U.S. patent application number 15/614194 was filed with the patent office on 2017-09-21 for polyhydroxyalkanoate production method.
The applicant listed for this patent is Newlight Technologies, Inc.. Invention is credited to Markus Herrema.
Application Number | 20170268026 15/614194 |
Document ID | / |
Family ID | 46798790 |
Filed Date | 2017-09-21 |
United States Patent
Application |
20170268026 |
Kind Code |
A1 |
Herrema; Markus |
September 21, 2017 |
POLYHYDROXYALKANOATE PRODUCTION METHOD
Abstract
Embodiments of the invention relate generally to processes for
the production and processing of polyhydroxyalkanoates (PHA) from
carbon sources. In several embodiments, PHAs are produced at high
efficiencies from carbon-containing gases or materials.
Inventors: |
Herrema; Markus; (Corona del
Mar, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Newlight Technologies, Inc. |
Irvine |
CA |
US |
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|
Family ID: |
46798790 |
Appl. No.: |
15/614194 |
Filed: |
June 5, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14698670 |
Apr 28, 2015 |
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15614194 |
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14003751 |
Sep 6, 2013 |
9040267 |
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PCT/US12/28210 |
Mar 8, 2012 |
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14698670 |
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61450512 |
Mar 8, 2011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C12P 39/00 20130101;
C12P 7/625 20130101 |
International
Class: |
C12P 7/62 20060101
C12P007/62; C12P 39/00 20060101 C12P039/00 |
Claims
1. A biological composition comprising carbon-utilizing
methanotrophic microorganisms having an intracellular
polyhydroxyalkanoate (PHA) concentration greater than 70% by
weight.
2. The composition of claim 1, wherein said intracellular PHA
concentration is greater than 75% by weight.
3. The composition of claim 2, wherein said intracellular PHA
concentration is greater than 80% by weight.
4. The composition of claim 3, wherein said intracellular PHA
concentration is greater than 85% by weight.
5. The composition of claim 4, wherein said intracellular PHA
concentration is greater than 90% by weight.
6. The composition of claim 5, wherein said intracellular PHA
concentration is greater than 95% by weight.
7. The composition of claim 1, wherein said carbon-utilizing
methanotrophic microorganisms utilize a carbon containing gas as a
source of carbon.
8. The composition of claim 7, wherein said carbon containing gas
contains methane.
9. The composition of claim 8, wherein said carbon containing gas
is methane.
10. The composition of claim 7, wherein said carbon containing gas
contains carbon dioxide.
11. The composition of claim 10, wherein said carbon containing gas
is carbon-dioxide.
12. The composition of claim 1, wherein said carbon-utilizing
methanotrophic microorganisms utilize PHA-reduced biomass as a
source of carbon.
13. A biological culture comprising methane-utilizing
methanotrophic microorganisms having an overall intracellular
polyhydroxyalkanoate (PHA) concentration greater than 70% and less
than 95% by weight of the dry weight of said microorganisms.
14. The biological culture of claim 13, wherein said PHA
concentration greater than 75% and less than 95% by weight.
15. The biological culture of claim 13, wherein said PHA
concentration greater than 80% and less than 95% by weight.
16. The biological culture of claim 13, wherein said PHA
concentration greater than 85% and less than 95% by weight.
17. The biological culture of claim 13, wherein said PHA
concentration greater than 90% and less than 95% by weight.
18. One or more polyhydroxyalkanoate (PHA)-producing methanotrophic
bacterial cells producing greater than 70 grams of PHA per 100
grams dry weight of said cells when said cells are grown in a
carbon-containing gas source.
19. The one or more bacterial cells of claim 18, wherein said one
or more bacterial cells comprise at least 80 grams of PHA per 100
grams dry weight of said cells.
20. The one or more bacterial cells of claim 19, wherein said one
or more bacterial cells comprise at least 85 grams of PHA per 100
grams dry weight of said cells.
21. The one or more bacterial cells of claim 20, wherein said one
or more bacterial cells comprise at least 90 grams of PHA per 100
grams dry weight of said cells.
