rRNA. Also
contained within the construct is a suc2 sucrose invertase gene
from S. cerevisiae for selection of positive clones on sucrose
containing media/plates. The cDNA sequence for the relevant
portions of the construct for Aat01 is listed in the Sequence
Listing as SEQ ID NO: 67. For the other constructs, the same
backbone was use, the only variable was the putative promoter/5'UTR
sequence. An additional control transgenic strain was generated in
which the C. reinhardtii beta tubulin promoter was used to drive
expression of the C. camphora thioesterase gene. This promoter have
shown to drive constitutive expression of the gene of interest, and
thus provides a useful control against which to measure expression
of the same thioesterase message when driven by the various
putative N-regulated promoters/5'UTRs tested.
[0655] Once the transgenic clones were generated, three separate
experiments were carried out. The first two experiments assess the
potential nitrogen regulatability of all eight putative promoters
by measuring steady state thioesterase mRNA levels via RT-PCR,
fatty acid profiles and ammonia levels in the culture supernatants.
Clones were initially grown at 28.degree. C. with agitation (200
rpm) in nitrogen rich seed medium (1 g/L ammonium nitrate-15 mM
nitrogen as ammonia, 4 g/L yeast extract) for 24 to 48 hours, at
which point 200D units (A.sub.750) were used to inoculate 50 ml of
low nitrogen media (0.2 g/L ammonium sulfate-3 mM nitrogen as
ammonia, 0.2 g/L yeast extract). Cells were sampled every 24 hours
for 6 days and a sample was also collected right before switching
to low nitrogen conditions. A portion of the cells from each sample
was then used for total RNA extraction using Trizol reagent
(according to manufacturer's suggested methods) Ammonia assays
revealed that ammonia levels in the supernatants fell below the
limits of detection (.about.100 .mu.M) after 24 hours in low
nitrogen medium.
[0656] For real-time RT-PCR, all RNA levels were normalized to
levels of an internal control RNA expressed in Prototheca
moriformis (UTEX 1435) for each time point. The internal control
RNA, termed cd189, is a product of the ARG9 gene which encodes
N-acetyl ornithine aminotransferase. Primers sets used for
real-time RT-PCR in these experiments were:
TABLE-US-00028 Gene specific to Primer sequence 5'-3' SEQ ID NO: C.
camphora TACCCCGCCTGGGGCGACAC SEQ ID NO: 68 TE forward C. camphora
CTTGCTCAGGCGGCGGGTGC SEQ ID NO: 69 TE reverse cd189 forward
CCGGATCTCGGCCAGGGCTA SEQ ID NO: 70 cd189 reverse
TCGATGTCGTGCACCGTCGC SEQ ID NO: 71
[0657] Lipid profiles from each of the transformants from each time
point were also generated and compared to the RT-PCR results. Based
on the ammonia levels, RT-PCR results and changes in C12-C14 fatty
acid levels, it was concluded that the Amino acid transporter 01
(Aat-01), Amino acid transporter 04 (Aat-04), and Ammonium
transporter 02 (Amt-02) sequences do contain a functional
nitrogen-regulatable promoter/5'UTR.
[0658] From the RT-PCR results, Aat-01 demonstrated the ability to
drive steady state C. camphora thioesterase mRNA levels up to four
times higher than control (C. reinhardtii beta tubulin promoter).
The mRNA levels also correlated with nitrogen limitation and a
marked increase in C12-C14 fatty acid levels. These results
demonstrate that the 5'UTR associated with the Aat-01 promoter is
likely more efficient at driving protein synthesis under lipid
biosynthesis than the control C. reinhardtii promoter. Like the
Aat-01 promoter, the Aat-04 promoter was able to drive mRNA
accumulation up to five times higher than that of the C.
reinhardtii control promoter. However, the Aat-04 promoter
construct only produced a modest ability to impact C12-C14 fatty
acid levels. These data demonstrate that the Aat-04 promoter is
clearly regulatable by nitrogen depletion, but the UTR associated
with the promoter likely functions poorly as a translational
enhancer. Finally, the Amt-02 promoter was similar to the Aat-01
promoter, in that it was able to drive mRNA accumulation up to
three times higher than that of the control promoter. The mRNA
levels also correlated with nitrogen limitation and a marked
increase in C12-C14 fatty acid levels. Taken together, all three of
these promoters were demonstrated to be nitrogen-regulated.
[0659] B. Further Characterization of the Ammonium Transporter 3
(Amt03) Promoter and Expression of Various Thioesterases.
[0660] As described above, partial cDNAs termed ammonium
transporter 02 and 03 (amt02 and amt03) were identified. Along with
these two partial cDNAs, a third partial cDNA termed ammonium
transporter 01 (amt01) was also identified. Alignment of the
partial cDNA and the putative translated amino acid sequences were
compared. Results show amt01 to be more distantly related of the
three sequences, while amt02 and amt03 differ by only a single
amino acid.
[0661] Promoters/5'UTRs were generated initially in silico by
blasting the partial cDNA sequences against Roche 454 genomic DNA
assemblies and Illumina transcriptome assemblies as described
above. Transcript contigs showing identity to the cDNA encoding
amt01, amt02, and amt03 were identified, however, the transcript
contigs could not differentiate between the three mRNAs as the
contigs contained sequences shared by all three. Roche 454 genomic
DNA assemblies gave hits to amt02 and amt03 cDNA sequences and
contained N-terminal protein sequences. PCR was carried out to
clone the 5' flanking regions. The PCR primers used to validate the
clone amt02 and amt03 promoter/UTR were:
TABLE-US-00029 Amt03 forward: (SEQ ID NO: 85)
5'-GGAGGAATTCGGCCGACAGGACGCGCGTCA-3' Amt03 reverse: (SEQ ID NO: 86)
5'-GGAGACTAGTGGCTGCGACCGGCCTGTG-3' Amt02 forward: (SEQ ID NO: 87)
5'-GGAGGAATTCTCACCAGCGGACAAAGCACCG-3' Amt02 reverse: (SEQ ID NO:
88) 5'-GGAGACTAGTGGCTGCGACCGGCCTCTGG-3'
In both cases, the 5' and 3' primers contained useful restriction
sites for the anticipated cloning into expression vectors to
validate the functionality of these promoter/5'UTR regions.
[0662] Pair wise alignments between the DNAs cloned through this
combined in silico and PCR-based method and the original cDNA
encoding amt02 (SEQ ID NO: 61) and amt03 (SEQ ID NO: 60) were
performed. Results of these alignments showed significant
differences between the original cDNAs and the cloned genomic
sequences, indicating that ammonium transporters likely represent a
diverse gene family. Additionally, the promoter/5'UTR clone based
on the combined method for amt03 was different than the original
amt03 sequence, whereas the amt02 sequences were identical. Further
experiments to characterize the amt03 promoter/UTR sequence (SEQ ID
NO: 89) was carried out and described below.
[0663] The above identified amt03 promoter/UTR sequence (SEQ ID NO:
89) was tested by cloning this putative promoter/UTR sequence to
drive the expression of four different thioesterases. The
expression cassette contained upstream and downstream homologous
recombination sequences to the 6S locus of the genome (SEQ ID NOs:
82 and 84, respectively). The cassette also contains a S.
cerevisiae SUC2 sucrose invertase cDNA to enable the selection for
positive clones on sucrose containing medium. The sucrose invertase
expression was driven by the C. reinhardtii beta tubulin promoter
and also contained a C. vulgaris nitrate reductase 3'UTR. The amt03
promoter/UTR sequence was then cloned downstream of the sucrose
invertase cassette followed by in-frame thioesterase cDNA sequence
from one of four thioesterase genes: (1) C14 thioesterase from C.
camphora; (2) C12 thioesterase from U. californica; (3) C10-C16
thioesterase from U. americana; or (4) C10 thioesterase from C.
hookeriana and also contained a C. vulgaris nitrate reductase
3'UTR. The C14 C. camphora thioesterase, C12 U. californica
thioesterase, and the C10-C16 U. americana all contained the
transit peptide from a Chlorella protothecoides stearoyl ACP
desaturase. The C10 C. hookeriana thioesterase contained the
transit peptide from a Prototheca moriformis delta 12 fatty acid
desaturase (FAD). In all cases, the sequences were codon optimized
for expression in Prototheca moriformis. The sequences to the
foregoing thioesterase constructs are described in the Sequence
Listing:
TABLE-US-00030 amt03 promoter/UTR::C. camphora thioesterase SEQ ID
NO: 90 construct C. camphora thioesterase construct SEQ ID NO: 91
U. californica thioesterase construct SEQ ID NO: 92 U. americana
thioesterase construct SEQ ID NO: 93 C. hookeriana thioesterase
construct SEQ ID NO: 94
[0664] Transgenic lines were generated via biolistic transformation
methods as described above in Example 2 into wild type Prototheca
moriformis cells and selection was carried out on sucrose
containing plates/medium. Positive lines were then screened for the
degree to which their fatty acid profiles were altered. Four lines,
one resulting from the transformation with each of the four
above-described constructs, were then subjected to additional
analysis. Line 76 expressed the C. camphora C14 thioesterase, line
37 expressed the U. californica C12 thioesterase, line 60 expressed
the U. americana C10-C16 thioesterase, and line 56 expressed the C.
hookeriana C10 thioesterase. Each line was grown for 48 hours in
medium containing sucrose as the sole carbon source and samples of
cells were removed at 14, 24, 36 and 48 hours (seed culture) for
determination of fatty acid profile via direct transesterification
to fatty acid methyl esters and subsequent analysis by GC-FID
(described above) and for isolation of total RNA. At the end of 48
hours, these cells were used to inoculate cultures with no or low
levels of nitrogen (containing sucrose as the sole carbon source)
maintained at either pH 5.0 (citrate buffered, 0.05M final
concentration) or pH 7.0 (HEPES buffered, 0.1M final
concentration). Culture samples were removed at 12, 24, 72 and 108
hours (lipid production) for fatty acid profiling and isolation of
total RNA Ammonia assays of these cultures revealed that ammonia
levels fell below the limits of detection (ca. 100 .mu.M) after 24
hours in low nitrogen medium.