22. The one or more bacterial cells of claim 18, wherein said
carbon-containing gas source comprises methane.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent
application Ser. No. 14/698,670, filed Apr. 28, 2015, which is
continuation of U.S. Pat. No. 9,040,267, filed Sep. 6, 2013, which
is the U.S. National Phase application under 35 U.S.C. .sctn.371 of
International Application No. PCT/2012/028210, filed Mar. 8, 2012,
which claims the benefit of U.S. Provisional Application No.
61/450,512 Mar. 8, 2011, the disclosure of each of which is
incorporated in its entirety by reference herein.
BACKGROUND
[0002] Field of the Invention
[0003] Embodiments of the invention relate to an improved process
for the production and processing of polyhydroxyalkanoates, and
specifically to a process for the production of
polyhydroxyalkanoates from carbon-containing gases and
materials.
[0004] Description of the Related Art
[0005] Polyhydroxyalkanoates (PHAs) are thermoplastic polyesters
that serve as carbon and energy storage vehicles in microorganisms.
PHAs are biodegradable in both aerobic and anaerobic conditions,
are biocompatible with mammalian tissues, and, as thermoplastics,
can be used as alternatives to fossil fuel-based plastics such as
polypropylene, polyethylene, and polystyrene. In comparison to
petrochemical-based plastics, which are neither biodegradable nor
made from sustainable sources of carbon, PHA plastics afford
significant environmental benefits.
[0006] The utilization of food crop derived sugars in genetically
engineered microorganism-based aqueous fermentation systems is
often regarded as the most efficient and economical platform for
PHA production. Specifically, sugar-based PHA production processes
are capable of generating high density fermentation cultures and
high PHA inclusion concentrations, and, by maximizing the cell
culture density and PHA inclusion concentration therein, it is
believed that carbon, chemical, and energy efficiencies are also
maximized. For example, comparing a low cell and PHA concentration
process to a high cell and PHA concentration process, a low
concentration process requires significantly more, per given unit
of PHA-containing biomass, i) energy for dewatering cells prior to
PHA extraction treatment, ii) liquid culture volume, and associated
chemicals, mixing energy, and heat removal energy, and iii) both
energy and chemicals for separating PHA from biomass. Accordingly,
whereas the sugar-based genetically-engineered microorganism PHA
process yields maximized cell densities and PHA concentrations
relative to low concentration processes, it is also regarded as the
most carbon, chemical, energy, and, thus, cost efficient PHA
production method.
[0007] Unfortunately, despite these maximized efficiency
advantages, sugar-based PHA production remains more expensive than
fossil fuel-based plastics production. Thus, given the apparent
efficiency maximization of the high density sugar-derived PHA
production process, PHAs are generally considered to be unable to
compete with fossil fuel-based plastics on energy, chemical, and
cost efficiency.
SUMMARY
[0008] Despite the environmental advantages of PHAs, the high cost
of PHA production relative to the low cost of fossil fuel-based
plastics production has significantly limited the industrial
production and commercial adoption of PHAs.
[0009] To reduce the carbon input cost of the PHA production
process, carbon-containing industrial off-gases, such as carbon
dioxide, methane, and volatile organic compounds, have been
proposed as an alternative to food crop-based and plant-based
sources of carbon. In addition to the wide availability and low
cost of carbon-containing gases, carbon-containing gases also do
not present the environmental challenges associated with food crop
and plant-derived sources of carbon. Specifically, whereas food
crop- and plant-based carbon substrates require land, fertilizers,
pesticides, and fossil fuels to produce, and also generate
greenhouse gas emissions during the course of production,
carbon-containing off-gases do not require new inputs of land,
fertilizers, or pesticides to generate. Thus, on both an economic
and environmental basis, the utilization of carbon emissions for
the production of PHA would appear to offer significant advantages
over sugar-based PHA production processes.
[0010] Unfortunately, the fermentation of carbon-containing gases
presents technical challenges and stoichiometric limitations that
have, in the past, rendered the gas-to-PHA production process
significantly more energy and chemical intensive, and thus more
costly, than the food crop-based PHA production process.
Specifically, these technical challenges and stoichiometric
limitations include: low mass transfer rates, low microorganism
growth rates, extended polymerization times, low cell densities,
high oxygen demand, and low PHA cellular inclusion concentrations.