[0665] Real-time RT-PCR assays on the mRNA levels of the
thioesterases were performed on total RNA from each of the time
points collected above and all mRNA levels were normalized to the
levels of an internal control RNA (cd189). Primer sets used in
real-time PCR are shown in Table 19 below:
TABLE-US-00031 TABLE 19 Primer sets for real-time PCR. Gene
specific to Primer sequence 5'-3' SEQ ID NO: C. camphora TE forward
TACCCCGCCTGGGGCGACAC SEQ ID NO: 68 C. camphora TE reverse
CTTGCTCAGGCGGCGGGTGC SEQ ID NO: 69 U. californica TE forward
CTGGGCGACGGCTTCGGCAC SEQ ID NO: 95 U. californica TE reverse
AAGTCGCGGCGCATGCCGTT SEQ ID NO: 96 U. americana TE forward
CCCAGCTGCTCACCTGCACC SEQ ID NO: 97 U. americana TE reverse
CACCCAAGGCCAACGGCAGC SEQ ID NO: 98 GCCGTG C. hookeriana TE forward
TACCCCGCCTGGGGCGACAC SEQ ID NO: 99 C. hookeriana TE reverse
AGCTTGGACAGGCGGCGGGT SEQ ID NO: 100 cd189 reverse
TCGATGTCGTGCACCGTCGC SEQ ID NO: 71 cd189 forward
CCGGATCTCGGCCAGGGCTA SEQ ID NO: 70
[0666] The results from the fatty acid profiles at each of the time
points in the seed culture phase showed very little impact from the
thioesterases. With the commencement of the lipid production phase,
the fatty acid profiles were significantly impacted, with the
increases that are far more dramatic for the cultures maintained at
pH 7.0 as compared to the cultures at pH 5.0. While the magnitude
of the difference between pH 7.0 and 5.0 target fatty acid
accumulation varied with each thioesterase tested, the overall
effect was the same: that the cells grown at pH 5.0 showed
significantly lower levels of the target fatty acids accumulated,
but more than compared to control wild type cells.
[0667] Analysis of the RNA isolated from these same samples
correlated very will with the fatty acid profile data, in that
there was a clear impact of culture pH on the steady state mRNA
levels for each of the thioesterases. Taking the fatty acid
accumulation data and the mRNA data together, the pH regulation of
thioesterase gene expression driven by the amt03 promoter/UTR was
clearly mediated either at the level of transcription, mRNA
stability or both. Additionally, it was observed that the steady
state levels of U. californica mRNA were four logs lower as
compared to the steady state levels of C. hookeriana mRNA. This
observation is consistent with the hypothesis that the individual
mRNA sequences may play a role in controlling expression. These
data imply that ammonium uptake in Prototheca moriformis by the
amt03 family of transporters is coupled directly to pH.
[0668] Additional fatty acid profile analysis was performed on
twelve lines generated from the transformation of Prototheca
moriformis cells with the construct amt03 promoter/UTR driving the
expression of the U. americana C10-C16 thioesterase. Line 60,
described above, was a part of the following analysis. Table 20
below shows the lipid profiles of three of the twelve lines that
were analyzed along with the wild type control.
TABLE-US-00032 TABLE 20 Fatty acid profiles of transformants
containing the U. americana TE driven by the amt03 promoter/UTR.
Total Area % C8:0 C10:0 C12:0 C14:0 C16:0 C18:0 C18:1 C18:2
Saturates wild type 0.00 0.01 0.04 1.27 27.20 3.85 58.70 7.18 32.36
Line 40 2.38 20.61 3.41 28.41 29.92 1.91 8.57 3.74 86.64 Line 44
1.50 20.16 4.44 31.88 26.66 1.88 6.95 5.42 86.50 Line 60 0.98 14.56
3.15 27.49 31.76 2.14 12.23 6.36 80.06
[0669] As shown in the table above, the levels of total saturates
was increased dramatically over that of wild type with over 2.6
fold in the case of line 40 compared to wildtype (total saturates
from the twelve lines analyzed ranged from about 63% to over 86%).
Additionally, the U. americana thioesterase, when expressed at
these levels, dramatically reduces the level of unsaturates,
especially C18:1 and C18:2 (see lines 40 and 44), where in line 44,
C18:1 levels are reduced by over 8 fold compared to the wild type.
Also, the U. americana thioesterase (driven by the amt03 promoter)
greatly increases the levels of mid-chain fatty acids. Line 44
shows C10:0-C14:0 levels at greater than 56%, approximately 42 fold
higher than the levels seen in the wildtype strain and C8:0-C14:0
levels at greater than 57%. Additional strains transformed with a
construct of the Amt03 promoter driving the expression of the U.
americana thioesterase had representative lipid profile of: 0.23%
C8:0; 9.64% C10:0; 2.62% C12:0; 31.52% C14:0; 37.63% C16:0; 5.34%
C18:0; 7.05% C18:1; and 5.03% C18:2, with a total saturates
percentage at 86.98%.
[0670] Additional lipid profiles generated from the transformation
of Prototheca moriformis cells with the construct amt03
promoter/UTR (SEQ ID NO: 89) driving the expression of the C.
hookeriana C10 thioesterase (SEQ ID NO: 94). Positive clones
expressing this construct were selected and grown at pH 7.0
conditions. Representative lipid profile from a positive clone was:
9.87% C8:0; 23.97% C10:0; 0.46% C12:0; 1.24% C14:0; 10.24% C16:0;
2.45% C18:0; 42.81% C18:1; and 7.32% C18:2. This clone had a
C.sub.8-C.sub.10 percentage of 33.84
[0671] Taken together, the data suggest that the amt03
promoter/UTR, and other promoters like it, can be used as a tightly
regulated promoter, which may be particularly useful for expressing
a potentially toxic compound and strict enforcement of gene
expression is required. The ability of Prototheca moriformis to
grow under a wide range (at least pH 5.0 to 7.0) of pH regimes
makes this organism particularly useful in combination with
regulatory elements such as the amt03 promoter/UTR. Additionally,
the lipid profile data above demonstrates the impressive ability of
the amt03 promoter/UTR to drive gene expression.
Example 11
Altering the Levels of Saturated Fatty Acids in the Microalgae
Prototheca moriformis
[0672] As part of a genomics screen using a bioinformatics based
approach based on cDNAs, Illumia transcriptome and Roche 454
squencing of genomic DNA from Prototheca moriformis (UTEX 1435),
two specific groups of genes involved in fatty acid desaturation
were identified: stearoyl ACP desaturases (SAD) and delta 12 fatty
acid desaturases (412 FAD). Stearoyl ACP desaturase enzymes are
part of the lipid synthesis pathway and they function to introduce
double bonds into the fatty acyl chains, for example, the synthesis
of C18:1 fatty acids from C18:0 fatty acids. Delta 12 fatty acid
desaturases are also part of the lipid synthesis pathway and they
function to introduce double bonds into already unsaturated fatty
acids, for example, the synthesis of C18:2 fatty acids from C18:1
fatty acids. Southern blot analysis using probes based on the two
classes of fatty acid desaturase genes identified during the
bioinformatics efforts indicated that each class of desaturase
genes was likely comprised of multiple family members. Additionally
the genes encoding stearoyl ACP desaturases fell into two distinct
families. Based on these results, three gene disruption constructs
were designed to potentially disrupt multiple gene family members
by targeting more highly conserved coding regions within each
family of desaturase enzymes.
[0673] Three homologous recombination targeting constructs were
designed using: (1) highly conserved portions of the coding
sequence of delta 12 fatty acid desaturase (d12FAD) family members
and (2) two constructs targeting each of the two distinct families
of SAD, each with conserved regions of the coding sequences from
each family. This strategy would embed a selectable marker gene
(the suc2 sucrose invertase cassette from S. cerevisiae conferring
the ability to hydrolyze sucrose) into these highly conserved
coding regions (targeting multiple family members) rather than a
classic gene replacement strategy where the homologous
recombination would target flanking regions of the targeted
gene.
[0674] All constructs were introduced into the cells by biolistic
transformation using the methods described above and constructs
were linearized before being shot into the cells. Transformants
were selected on sucrose containing plates/media and changes in
lipid profile were assayed using the above-described method.
Relevant sequences from each of the three targeting constructs are
listed below.
TABLE-US-00033 Description SEQ ID NO: 5' sequence from coding
region of d12FAD from SEQ ID NO: 72 targeting construct 3' sequence
from coding region of d12FAD from SEQ ID NO: 73 targeting construct
d12FAD targeting construct cDNA sequence SEQ ID NO: 74 5' sequence
from coding region of SAD2A SEQ ID NO: 75 3' sequence from coding
region of SAD2A SEQ ID NO: 76 SAD2A targeting construct cDNA
sequence SEQ ID NO: 77 5' sequence from coding region os SAD2B SEQ
ID NO: 78 3' sequence from coding region of SAD2B SEQ ID NO: 79
SAD2B targeting construct cDNA sequence SEQ ID NO: 80
[0675] Representative positive clones from transformations with
each of the constructs were picked and the lipid profiles for these
clones were determined (expressed in Area %) and summarized in
Table 21 below.
TABLE-US-00034 TABLE 21 Lipid profiles for desaturase knockouts.
Fatty Acid d12FAD KO SAD2A KO SAD2B KO wt UTEX 1435 C8:0 0 0 0 0
C10:0 0.01 0.01 0.01 0.01 C12:0 0.03 0.03 0.03 0.03 C14:0 1.08
0.985 0.795 1.46 C16:0 24.42 25.335 23.66 29.87 C18:0 6.85 12.89
19.555 3.345 C18:1 58.35 47.865 43.115 54.09 C18:2 7.33 10.27 9.83
9.1 C18:3 alpha 0.83 0.86 1 0.89 C20:0 0.48 0.86 1.175 0.325
[0676] Each of the construct had a measurable impact on the desired
class of fatty acid and in all three cases C18:0 levels increased
markedly, particularly with the two SAD knockouts. Further
comparison of multiple clones from the SAD knockouts indicated that
the SAD2B knockout lines had significantly greater reductions in
C18:1 fatty acids than the C18:1 fatty acid levels observed with
the SAD2A knockout lines.
[0677] Additional .DELTA.12 fatty acid desaturase (FAD) knockouts
were generated in a Prototheca moriformis background using the
methods described above. In order to identify potential homologous
of .DELTA.12FADs, the following primers were used in order to
amplify a genomic region encoding a putative FAD:
TABLE-US-00035 Primer 1 SEQ ID NO: 101 5'-TCACTTCATGCCGGCGGTCC-3'
Primer 2 SEQ ID NO: 102 5'-GCGCTCCTGCTTGGCTCGAA-3'
The sequences resulting from the genomic amplification of
Prototheca moriformis genomic DNA using the above primers were
highly similar, but indicated that multiple genes or alleles of
.DELTA.12FADs exist in Prototheca.
[0678] Based on this result, two gene disruption constructs were
designed that sought to inactivate one or more .DELTA.12FAD genes.
The strategy would to embed a sucrose invertase (suc2 from S.
cerevisiae) cassette, thus conferring the ability to hydrolyze
sucrose as a selectable marker, into highly conserved coding
regions rather than use a classic gene replacement strategy. The
first construct, termed pSZ1124, contained 5' and 3' genomic
targeting sequences flanking a C. reinhardtii .beta.-tubulin
promoter driving the expression of the S. cerevisiae suc2 gene and
a Chlorella vulgaris nitrate reductase 3'UTR (S. cerevisiae suc2
cassette). The second construct, termed pSZ1125, contained 5' and
3' genomic targeting sequences flanking a C. reinhardtii
.beta.-tubulin promoter driving the expression of the S. cerevisiae
suc2 gene and a Chlorella vulgaris nitrate reductase 3'UTR. The
relevant sequences of the constructs are listed in the Sequence
Listing:
TABLE-US-00036 pSZ1124 (FAD2B) 5' genomic targeting sequence SEQ ID
NO: 103 pSZ1124 (FAD2B) 3' genomic targeting sequence SEQ ID NO:
104 S. cerevisiae suc2 cassette SEQ ID NO: 105 pSZ1125 (FAD2C) 5'
genomic targeting sequence SEQ ID NO: 106 pSZ1125 (FAD2C) 3'
genomic targeting sequence SEQ ID NO: 107
[0679] pSZ1124 and pSZ1125 were each introduced into a Prototheca
moriformis background and positive clones were selected based on
the ability to hydrolyze sucrose. Table 22 summarizes the lipid
profiles (in Area %, generated using methods described above)
obtained in two transgenic lines in which pSZ1124 and pSZ1125
targeting vectors were utilized.
TABLE-US-00037 TABLE 22 Lipid profiles of .DELTA.12 FAD knockouts
C10:0 C12:0 C14:0 C16:0 C16:1 C18:0 C18:1 C18:2 C18:3 .alpha.
parent 0.01 0.03 1.15 26.13 1.32 4.39 57.20 8.13 0.61 FAD2B 0.02
0.03 0.80 12.84 1.92 0.86 74.74 7.08 0.33 FAD2C 0.02 0.04 1.42
25.85 1.65 2.44 66.11 1.39 0.22
[0680] The transgenic containing the FAD2B (pSZ1124) construct gave
a very interesting and unexpected result in lipid profile, in that
the C18:2 levels, which would be expected to decrease, only
decreased by about one area %. However, the C18:1 fatty acid levels
increased significantly, almost exclusively at the expense of the
C16:0 levels, which decreased significantly. The transgenic
containing the FAD2C (pSZ1125) construct also gave a change in
lipid profile: the levels of C18:2 are reduced significantly along
with a corresponding increase in C18:1 levels.
Beef Tallow Mimetic
[0681] One positive clone generated from the above SAD2B knockout
experiment as described above was selected to be used as the
background for the further introduction of a C14-preferring fatty
acyl-ACP thioesterase gene. The construct introducing the C.
camphora C14-preferring thioesterase contained targeting sequence
to the 6S rRNA genomic region (allowing for targeted integration of
the transforming DNA via homologous recombination) and the
expression construct contained the C. reinhardtii .beta.-tubulin
promoter driving the expression of the neoR gene with the Chlorella
vulgaris nitrate reductase 3'UTR, followed by a second C.
reinhardtii .beta.-tubulin promter driving the expression of a
codon-optimized C. camphora thioesterase with a Chlorella
protothecoides stearoyl ACP desaturase transit peptide with a
second Chlorella vulgaris nitrate reductase 3'UTR. The 5' 6S rRNA
genomic donor sequence is listed in SEQ ID NO: 82; the 3' 6S rRNA
genomic donor sequence is listed in SEQ ID NO: 84; and the relevant
expression construct for the C. camphora thioesterase is listed in
SEQ ID NO: 83.
[0682] Transformation was carried out using biolistic methods as
described above and the cells were allowed to recover for 24 hours
on plates containing 2% sucrose. After this time, the cells were
re-suspended and re-plated on plates containing 2% sucrose and 50
.mu.g/ml G418 for selection. Nine clones out of the positive clones
generated were selected for lipid production and lipid profile. The
nine transgenic clones (with the SAD2B KO and expressing C.
camphora C14-preferring thioesterase) were cultured as described
above and analyzed for lipid profile. The results are summarized
below in Table 23. The lipid profile for tallow is also included in
Table 23 below (National Research Council 1976: Fat Content and
Composition of Animal Product).
TABLE-US-00038 TABLE 23 Lipid profile of thioesterase transformed
clones. C10:0 C12:0 C14:0 C16:0 C16:1 C18:0 C18:1 C18:2 C18:3 C20
SAD2BKO 0.01 0.33 6.13 24.24 0.19 11.08 42.03 13.45 0.98 0.73 C.
camphora TE clone 1 SAD2BKO 0.01 0.16 3.42 23.80 0.40 9.40 50.62
10.2 0.62 0.70 C. camphora TE clone 2 SAD2BKO 0.01 0.20 4.21 25.69
0.40 7.79 50.51 9.37 0.66 0.63 C. camphora TE clone 3 SAD2BKO 0.01
0.21 4.29 23.57 0.31 9.44 50.07 10.07 0.70 0.70 C. camphora TE
clone 4 SAD2BKO 0.01 0.18 3.87 24.42 0.32 9.24 49.75 10.17 0.71
0.71 C. camphora TE clone 5 SAD2BKO 0.01 0.28 5.34 23.78 0.33 9.12
49.12 10.00 0.68 0.70 C. camphora TE clone 6 SAD2BKO 0.01 0.15 3.09
23.07 0.32 10.08 51.21 10.00 0.66 0.74 C. camphora TE clone 7
SAD2BKO 0.01 0.29 5.33 24.62 0.37 7.02 49.67 10.74 0.69 0.70 C.
camphora TE clone 8 SAD2BKO 0.01 0.12 2.74 25.13 0.30 10.17 50.18
9.42 0.71 0.71 C. camphora TE clone 9 wt UTEX 0.01 0.02 0.96 23.06
0.79 3.14 61.82 9.06 0.46 0.27 1435 SAD2BKO 0.01 0.03 0.80 23.66
0.13 19.56 43.12 9.83 1.00 1.18 Tallow 0.00 0.00 4.00 26.00 3.00
14.00 41.00 3.00 1.00 0.00
[0683] As can be seen in Table 23, the lipid profiles of the
transgenic lines are quite similar to the lipid profile of tallow.