Whereas sugar-based fermentation systems have the ability to
generate high cellular densities and PHA inclusion concentrations,
based on cell morphology and mass transfer constraints,
carbon-containing gas-based fermentation processes typically
generate 10-50% of the biomass and intracellular PHA inclusion
concentrations achieved in sugar-based processes. As a result, the
ratio of energy-to-PHA required to carry out upstream carbon
injection, optional oxygen injection, and culture mixing, as well
as downstream PHA purification, significantly exceeds the
energy-to-PHA ratio required for sugar-based PHA production
methods, thereby rendering the emissions-based process
uncompetitive when compared to both petroleum-based plastics and
sugar-based PHAs.
[0011] In light of the potential environmental advantages and
carbon cost efficiencies of utilizing carbon-containing gases as a
source of carbon for PHA production, there exists a significant
need to reduce the energy, chemical, and carbon input-to-PHA output
ratio in a carbon emissions-based PHA production system, and
thereby render carbon gas-derived PHA economically competitive with
petrochemical-based plastics.
[0012] Thus, in several embodiments, the present invention relates
to a novel process for the conversion of carbon-containing gases
into PHAs at previously unattainable energy and carbon PHA
conversion ratios.
[0013] In some embodiments, the invention also relates to a process
that generates a carbon emissions-based PHA material that is
cost-competitive with both food crop-based PHAs and fossil
fuel-based thermoplastics.
[0014] While PHAs are widely considered to be noncompetitive with
fossil fuel-based plastics on energy, chemical, and cost
efficiency, several embodiments of the invention relate to a
process for producing PHAs from carbon-containing gases that yields
unexpectedly improved energy, carbon, chemical, and cost
efficiencies over sugar-based PHA production methodologies.
[0015] There is provided, in several embodiments, a method for
enhancing polyhydroxyalkanoate (PHA) generation in a methanotrophic
culture by reducing copper concentrations to effect particulate
methane monooxygenase (pMMO) production comprising
[0016] contacting a culture of methanotrophic microorganisms with a
medium comprising copper, one or more additional nutrients, and a
carbon-containing gas that can be metabolized by the culture,
incubating the culture in the medium to cause growth of the
culture, inducing a selection pressure in the culture to transform
the culture into a culture that generates PHA preferentially
through pMMO by: (i) reducing the concentration of copper in the
medium to cause production of soluble methane monooxygenase (sMMO)
and/or particulate methane monooxygenase by the culture, wherein
the concentration of copper causes the production of sMMO in some
methanotrophic microorganisms; (ii) reducing the concentration of
one or more the nutrient in the medium to cause the culture to
generate PHA from the carbon-containing gas using the sMMO or the
pMMO, wherein PHA is generated by pMMO at a greater rate as
compared to sMMO, (iii) returning the culture to the growth
conditions, wherein microorganisms having higher intracellular
concentrations of pMMO and PHA grow at a greater rate as compared
to those with lower intracellular pMMO and PHA concentrations; and
(iv) repeating steps (ii) and (iii), wherein the repetitions
selectively favor growth of microorganisms that produce PHA via
pMMO, thereby facilitating the pMMO-mediated production of PHA at
reduced copper concentrations, and resulting in a culture
comprising essentially only microorganisms that use pMMO to produce
PHA.
[0017] There is also provided a method for enhancing particulate
methane monooxygenase (pMMO) mediated polyhydroxyalkanoate (PHA)
generation comprising contacting a culture of methanotrophic
microorganisms with a medium comprising copper, nitrogen, one or
more additional nutrients, and a carbon-containing gas that can be
metabolized by the culture, incubating the culture in the medium to
cause growth of the culture; and transforming the culture into a
culture that generates PHA preferentially through pMMO by: (i)
reducing the concentration of copper in the medium to cause
production of soluble methane monooxygenase (sMMO) and particulate
methane monooxygenase by the culture, wherein the concentration of
copper favors the production of sMMO; (ii) reducing the
concentration of nitrogen to cause the culture to generate PHA from
the carbon-containing gas using the sMMO or the pMMO, wherein PHA
is generated by pMMO at a more rapid rate as compared to sMMO,
resulting in a portion of the microorganisms having higher
intracellular concentrations of PHA as compared to those using
sMMO; and (iii) returning the culture to the growth conditions,
wherein the microorganisms having higher intracellular
concentrations of PHA grow at a greater rate as compared to those
with lower intracellular PHA concentrations; and (iv) repeating
steps (ii) and (iii), wherein the repetitions selectively favor
growth of microorganisms that produce PHA via pMMO, thereby
facilitating the pMMO-mediated production of PHA.