Taken collectively, the data demonstrate the utility of combining
specific transgenic backgrounds, in this case, a SAD2B knockout
with a C14-preferring thioesterase (from C. camphora), to generate
an transgenic algal strain that produce oil similar to the lipid
profile of tallow.
Construct Used to Down Regulate the Expression of .beta.-Ketoacyl
Synthase II (Kasii) by Targeted Knock-Out Approach
[0684] Vector down-regulating KASII gene expression by targeted
knock-out approach was introduced into a classically mutagenized
derivative of UTEX 1435, S1331. The Saccharomyces cerevisiae
invertase gene was utilized as a selectable marker, conferring the
ability to grow on sucrose. The invertase expression cassette under
control of C. reinhardtii B-tubulin promoter was inserted in the
middle of the 315 bp long KASII genomic region to permit targeted
integration (pSZ1503).
[0685] Relevant restriction sites in pSZ1503 are indicated in
lowercase, bold and underlining and are 5'-3' BspQ 1, Kpn I, AscI,
Xho I, Sac I, BspQ I, respectively. BspQI sites delimit the 5' and
3' ends of the transforming DNA. Bold, lowercase sequences
represent genomic DNA from S1331 that permit targeted integration
at KASII locus via homologous recombination. Proceeding in the 5'
to 3' direction, the C. reinhardtii B-tubulin promoter driving the
expression of the yeast sucrose invertase gene (conferring the
ability of S1331 to metabolize sucrose) is indicated by boxed text.
The initiator ATG and terminator TGA for invertase are indicated by
uppercase, bold italics while the coding region is indicated in
lowercase italics. The Chlorella vulgaris nitrate reductase 3' UTR
is indicated by lowercase underlined text.
[0686] Nucleotide sequence of transforming DNA contained in
pSZ1503_[KASII_btub-y.inv-nr_KASII]:
TABLE-US-00039 ##STR00002## ##STR00003##
ccggcttcgccgccaagatcagcgcctccatgacgaacgagacgtccgaccgccccctggtgcacttcaccccc-
aacaagggct
ggatgaacgaccccaacggcctgtggtacgacgagaaggacgccaagtggcacctgtacttccagtacaacccg-
aacgacac
cgtctgggggacgcccttgttctggggccacgccacgtccgacgacctgaccaactgggaggaccagcccatcg-
ccatcgcccc
gaagcgcaacgactccggcgccttctccggctccatggtggtggactacaacaacacctccggcttcttcaacg-
acaccatcgac
ccgcgccagcgctgcgtggccatctggacctacaacaccccggagtccgaggagcagtacatctcctacagcct-
ggacggcgg
ctacaccttcaccgagtaccagaagaaccccgtgctggccgccaactccacccagttccgcgacccgaaggtct-
tctggtacgag
ccctcccagaagtggatcatgaccgcggccaagtcccaggactacaagatcgagatctactcctccgacgacct-
gaagtcctgg
aagctggagtccgcgttcgccaacgagggcttcctcggctaccagtacgagtgccccggcctgatcgaggtccc-
caccgagcag
gaccccagcaagtcctactgggtgatgttcatctccatcaaccccggcgccccggccggcggctccttcaacca-
gtacttcgtcgg
cagcttcaacggcacccacttcgaggccttcgacaaccagtcccgcgtggtggacttcggcaaggactactacg-
ccctgcagacc
ttcttcaacaccgacccgacctacgggagcgccctgggcatcgcgtgggcctccaactgggagtactccgcctt-
cgtgcccacca
acccctggcgctcctccatgtccctcgtgcgcaagttctccctcaacaccgagtaccaggccaacccggagacg-
gagctgatcaa
cctgaaggccgagccgatcctgaacatcagcaacgccggcccctggagccggttcgccaccaacaccacgttga-
cgaaggcc
aacagctacaacgtcgacctgtccaacagcaccggcaccctggagttcgagctggtgtacgccgtcaacaccac-
ccagacgatc
tccaagtccgtgttcgcggacctctccctctggttcaagggcctggaggaccccgaggagtacctccgcatggg-
cttcgaggtgtc
cgcgtcctccttcttcctggaccgcgggaacagcaaggtgaagttcgtgaaggagaacccctacttcaccaacc-
gcatgagcgtg
aacaaccagcccttcaagagcgagaacgacctgtcctactacaaggtgtacggcttgctggaccagaacatcct-
ggagctgtact
tccaagtccgtgttcgcggacctctccctctggttcaagggcctggaggaccccgaggagtacctccgcatggg-
cttcgaggtgtc
gtggacaacctgttctacatcgacaagttccaggtgcgcgaggtcaagTGAcaattggcagcagcagctcggat-
agtatcgac
acactctggacgctggtcgtgtgatggactgttgccgccacacttgctgccttgacctgtgaatatccctgccg-
cttttatcaaacagcct
cagtgtgtttgatcttgtgtgtacgcgcttttgcgagttgctagctgcttgtgctatttgcgaataccaccccc-
agcatccccttccctcgttt
catatcgcttgcatcccaaccgcaacttatctacgctgtcctgctatccctcagcgctgctcctgctcctgctc-
actgcccctcgcacagc
cttggtttgggctccgcctgtattctcctggtactgcaacctgtaaaccagcactgcaatgctgatgcacggga-
agtagtgggatggga
acacaaatggaggatcgtagagctcatcttccgaaagtacgacgagtgagcgagctgattctctttgagcgggg-
tcgggtggttc
ggggagagtgcgcggaaaggcgcagagacgtgcggccggccgtgtccctccgtcttcccctggttggtgctata-
gtaacctgc ctgtgtcgcgtgcgcgtcgggaagagc (SEQ ID NO: 149)
[0687] The cDNAs of the KAS II allele 1 and allele 2 are identified
in SEQ ID NOs: 279 and 280, respectively. The amino acid sequences
of alleles 1 and 2 are identified in SEQ ID NOs: 281 and 282,
respectively.
[0688] To determine the impact of KASII inactivation on lipid
composition, pSZ1503 vector DNA was transformed into S1331 to
generate a targeted KASII knock-out phenotype. Initial single
clones were isolated and grown under standard lipid production
conditions at pH5.0. The resulting profiles of the best
representative clone and the wild-type cells are shown below in
Table 31
TABLE-US-00040 TABLE 31 Fatty acid profiles in S1331 and a
derivative transgenic line transformed with pSZ1503 DNA. Sample ID
C10:0 C12:0 C14:0 C16:0 C16:1 C18:0 C18:1 C18:2 C18:3 .alpha.
1331-5 0.01 0.03 0.96 24.28 0.64 3.94 62.69 6.21 0.49 D698-2 0.01
0.01 0.83 38.36 1.38 2.21 48.31 7.60 0.55
Example 12
Engineering Prototheca with Alternative Selectable Markers
[0689] A. Expression of a Secretable .alpha.-Galactosidase in
Prototheca moriformis
[0690] Methods and effects of expressing a heterologous sucrose
invertase gene in Prototheca species have been previously described
in PCT Application No. PCT/US2009/66142, hereby incorporated by
reference. The expression of other heterologous polysaccharide
degrading enzymes was examined in this Example. The ability to grow
on melibiose (.alpha.-D-gal-glu) by Prototheca moriformis UTEX 1435
with one of the following exogenous gene encoding a
.alpha.-galactosidase was tested: MEL1 gene from Saccharomyces
carlbergensis (amino acid sequence corresponding to NCBI accession
number P04824 (SEQ ID NO: 108)), AglC gene from Aspergillus niger
(amino acid sequence corresponding to NCBI accession number Q9UUZ4
(SEQ ID NO: 116)), and the .alpha.-galactosidase from the higher
plant Cyamopsis tetragobobola (Guar bean) (amino acid sequence
corresponding to NCBI accession number P14749 (SEQ ID NO: 120). The
above accession numbers and corresponding amino acid sequences are
hereby incorporated by reference. In all cases, genes were
optimized according to the preferred codon usage in Prototheca
moriformis. The relevant portions of the expression cassette are
listed below along with the Sequence Listing numbers. All
expression cassettes used the 5' and 3' Clp homologous
recombination targeting sequences for stable genomic integration,
the Chlamydomonas reinhardtii TUB2 promoter/5'UTR, and the
Chlorella vulgaris nitrate reductase 3'UTR.