[0018] There is also provided, in several embodiments, a method for
converting a carbon-containing material into a polyhydroxyalkanoate
(PHA), the method comprising (a) contacting a culture of
methanotrophic microorganisms with a medium comprising copper, one
or more additional nutrients, and a carbon-containing material that
can be metabolized by the culture, thereby inducing growth of the
culture (b) reducing or controlling the concentration of copper in
the medium to cause at least a portion of the culture to produce
soluble methane monooxygenase (sMMO) and/or particulate methane
monooxygenase (pMMO), wherein the copper concentration can cause
one or more methanotrophic microorganism to produce sMMO, (c)
reducing the concentration of at least one of the nutrients in the
medium to cause at least a portion of the culture to utilize the
produced sMMO or the produced pMMO to convert the carbon from the
carbon-containing material into PHA, (d) repeating steps (a)
through (c) a plurality of times, wherein the portion of the
culture utilizing the pMMO to generate PHA grows and/or generates
PHA at a greater rate than the portion of the culture utilizing the
sMMO to generate PHA, thereby inducing a selective pressure in the
culture resulting in a culture comprising essentially only
microorganisms that use pMMO to produce PHA.
[0019] In several embodiments, the induced selection pressure
selects for microorganisms in which the presence and/or expression
of the gene encoding the sMMO is reduced. This is unexpected, in
several embodiments, as the copper concentrations are such that
sMMO production would typically be favored. When employed in
combination with periods of growth, PHA production, and growth, the
selection pressure unexpectedly and advantageously allows those
microorganisms operating through the pMMO pathway to become grow
more quickly, thereby outcompeting many, if not all, organisms
using an alternate MMO pathway. In several embodiments, as the
growth-polymerization-growth cycles are repeated in conjunction
with the existence of conditions favoring pMMO metabolism, the
expression of the gene encoding the soluble methane monooxygenase
enzyme is reduced. Thus, the growth advantage of those
microorganisms utilizing P MMO provides, in each cycle, at least a
marginal gain with respect to the pMMO-utilizing microorganisms
increasing their percentage contribution to the overall
demographics of the culture. With each successive round,
pMMO-utilizing microorganisms outcompete the sMMO-utilizing
microorganisms, thereby eventually being the primary, if not only,
microorganism in the culture. As a result this process, the
"weaker" sMMO-utilizing microorganisms will be reduced in number,
and in some cases may undergo an evolutionary-pressure induced
change to reduce/eliminate sMMO expression in favor of pMMO.
[0020] In additional embodiments, alternative methods may be used
to achieve a reduction in the presence and/or expression of the
sMMO gene and/or protein. For example, as disclosed herein
genetically modified microorganisms may be used in certain
embodiments. Thus, prior to a culturing process in which PHA would
be produced, in some embodiments, microbiological techniques are
used to excise the genetic material encoding sMMO from the genome
of the microorganism. Similarly, microorganisms having the genetic
material for sMMO could be cultured with (e.g., bred with) an
alternative strain of microorganisms having genetic material for a
metabolically favorable (e.g., more active) pMMO. After successive
rounds of crossbreeding, microorganisms are selected based on a
combination of limited sMMO expression and robust high activity
pMMO expression. In additional embodiments, methods can be used to
suppress one or more of the expression where the activity of the
sMMO enzyme, rather than manipulating the microorganism on genomic
level. For example, RNA interference or antisense RNA could be used
to suppress expression and/or function of sMMO. Similarly site
directed mutagenesis could be used such that a microorganism would
produce a mutant (e.g., nonfunctional or minimally functional)
sMMO. Site directed mutagenesis can also be employed to introduce a
specific mutation in the sMMO gene such that a truncated and/or
nonfunctional (or reduced function) S MMO is produced. For example,
the introduction of mutation that results in early placement of a
stop codon in the sMMO gene would result in a truncated, and likely
nonfunctional enzyme (if any enzyme and all were in fact be
produced). In addition to, or in place of such approaches,
inducible or repressible promoters could be employed such that sMMO
would only be expressed under certain conditions (e.g., the
addition of an inducing agent to the culture media) or
alternatively would normally be repressed absent the removal of
repressing agent from the media. Akin to gene therapy approaches,
microorganisms could be modified to carry exogenous DNA that
produces a repressor of sMMO function (or alternatively, a promoter
of pMMO function).