TABLE-US-00041 S. carlbergensis MEL1 amino acid sequence SEQ ID NO:
108 S. carlbergensis MEL1amino acid sequence signal SEQ ID NO: 109
peptide S. carlbergensis MEL1transformation cassette SEQ ID NO: 110
S. carlbergensis MEL1 sequence (codon optimized) SEQ ID NO: 111 5'
Clp homologous recombination targeting sequence SEQ ID NO: 112 3'
Clp homologous recombination targeting sequence SEQ ID NO: 113
Chlamydomonas reinhardtii TUB2 promoter/5'UTR SEQ ID NO: 114
Chlorella vulgaris nitrate reductase 3'UTR SEQ ID NO: 115 A. niger
AlgC amino acid sequence SEQ ID NO: 116 A. niger AlgC amino acid
sequence signal peptide SEQ ID NO: 117 A. niger AlgC sequence
(codon optimized) SEQ ID NO: 118 A. niger AlgC transformation
cassette SEQ ID NO: 119 C. tetragonobola .alpha.-galactosidase
amino acid sequence SEQ ID NO: 120 C. tetragonobola
.alpha.-galactosidase sequence SEQ ID NO: 121 (codon optimized) C.
tetragonobola .alpha.-galactosidase transformation SEQ ID NO: 122
cassette
[0691] Prototheca moriformis cells were transformed with each of
the three expression cassettes containing S. carlbergensis MEL1, A.
niger AlgC, or C. tetragonobola .alpha.-galactosidase gene using
the biolistic transformation methods as described in Example 2
above. Positive clones were screened using plates containing 2%
melibiose as the sole carbon source. No colonies appeared on the
plates for the C. tetragonobola expression cassette transformants.
Positive clones were picked from the plates containing the S.
carlbergensis MEL1 transformants and the A. niger AlgC
transformants. Integration of the transforming DNA was confirmed
using PCR with primers targeting a portion of the C. vulgaris 3'UTR
and the 3' Clp homologous recombination targeting sequence.
TABLE-US-00042 5' primer C.vulgaris 3'UTR: downstream Clp sequence
(SEQ ID NO: 123) ACTGCAATGCTGATGCACGGGA 3' primer C.vulgaris 3'UTR:
downstream Clp sequence (SEQ ID NO: 124) TCCAGGTCCTTTTCGCACT
[0692] As a negative control, genomic DNA from untransformed
Prototheca moriformis cells were also amplified with the primer
set. No products were amplified from genomic DNA from the wild type
cells.
[0693] Several positive clones from each of the S. carlbergensis
MEL1 transformants and the A. niger AlgC transformants (as
confirmed by PCR) were tested for their ability to grow on
melibiose as the sole carbon source in liquid media. These selected
clones were grown for 3 days in conditions and base medium
described in Example 1 above with melibiose as the sole carbon
source. All clones containing either .alpha.-galactosidase-encoding
genes grew robustly during this time, while the untransformed wild
type strain and Prototheca moriformis expressing a Saccharomyces
cerevisiae SUC2 sucrose invertase both grew poorly on the melibiose
media. These results suggest that the .alpha.-galactosidase
encoding genes may be used as a selectable marker for
transformation. Also, these data indicate that the native signal
peptides present in the S. carlbergensis MEL1 (SEQ ID NO: 109) or
A. niger AlgC (SEQ ID NO: 117) are useful for targeting proteins to
the periplasm in Prototheca moriformis cells.
[0694] B. THIC Genes Complements Thiamine Auxotrophs in
Prototheca
[0695] Thiamine prototrophy in Prototheca moriformis cells was
examined using expression of exogenous THIC genes. Thiamine
biosynthesis in plants and algae is typically carried out in the
plastid, hence most nuclear encoded proteins involved in its
production will need to be efficiently targeted to the plastid. DNA
sequencing and transcriptome sequencing of Prototheca moriformis
cells revealed that all of the genes encoding the thiamine
biosynthetic enzymes were present in the genome, with the exception
of THIC. To dissect the lesion responsible for thiamine auxotrophy
at the biochemical level, the growth of Prototheca moriformis cells
under five different regimes were examined: (1) in the presence of
2 .mu.M thiamine hydrochloride; (2) without thiamine; (3) without
thiamine, but with 2 .mu.M hydroxyethyl thiazole (THZ); (4) without
thiamine, but with 2 .mu.M
2-methyl-4-amino-5-(aminomethyl)pyrimidine (PYR); and (5) without
thiamine, but with 2 .mu.M THZ and 2 .mu.M PYR. Results from the
growth experiments under these 5 different conditions indicated
that Prototheca moriformis cells are capable of de novo synthesis,
but can only produce thiamine pyrophosphate (TPP) if the PYR
precursor is provided. This result is consistent with the
hypothesis that the thiamine auxotrophy of Prototheca moriformis is
due to the inability to synthesize hydroxymethylpyrimidine
phosphate (HMP-P) from aminoimidazole ribonucleotide, which is the
conversion catalyze by THIC enzyme.
[0696] Prototheca moriformis cells were transformed using the
biolistic transformation methods described above in Example 2,
expressing the Coccomyxa C-169 THIC (amino acid sequence
corresponding to JGI Protein ID 30481, and hereby incorporated by
reference) and a S. cerevisiae SUC2 sucrose invertase as the
selective marker. This expression construct contained the native
transit peptide sequence from Coccomyxa C-169 THIC, upstream and
downstream homologous recombination targeting sequences to the 6S
region of genomic DNA, a C. reinhardtii TUB2 promoter/5'UTR region
(SEQ ID NO: 104), and a Chlorella vulgaris nitrate reductase 3'UTR
(SEQ ID NO: 115). The S. cerevisiae SUC2 expression was also driven
by a C. reinhardtii TUB2 promoter/5'UTR region (SEQ ID NO: 114) and
contained a Chlorella vulgaris nitrate reductase 3'UTR (SEQ ID NO:
115). Genes were optimized according to the preferred codon usage
in Prototheca moriformis. The relevant expression cassette
sequences are listed in the Sequence Listing and detailed
below:
TABLE-US-00043 Coccomyxa C-169 THIC amino acid sequence SEQ ID NO:
125 Coccomyxa C-169 THIC amino acid sequence SEQ ID NO: 126 native
transit peptide Coccomyxa C-169 THIC transformation cassette SEQ ID
NO: 127 Coccomyxa C-169 THIC sequence (codon optimized) SEQ ID NO:
128 S. cerevisiae SUC2 sequence (codon optimized) SEQ ID NO: 129 5'
6S homologous recombination targeting sequence SEQ ID NO: 82 3' 6S
homologous recombination targeting sequence SEQ ID NO: 84
Selection of positive clones were performed on plates without
thiamine and containing sucrose as the sole carbon source. Positive
clones were confirmed using PCR with a 5' primer that binds within
the Coccomyxa C-169 THIC gene and a 3' primer that anneals
downsteam of the transforming DNA in the 6S locus. PCR confirmed
positive clones were also confirmed using Southern blot assays.
[0697] To observe the thiamine auxotrophy of wildtype Prototheca
moriformis cells, it was necessary to first deplete cells of
internal thiamine reserves. To test growth in medium without
thiamine, cells were first grown to stationary phase in medium
containing 2 .mu.M thiamine and then the cells were diluted to an
optical density at 750 nm (OD750) of approximately 0.05 in medium
without thiamine. The diluted cells were then grown once more to
stationary phase in medium without thiamine (about 2-3 days). These
thiamine-depleted cells were used to inoculate cultures for growth
studies in medium without thiamine. Wildtype cells were grown in
medium with glucose as the carbon source (with or without thiamine)
and positive clones with the native transit peptide Coccomyxa C-169
THIC construct were grown in medium with sucrose as the sole carbon
source. Growth was measured by monitoring the absorbance at 750 nm.
Results of the growth experiments showed substantial greater growth
in thiamine-free medium of strains expressing the transgene
compared to wildtype cells in thiamine-free medium. However, the
transformants failed to achieve the growth rate and cell densities
of wildtype cells in thiamine-containing media. There was also a
strong correlation between the amount of growth in the transformant
clones in thiamine-free medium and the copy number of the
integrated Coccomyxa enzyme (i.e., the more copy numbers of the
transgene, the better the growth of the cells in thiamine-free
medium).
[0698] Additional transformants were generated using expression
constructs containing the Coccomyxa THIC, the Arabidopsis thaliana
THIC gene, and the Synechocystis sp. PCC 6803 thiC gene. In the
case of the Coccomyxa and the A. thaliana THIC gene, the native
transit peptide sequence was replaced with the transit peptide
sequence from a Chlorella protothecoides stearoyl-ACP desaturase
(SAD) gene. Synechocystis sp. is a cyanobacterium and the thiC
protein does not contain a native transit peptide sequence. In the
Synechocystis sp thiC construct, the transit peptide sequence from
a Chlorella protothecoides SAD gene was fused to the N-terminus of
the Synechocystis sp. thiC. In all cases, the sequences were codon
optimized for expression in Prototheca moriformis. All three of the
foregoing constructs contained a upstream and downstream homologous
recombination targeting sequence to the 6S region of the genome
(SEQ ID NOs: 82 and 84), a Chlorella protothecoides actin
promoter/5' UTR, and a Chlorella protothecoides EFTA gene 3'UTR.