[0021] In some embodiments, the actual and/or bioavailable
concentration of the copper in the medium is reduced to a
concentration less than about 0.001 mg/L, less than about 0.5
micromolar, less than about 0.1 mg per dry weight gram of the
microorganisms, less than about 100 mg/L, or less than about 1
mg/L. In some embodiments, the concentration of copper is
maintained at the reduced level. In some embodiments, the copper
concentration is returned to initial concentrations. In several
embodiments, reduction of one or more additional nutrient comprises
a substantial depletion of nitrogen from the media. Substantial
depletion comprises, in some embodiments, depletion of nitrogen
concentrations by about 50%, about 60%, about 70%, about 80%, about
90%, about 95%, or more. In other embodiments, depending on the
metabolic status of the culture, smaller reductions in nitrogen,
another nutrient in the media, or combinations thereof may be used
to effect PHA polymerization.
[0022] In several embodiments, the carbon-containing gas that the
culture uses as a source of carbon to generate PHA comprises
methane. In some embodiments, the carbon-containing gas comprises
carbon dioxide. In some embodiments, the carbon-containing gas
comprises one or more volatile organic compounds. In some
embodiments, one or more of methane, carbon dioxide, volatile
organic compounds, and other gasses or compounds may be present in
the carbon-containing gas.
[0023] In some embodiments, the carbon source need not be a gas. A
carbon-containing material comprising a non-gaseous material
(either alone or in combination with a gas) may also be used in
certain embodiments. For example, in some embodiments, the
non-gaseous material comprises one or more volatile fatty acids,
methanol, acetate, acetone or acetic acid, formate, formaldehyde or
formic acid, propane, ethane, or combinations thereof (or in
combination with other metabolizable carbonaceous materials). In
addition, in some embodiments, the non-gaseous material comprises
microorganism biomass removed from one polymerization stage and
added to the medium in a subsequent growth stage.
[0024] Advantageously, the methods disclosed herein allow
production PHA at high intracellular concentrations. The
concentrations, in some embodiments, are at least 70% of the dry
biomass weight of the microorganisms. In some embodiments, the
concentrations are particularly advantageous because the high
intracellular PHA concentration enables more rapid growth of those
microorganisms. Thus, a feed-forward cycle exists, in some
embodiments, in that a microorganism that is selected for by the
induced pressures produces PHA more rapidly through the pMMO
pathway, thereby having a greater concentration of PHA, which
further imparts the ability to grow more rapidly (vis-a-vis those
microorganisms with lower PHA concentrations, such as those
utilizing the sMMO pathway). As the process is repeated, the
pMMO-utilizing microorganisms possess a growth advantage at (at
least) two stages in the process, thereby allowing their dominance
in the culture. As such, in several embodiments, the culture
comprising essentially only microorganisms that use pMMO to produce
PHA comprises a culture wherein over 50% of the culture uses pMMO
to produce PHA. Additionally, in several embodiments, the culture
comprising essentially only microorganisms that use pMMO to produce
PHA comprises over 80% of the culture. In several embodiments, the
microorganisms in the culture are from the genus methylocystis.
[0025] In addition, several embodiments, the repeated cycling
between growth, copper reduction to favor pMMO production, PHA
production and back to growth also favors the production of
microorganisms that possess the genetic material encoding the
ethylmalonyl-CoA pathway. Advantageously, this pathway allows, in
some embodiments, additional carbon sources to be used by the
culture, thereby broadening the range of substrates that can
eventually be used as substrates for the generation of PHA.