All three constructs contained a neoR gene driven by the C.
reinhardtii TUB2 promoter/5'UTR (SEQ ID NO: 114) and contained the
C. vulgaris 3'UTR (SEQ ID NO: 115), conferring the selection by
G418. The amino acid sequence of the A. thaliana THIC corresponded
to NCBI accession number NP.sub.--180524 and the amino acid
sequence of the Synechocystis sp. thiC corresponded to NCBI
accession number NP.sub.--442586, both sequences hereby
incorporated by reference. The relevant expression cassette
sequences are listed in the Sequence Listing and detailed
below:
TABLE-US-00044 Coccomyxa THIC expression construct with SEQ ID NO:
130 C. protothecoides transit peptide Coccomyxa THIC with C.
protothecoides transit SEQ ID NO: 131 peptide C. protothecoides
actin promoter/5' UTR SEQ ID NO: 132 C. protothecoides EF1A 3'UTR
SEQ ID NO: 133 A. thaliana THIC expression construct SEQ ID NO: 134
A. thaliana THIC with C. protothecoides transit SEQ ID NO: 135
peptide A. thaliana THIC amino acid sequence with native SEQ ID NO:
136 transit peptide Synechocystis sp. thiC expression construct SEQ
ID NO: 137 Synechocystis sp. thiC with C. protothecoides transit
SEQ ID NO: 138 peptide Synechocystis sp. thiC amino acid sequence
SEQ ID NO: 139 neoR gene SEQ ID NO: 140
[0699] Positive clones were screened on plates containing G418 and
several clones from each transformation were picked for
verification by PCR. Integration of the transforming DNA constructs
containing the Coccomyxa C-169 (with C. protothecoides transit
peptide), A. thaliana and Synechocystis sp. PCC 6803 THIC genes,
respectively into the 6S locus of the genome was confirmed using
PCR analysis with the following primers:
TABLE-US-00045 5' THIC Coccomyxa confirmation primer sequence (SEQ
ID NO: 141) ACGTCGCGACCCATGCTTCC 3' THIC confirmation primer
sequence (SEQ ID NO: 142) GGGTGATCGCCTACAAGA 5' THIC A. thaliana
confirmation primer sequence (SEQ ID NO: 143) GCGTCATCGCCTACAAGA 5'
thiC Synechocystis sp. confirmation primer sequence (SEQ ID NO:
144) CGATGCTGTGCTACGTGA
[0700] Growth experiments on thiamine depleted cells (as described
above) were performed using selected confirmed positive clones from
transformants of each of the different constructs in medium
containing G418. All transformants were able to grow (with varying
degrees of robustness) in thiamine-free medium. Comparison of the
growth of the transformants in thiamine-free medium to wild type
cells on thiamine-containing medium showed the following ranking
with respect to their ability to support growth in thiamine-free
medium: (1) A. thaliana transformants; (2) Coccomyxa C-169 (with C.
protothecoides transit peptide) transformants; and (3)
Synechocystis sp. transformants. These results suggest that while a
single copy of A. thaliana THIC was able to complement thiamine
auxotrophy in Prototheca moriformis cells, multiple copies of
Coccomyxa C-169 (with either the native transit peptide sequence or
a transit peptide sequence from C. protothecoides) and
Synechocystis sp. THIC was required to enable rapid growth in the
absence of thiamine. Given the variability in results of the
different THIC from the different sources, the ability of any
particular THIC gene to fully complement the lesion present in
Prototheca species is not predictable.
[0701] An alignment of the three THIC amino acid sequences was
performed. While there exist significant sequence conservation
between thiC from Synechocystis sp. compared to the THICs from
Coccomyxa and A. thaliana (41% identity at the amino acid level),
the cyanobacterial protein is missing a domain at the N-terminus
that is well-conserved in the algal and plant proteins. Despite the
missing domain (and presumably resulting in structural
differences), the construct expressing the Synechocystis sp. thiC
was able to at least partially restore thiamine prototrophic in
Prototheca moriformis cells.
Example 13
Fuel Production
[0702] A. Extraction of Oil from Microalgae Using an Expeller Press
and a Press Aid
[0703] Microalgal biomass containing 38% oil by DCW was dried using
a drum dryer resulting in resulting moisture content of 5-5.5%. The
biomass was fed into a French L250 press. 30.4 kg (67 lbs.) of
biomass was fed through the press and no oil was recovered. The
same dried microbial biomass combined with varying percentage of
switchgrass as a press aid was fed through the press. The
combination of dried microbial biomass and 20% w/w switchgrass
yielded the best overall percentage oil recovery. The pressed cakes
were then subjected to hexane extraction and the final yield for
the 20% switchgrass condition was 61.6% of the total available oil
(calculated by weight). Biomass with above 50% oil dry cell weight
did not require the use of a pressing aid such as switchgrass in
order to liberate oil. Other methods of extraction of oil from
microalgae using an expeller press are described in PCT Application
No. PCT/US2010/31108 and is hereby incorporated by reference.
[0704] B. Production of Biodiesel from Prototheca Oil
[0705] Degummed oil from Prototheca moriformis UTEX 1435, produced
according to the methods described above, was subjected to
transesterification to produce fatty acid methyl esters. Results
are shown in Table 24 below.
[0706] The lipid profile of the oil was:
C10:0 0.02
C12:0 0.06
C14:0 1.81
C14.1 0.07
C16:0 24.53
C16:1 1.22
C18:0 2.34
C18:1 59.21
C18:2 8.91
C18:3 0.28
C20:0 0.23
C20:1 0.10
C20:1 0.08
C21:0 0.02
C22:0 0.06
C24:0 0.10
TABLE-US-00046 [0707] TABLE 24 Biodiesel profile from Prototheca
moriformis triglyceride oil. Method Test Result Units ASTM Cold
Soak Filterability of Filtration Time 120 sec D6751 A1 Biodiesel
Blend Fuels Volume Filtered 300 ml ASTM D93 Pensky-Martens Closed
Cup Procedure Used A Flash Point Corrected Flash 165.0 .degree. C.
Point ASTM Water and Sediment in Middle Sediment and Water 0.000
Vol % D2709 Distillate Fuels (Centrifuge Method) EN 14538
Determination of Ca and Mg Sum of (Ca and <1 mg/kg Content by
ICP OES Mg) EN 14538 Determination of Ca and Mg Sum of (Na and K)
<1 mg/kg Content by ICP OES ASTM D445 Kinematic/Dynamic
Kinematic Viscosity 4.873 mm.sup.2/s Viscosity @ 104.degree.
F./40.degree. C. ASTM D874 Sulfated Ash from Lubricating Sulfated
Ash <0.005 Wt % Oils and Additives ASTM Determination of Total
Sulfur Sulfur, mg/kg 1.7 mg/kg D5453 in Light Hydrocarbons, Spark
Ignition Engine Fuel, Diesel Engine Fuel, and Engine Oil by
Ultraviolet Fluorescence. ASTM D130 Corrosion - Copper Strip
Biodiesel-Cu 1a Corrosion 50.degree. C. (122.degree. F.)/3 hr ASTM
Cloud Point Cloud Point 6 .degree. C. D2500 ASTM Micro Carbon
Residue Average Micro <0.10 Wt % D4530 Method Carbon Residue
ASTM D664 Acid Number of Petroleum Procedure Used A Products by
Potentiometric Acid Number 0.20 mg Titration KOH/g ASTM
Determination of Free and Free Glycerin <0.005 Wt % D6584 Total
Glycerin in B-100 Total Glycerin 0.123 Wt % Biodiesel Methyl Esters
By Gas Chromatography ASTM Additive Elements in Phosphorus 0.000200
Wt % D4951 Lubricating Oils by ICP-AES ASTM Distillation of
Petroleum IBP 248 .degree. C. D1160 Products at Reduced Pressure
AET @ 5% 336 .degree. C. Recovery AET @ 10% 338 .degree. C.
Recovery AET @ 20% 339 .degree. C. Recovery AET @ 30% 340 .degree.
C. Recovery AET @ 40% 342 .degree. C. Recovery AET @ 50% 344
.degree. C. Recovery AET @ 60% 345 .degree. C. Recovery AET @ 70%
347 .degree. C. Recovery AET @ 80% 349 .degree. C. Recovery AET @
90% 351 .degree. C. Recovery AET @ 95% 353 .degree. C. Recovery FBP
362 .degree. C. % Recovered 98.5 % % Loss 1.5 % % Residue 0.0 %
Cold Trap Volume 0.0 ml IBP 248 .degree. C. EN 14112 Determination
of Oxidation Oxidation Stability >12 hr Stability (Accelerated
Operating Temp 110 .degree. C. Oxidation Test) (usually 110 deg C.)
ASTM Density of Liquids by Digital API Gravity @ 60.degree. F. 29.5
.degree.API D4052 Density Meter ASTM D6890 Determination of
Ignition Derived Cetane >61.0 Delay (ID) and Derived Number
(DCN) Cetane Number (DCN)
[0708] The lipid profile of the biodiesel was highly similar to the
lipid profile of the feedstock oil. Other oils provided by the
methods and compositions of the invention can be subjected to
transesterification to yield biodiesel with lipid profiles
including (a) at least 4% C8-C14; (b) at least 0.3% C8; (c) at
least 2% C10; (d) at least 2% C12; and (3) at least 30% C8-C14.
[0709] The Cold Soak Filterability by the ASTM D6751 A1 method of
the biodiesel produced was 120 seconds for a volume of 300 ml. This
test involves filtration of 300 ml of B 100, chilled to 40.degree.
F. for 16 hours, allowed to warm to room temp, and filtered under
vacuum using 0.7 micron glass fiber filter with stainless steel
support. Oils of the invention can be transesterified to generate
biodiesel with a cold soak time of less than 120 seconds, less than
100 seconds, and less than 90 seconds.
[0710] C. Production of Renewable Diesel
[0711] Degummed oil from Prototheca moriformis UTEX 1435, produced
according to the methods described above and having the same lipid
profile as the oil used to make biodiesel in this Example, above,
was subjected to transesterification to produce renewable
diesel.
[0712] The oil was first hydrotreated to remove oxygen and the
glycerol backbone, yielding n-paraffins. The n-parrafins were then
subjected to cracking and isomerization. A chromatogram of the
material is shown in FIG. 1. The material was then subjected to
cold filtration, which removed about 5% of the C18 material.
Following the cold filtration the total volume material was cut to
flash point and evaluated for flash point, ASTM D-86 distillation
distribution, cloud point and viscosity. Flash point was 63.degree.
C.; viscosity was 2.86 cSt (centistokes); cloud point was 4.degree.
C. ASTM D86 distillation values are shown in Table 25:
TABLE-US-00047 TABLE 25 ASTM D86 distillation values. Readings in
.degree. C.: Volume Temperature IBP 173 5 217.4 10 242.1 15 255.8
20 265.6 30 277.3 40 283.5 50 286.6 60 289.4 70 290.9 80 294.3 90
300 95 307.7 FBP 331.5
[0713] The T10-T90 of the material produced was 57.9.degree. C.
Methods of hydrotreating, isomerization, and other covalent
modification of oils disclosed herein, as well as methods of
distillation and fractionation (such as cold filtration) disclosed
herein, can be employed to generate renewable diesel compositions
with other T10-T90 ranges, such as 20, 25, 30, 35, 40, 45, 50, 60
and 65.degree. C. using triglyceride oils produced according to the
methods disclosed herein.
[0714] The T10 of the material produced was 242.1.degree. C.
Methods of hydrotreating, isomerization, and other covalent
modification of oils disclosed herein, as well as methods of
distillation and fractionation (such as cold filtration) disclosed
herein, can be employed to generate renewable diesel compositions
with other T10 values, such as T10 between 180 and 295, between 190
and 270, between 210 and 250, between 225 and 245, and at least
290.
[0715] The T90 of the material produced was 300.degree. C. Methods
of hydrotreating, isomerization, and other covalent modification of
oils disclosed herein, as well as methods of distillation and
fractionation (such as cold filtration) disclosed herein can be
employed to generate renewable diesel compositions with other T90
values, such as T90 between 280 and 380, between 290 and 360,
between 300 and 350, between 310 and 340, and at least 290.
[0716] The FBP of the material produced was 300.degree. C. Methods
of hydrotreating, isomerization, and other covalent modification of
oils disclosed herein, as well as methods of distillation and
fractionation (such as cold filtration) disclosed herein, can be
employed to generate renewable diesel compositions with other FBP
values, such as FBP between 290 and 400, between 300 and 385,
between 310 and 370, between 315 and 360, and at least 300.
[0717] Other oils provided by the methods and compositions of the
invention can be subjected to combinations of hydrotreating,
isomerization, and other covalent modification including oils with
lipid profiles including (a) at least 4% C8-C14; (b) at least 0.3%
C8; (c) at least 2% C10; (d) at least 2% C12; and (3) at least 30%
C8-C14.
Example 14
Production of Tailored Oils
[0718] Using the methods and materials as disclosed herein, various
tailored oils were produced. Table 32 shows the strain, the gene
and the genbank accession numbers of the genes conferring the
phenotype and the various fatty acid profiles produced by the
indicated strain. Strains A and B are both Prototheca moriformis
(UTEX 1435) strains, both of which were classically mutagenized by
a fee-for-service laboratory to improve oil yield. Strains A and B
were then genetically engineered as described herein with the
appropriate DNA constructs to express the desired genes. The
strains were also engineered to inactivate endogenous desaturases,
as indicated. The nucleotide sequences of the thioesterases were
codon optimized for expression and use in Prototheca.
[0719] The fatty acid profile of wild type, un-engineered
Prototheca is shown in the first line of Table 32. As can be seen,
the fatty acid profile has been dramatically altered in different
ways in the different strains. For example, the percentage of C8:0
produced by non-genetically engineered P. moriformis cells is 0%.
However, P. moriformis cells engineered to express a C. hookeriana
thioesterase increased C8:0 production from 0% to 13.2% of the
total triglycerides. As another example, the total combined amount
of C8:0 and C10:0 in the engineered strains was about 39% of the
total fatty acids. In contrast, the total combined amount of C8:0
and C10:0 in the wild type cells is 0.01%. In another example, the
total amount of saturated fatty acids was increased from about 32%
to about 90% by the expression of an U. americana thioesterase in
cells in which expression of endogenous SAD2b was disrupted. This
is an increase of almost 300%.
[0720] The various fatty acid profiles as disclosed below are
useful in myriad applications involving triglyceride oils. For
example, high levels of lower carbon chain length saturated fatty
acids comprising triglyceride (C12:0, C14:0, C16:0) are
particularly useful in renewable jet fuel production. For biodiesel
production, high amounts of C18:1 are desirable. For bar soap
production, controlling and achieving the appropriate balance
between the levels of saturation and shorter chain fatty acids is
desirable. As an example, high amounts of C12:0 are desirable for
lathering properties while longer chain lengths provide more
structure, while linoleic and linolenic containing triglycerides
are less desirable as they contribute to oxidative instability. For
liquid soaps, high amounts of C12:0 and C14:0 are desirable.
Additionally, for both bar soap and liquid soap production, low
amounts of C6:0, C8:0 and C10:0 are desirable as these lower chain
triglycerides are skin irritants.
TABLE-US-00048 TABLE 32 Genes and accession numbers conferring
phenotypes of various triglyceride profiles. Gen Bank Strain
Accession Gene Seq. Genetic Total and De- Conferring Con- Id. Back-
Satu- Trait scriptoin Phenotype struct* No. ground C8:0 C10:0 C12:0
C14:0 C16:0 C18:0 C18:1 C18:2 rates Wild na UTEX 0.00 0.01 0.04
1.27 27.20 3.85 58.70 7.18 32.36 Type 1435 Highest U39834 C. pSZ
1458 A 13.20 25.84 0.51 1.41 10.22 1.39 38.21 7.42 52.57 C8
hookeriana TE Highest U39834 C. pSZ 1458 A 13.20 25.84 0.51 1.41
10.22 1.39 38.21 7.42 52.57 C10 hookeriana TE Highest U56104 and C.
pSZ 1491 B .02 13.63 50.59 6.49 6.64 0.87 13.74 6.83 78.00 C12
U67317 wrightii (SEQ ID (SEQ ID TE + C. NO: 232) NO: 185) wrightii
KASA1 Highest U31813 Cinna- pSZ 941 UTEX 0.00 0.06 5.91 43.27 19.63
0.87 13.96 13.78 69.74 C14 momum (SEQ ID 1435 camphora NO: TE
236)/944 (SEQ ID NO: 228) Highest Q39513.1 C. pSZ 1417 A 0.00 0.02
0.11 10.62 69.92 2.18 12.95 5.15 80.35 C16 hookeriana (SEQ ID TE
NO: 226) Highest U56104 as C. pSZ 1410 A 0.00 0.11 1.28 1.82 24.55
37.38 23.51 7.88 65.14 C18 SAD2B gene wrightii (SEQ ID disruption
TE NO: 230) Highest U39834 C. pSZ 1458 A 13.20 25.84 0.51 1.41
10.22 1.39 38.21 7.42 52.57 C8- hookeriana C10 TE Highest U56104 C.