[0026] A method for converting a carbon-containing material into a
polyhydroxyalkanoate is also provided in several embodiments, the
method comprising: (a) contacting a methanotrophic culture with a
medium comprising one or more nutrients and a carbon-containing
material that can be metabolized by the culture, (b) controlling
the concentration of the one or more nutrients in the medium to
cause at least a portion of the culture to produce sMMO and/or
pMMO, (c) controlling the concentration of the one or more
nutrients in the medium to cause the culture to produce PHA; (d)
repeating steps (a) through (c) a plurality of times.
[0027] In several embodiments, the nutrient of step (b) and the
nutrient of step (c) are the same nutrient, while in other
embodiments, the nutrient of step (b) and the nutrient of step (c)
are different nutrients. In one embodiment, the nutrient is
selected from the group consisting of copper, methane, oxygen,
phosphorus, potassium, magnesium, boron, sodium, calcium, nitrogen,
iron, carbon dioxide, and combinations thereof.
[0028] Also provided for in several embodiments herein is a method
for converting a carbon-containing material into a
polyhydroxyalkanoate (PHA), the method comprising: (a) providing a
microorganism culture, (b) providing a medium comprising one or
more nutrient comprising a carbon-containing material that can be
metabolized by the culture, (c) controlling the concentration of
the one or more nutrient in the medium to cause the cellular
replication of one or more microorganisms in the culture, wherein
the genetic material encoding the ethylmalonyl-CoA pathway is
present in the one or more microorganisms, (d) controlling the
concentration of the one or more nutrient in the medium to cause
the culture to produce PHA, and (e) repeating steps (a) through
(d).
[0029] In several embodiments, the nutrient is copper, and step (c)
comprises periodically or permanently reducing the concentration of
the copper in the medium. In several embodiments, the actual and/or
bioavailable concentration of the copper in the medium to be less
than about 0.001 mg/L, less than about 0.5 micromolar, less than
about 0.1 mg per dry weight gram of the microorganisms, less than
about 100 mg/L, or less than about 1 mg/L. In several embodiments,
controlling the actual and/or bioavailable concentration of the
copper in the medium effects the production of microorganisms that
do not possess the gene encoding soluble methane monooxygenase or
express sMMO at reduced amounts. In other embodiments, the
organisms, have the gene, but the enzyme is not expressed.
[0030] In some embodiments, the nutrient is selected from the group
consisting of copper, methane, oxygen, phosphorus, potassium,
magnesium, boron, sodium, calcium, nitrogen, iron, carbon dioxide,
and combinations thereof, and step (c) comprises periodically or
permanently increasing, reducing, or maintaining the concentration
of the nutrient in the medium to effect the production of
microorganisms that do not possess the gene encoding soluble
methane monooxygenase. In several embodiments, the nutrient of step
(c) and the nutrient of step (d) are the same nutrient, while in
other embodiments, the of nutrient of step (c) and the nutrient of
step (d) are different nutrients.
[0031] In several embodiments, steps (a) through (d) are repeated a
plurality of times and the concentration of the one or more
microorganisms in the culture increases as the steps (a) through
(d) are repeated.
[0032] There is also provided, in several embodiments, a method for
converting a carbon-containing material into a polyhydroxyalkanoate
(PHA), the method comprising: (a) providing a microorganism
culture, (b) providing a medium comprising one or more nutrient
comprising a carbon-containing material that can be metabolized by
the culture, (c) controlling the concentration of the one or more
nutrient in the medium to cause the cellular replication of one or
more microorganisms in the culture, wherein the genetic material
encoding the ethylmalonyl-CoA pathway is present in the one or more
microorganisms, and wherein the expression of soluble methane
monooxygenase is reduced in the one or more microorganisms as
compared to a first instance of step (a), (d) controlling the
concentration of the one or more nutrient in the medium to cause
the culture to produce PHA, and (e) repeating steps (a) through
(d).