pSZ 1283 A .22 17.64 45.85 10.94 5.55 0.79 13.49 4.68 74.65 C8-
wrightii (SEQ ID C14 TE NO: 229) Highest U56104 C. pSZ 1283 A .22
17.64 45.85 10.94 5.55 0.79 13.49 4.68 74.65 C10- wrightii (SEQ ID
C14 TE NO: 229) Highest ABB71579.1 C. pSZ 1570 B .01 0.88 28.04
34.08 19.82 1.00 10.52 4.42 83.83 C12- (SEQ ID callophylla (SEQ ID
C14 NO: 286) TE NO: 235) Lowest AAB71731 Ulmus pSZ 1321 A .12 10.39
3.55 35.21 33.54 4.90 5.15 5.69 87.71 18:1 (SEQ ID americana (SEQ
ID NO: 287) as TE NO: 242) SAD2B gene disruption Highest FADc
Carthamus pSZ 1500 A 0 0 0 0 16.49 0 83.51 0.00 16.49 18:1
Disruption tinctorus (SEQ ID with TE NO: 233) Carthamus tincorusTE
AAA33019.1 Lowest FADc Carthamus pSZ 1501 A 0 0 .03 1.05 18.01 1.44
77.11 0.00 20.53 18:2 Disruption tinctorus (SEQ ID with TE NO: 234)
Carthamus tincorusTE AAA33019.1 Highest AAB71731 Ulmus pSZ 1321 A
.30 13.07 3.57 33.58 33.52 5.16 5.36 4.50 89.20 Satu- as a SAD2B
americana (SEQ ID rates Disruption TE NO: 242)
Palm Kernel Oil
[0721] We produced a microbial palm kernel oil mimetic that was
similar to palm kernel oil (PKO). To produce the palm kernel oil
mimetic, a plasmid was constructed and used to transform Strain A
and oil production was carried out. The construct, pSZ1413 (SEQ ID
NO: 231), comprised codon optimized Cuphea wrightii FATB2 gene (SEQ
ID NO: 284) (Gen bank accession no. U56106) and SAD2B (stearoyl ACP
desaturase) gene disruption.
[0722] As shown in Table 33 below, the palm kernel oil mimetic was
similar to palm kernel oil. The percentages of the three most
abundant fatty acids of the PKO mimetic (C12:0, C14:0 and C18:1)
were identical to or within 10% of the palm kernel oil.
TABLE-US-00049 TABLE 33 Triglyceride profile of palm kernel oil
mimetic. C8:0 C10:0 C12:0 C14:0 C16:0 C18:0 C18:1 C18:2 E.
guineensis 3.0-5.0 2.5-6.0 40-52 14.0-18.0 7.0-10.0 1.0-3.0
11.0-19.0 0.5-4.0 (Palm kernel) pSZ1413 8.33 37.45 18.22 13.52 1.25
15.29 4.95
Palm Oil
[0723] We produced a microbial palm oil mimetic that was similar to
palm oil. Several different plasmids were constructed and
transformed individually into Strain A and oil production was
carried out. The construct, pSZ1503 (SEQ ID NO: 283), was designed
to disrupt an endogenous KASII gene. The construct, pSZ1439 (SEQ ID
NO: 237), comprised a codon optimized Elaeis guiniensis TE gene
(SEQ ID NO: 205) (Gen bank accession no. AAD42220.2). The
construct, pSZ1420 (SEQ ID NO: 225), comprised a codon optimized
Cuphea hookeriana TE gene (SEQ ID NO: 201) (Gen Bank Accession no.
Q39513). The construct, pSZ1119 (SEQ ID NO: 227), comprised a codon
optimized Cuphea hookeriana KAS IV gene (SEQ ID NO: 186) (Gen Bank
Accession no. AF060519) as well as a Cuphea wrightii FATB2 gene
(SEQ ID NO: 184) (Gen Bank Accession no. U56104).
[0724] As shown in Table 34 below, the palm oil mimetic was similar
to palm oil. The percentages of the three most abundant fatty acids
of the palm oil mimetic (C16:0, C18:1 and C18:2) were identical to
or within 10% of palm oil.
TABLE-US-00050 TABLE 34 Triglyceride profile of palm oil mimetic.
C10:0 C12:0 C14:0 C16:0 C18:0 C18:1 C18:2 E. guineensis 0 0 0.5-5.9
32.0-47.0 2.0-8.0 34-44 7.2-12.0 (Palm) pSZ1503 0.01 0.01 0.83
38.36 2.21 48.31 7.60 pSZ1439 0.01 0.04 1.88 43.50 3.32 39.95 9.16
pSZ1420 0.02 0.04 2.44 48.04 2.76 35.62 8.91 pSZ1119 1.77 0.40 7.85
35.45 2.47 42.85 8.15
Cocoa Butter
[0725] We produced a microbial cocoa butter mimetic that was
similar to cocoa butter. The construct, pSZ1451, was constructed
and transformed into Strain A and oil production was carried out.
The construct, pSZ1451 (SEQ ID NO: 239), comprised codon optimized
Carthamus tinctorus TE gene (SEQ ID NO: 187) (Gen Bank Accession
no. AAA33019.1).
[0726] As shown in Table 35 below, the cocoa butter oil mimetic was
similar to cocoa butter. The percentages of the three most abundant
fatty acids of the cocoa butter mimetic (C16:0, C18:0 and C18:1)
were identical to or within 10% of cocoa butter.
TABLE-US-00051 TABLE 35 Triglyceride profile of cocoa butter
mimetic. C8:0 C10:0 C12:0 C14:0 C16:0 C18:0 C18:1 C18:2 Cocoa
Butter 0 0-1 0-1 0-4 22-38 24-37 29-38 0-3 pSZ1451 0.05 0.14 0.99
28.34 27.39 29.40 10.26
Lard
[0727] We produced a microbial lard mimetic that was similar to
lard. Several different plasmids were constructed and transformed
individually into Strain A and oil production was carried out. The
construct, pSZ1493 (SEQ ID NO: 241), was designed to disrupt the
endogenous SAD 2B gene and simultaneously express a codon optimized
Umbellularia californica TE gene (SEQ ID NO: 285) (Gen Bank
Accession no. M94159). The construct, pSZ1452 (SEQ ID NO: 240), was
designed to disrupt the endogenous SAD 2B gene and express a codon
optimized Garcinia mangostana TE gene (SEQ ID NO: 196) (Gen Bank
Accession no. AAB51525.1). The construct, pSZ1449 (SEQ ID NO: 238),
was designed to express the codon optimized Brassica napus TE gene
(SEQ ID NO: 195) (Gen Bank Accession no. CAA52070.1). The
polynucleotide sequence of the construct pSZ1458 was identical to
pSZ1449 except that a codon optimized polynucleotide sequence
encoding a Cuphea hookeriana thioesterase (Gen Bank accession No.
U39834) replaced the polynucleotide sequence encoding Brassica
napus TE gene (SEQ ID NO: 195) (Gen Bank Accession no.
CAA52070.1).
[0728] As shown in Table 36 below, the lard mimetic was similar to
lard. The percentages of the three most abundant fatty acids of the
lard mimetic (C16:0, C18:0 and C18:1) were identical to or within
10% of lard.
TABLE-US-00052 TABLE 36 Triglyceride profile of lard mimetic. C14:0
C16:0 C18:0 C18:1 C18:2 Lard 3-4 22-26 13-18 39-45 8-15 pSZ1493
1.32 24.79 17.49 41.87 10.01 pSZ1452 1.16 24.49 17.94 45.49 8.05
pSZ1449 1.16 23.98 15.79 47.88 8.29
[0729] Although this invention has been described in connection
with specific embodiments thereof, it will be understood that it is
capable of further modifications. This application is intended to
cover any variations, uses, or adaptations of the invention
following, in general, the principles of the invention and
including such departures from the present disclosure as come
within known or customary practice within the art to which the
invention pertains and as may be applied to the essential features
hereinbefore set forth.
[0730] All references cited herein, including patents, patent
applications, and publications, including Genbank Accession
numbers, are hereby incorporated by reference in their entireties,
whether previously specifically incorporated or not. The
publications mentioned herein are cited for the purpose of
describing and disclosing reagents, methodologies and concepts that
may be used in connection with the present invention. Nothing
herein is to be construed as an admission that these references are
prior art in relation to the inventions described herein. In
particular, the following patent applications are hereby
incorporated by reference in their entireties for all purposes: PCT
Application No. PCT/US2008/065563, filed Jun. 2, 2008, entitled
"Production of Oil in Microorganisms", PCT Application No.
PCT/US2010/31108, filed Apr. 14, 2010, entitled "Methods of
Microbial Oil Extraction and Separation", and PCT Application No.
PCT/US2009/066142, filed Nov. 30, 2009, entitled "Production of
Tailored Oils in Heterotrophic Microorganisms".
Sequence CWU 0 SQTB SEQUENCE LISTING The patent application
contains a lengthy "Sequence Listing" section. A copy of the
"Sequence Listing" is available in electronic form from the USPTO
web site
(http://seqdata.uspto.gov/?pageRequest=docDetail&DocID=US20110293785A1).
An electronic copy of the "Sequence Listing" will also be available
from the USPTO upon request and payment of the fee set forth in 37
CFR 1.19(b)(3).
0 SQTB SEQUENCE LISTING The patent application contains a lengthy
"Sequence Listing" section. A copy of the "Sequence Listing" is
available in electronic form from the USPTO web site
(http://seqdata.uspto.gov/?pageRequest=docDetail&DocID=US20110293785A1).
An electronic copy of the "Sequence Listing" will also be available
from the USPTO upon request and payment of the fee set forth in 37
CFR 1.19(b)(3).
* * * * *
References