[0033] Copper concentrations can be reduced, in several
embodiments, as discussed herein, e.g., to concentrations less than
about 0.001 mg/L, less than about 0.5 micromolar, less than about
0.1 mg per dry weight gram of the microorganisms, less than about
100 mg/L, or less than about 1 mg/L. Also as discussed above, the
nutrients can be the same in steps (b) and (c), or alternatively
they may be different. In one embodiment, the nutrient of step (c)
is selected from the group consisting of methane, oxygen,
phosphorus, potassium, magnesium, boron, sodium, calcium, nitrogen,
iron, carbon dioxide, and combinations thereof and the nutrient of
step (d) is selected from the group consisting of methane, oxygen,
phosphorus, potassium, magnesium, boron, sodium, calcium, nitrogen,
iron, carbon dioxide, and combinations thereof, but is not the same
as the nutrient of step (c).
[0034] There is also provided, method for controlling the
functional characteristics of polyhydroxyalkanoate (PHA) produced
by a methanotrophic culture exposed to methane and one or more
non-methane materials that influence the metabolism of the culture,
the method comprising: (a) providing a methanotrophic culture in a
medium comprising one or more nutrients, (b) controlling the
concentration of one or more of the nutrients in the medium to
cause the culture to produce soluble methane monooxygenase (sMMO)
and/or particulate methane monooxygenase (pMMO), (c) controlling
the concentration of the one or more nutrients in the medium to
cause the culture to produce PHA, and (d) repeating steps (a)
through (c), wherein the concentration of sMMO relative to pMMO in
step (c) is substantially the same in each repetition, wherein one
or more functional characteristics of the PHA produced by the
culture are controlled in multiple PHA production repetitions, and
wherein the culture selectively generates microorganisms that
synthesize PHA at high efficiency.
[0035] In several embodiments, the concentration of the sMMO
relative to the pMMO in the culture is substantially the same in
step (c) in at least two consecutive repetitions. Advantageously,
this consistency results in a more defined and predictable PHA. For
example, in several embodiments, PHA produced by the culture
exhibits substantially the same of one or more of the following
characteristics in one or more the repetitions: molecular weight,
polydispersity, impact strength, elasticity, elongation, and/or
modulus. As discussed above, a variety of carbon sources may be
used. In some embodiments, non-methane sources are used, such as
carbon dioxide, volatile organic compounds, volatile fatty acids,
methanol, acetate, acetone, and acetic acid, formate, formaldehyde,
and formic acid, propane, ethane, oxygen, a carbon-containing
material that can be metabolized by the culture, or combinations
thereof.
[0036] In one embodiment, at least 60% of microorganisms in the
culture produce only the pMMO, while in one embodiment at least 60%
of microorganisms in the culture produce only the sMMO. In still
additional embodiments, the culture comprises an equal
concentration of the sMMO and the pMMO. In one embodiment, the
concentration of the sMMO is more than 2 times greater than the
concentration of the pMMO in the culture. In one embodiment, the
concentration of the sMMO is more than 5 times greater than the
concentration of the pMMO in the culture. In one embodiment, the
concentration of the sMMO is more than 10 times greater than the
concentration of the pMMO in the culture. In other embodiments, the
concentration of the pMMO is more than 2 times greater than the
concentration of the sMMO in the culture. In one such embodiment,
the concentration of the pMMO is more than 5 times greater than the
concentration of the sMMO in the culture.
[0037] There is also provided a method for modifying the functional
characteristics of a polyhydroxyalkanoate (PHA) material,
comprising the steps of: (a) providing a PHA and a biomass, (b)
subjecting the PHA and/or the biomass to a processing step in order
to render the at least a portion of the biomass miscible with the
PHA, (c) combining the PHA and the biomass in a mixture to form a
compound, (d) heating the compound to between 50 degrees Celsius
and 250 degrees Celsius, and (e) causing the biomass to effect a
functional modification of the PHA, wherein the functional
modification comprises plasticization, nucleation,
compatibilization, melt flow modification, strengthening, and/or
elasticizaton.
[0038] Advantageously, a variety of types of biomass may be used,
for example, one or more of methanotrophic, autotrophic, and
heterotrophic biomass are used in several embodiments. In one
embodiment, the processing comprises treating the PHA and/or the
biomass with one or more of the treatments selected from the group
consisting of: heat, shear, pressure, solvent extraction, washing,
filtration, centrifugation, sonication, enzymatic treatment, super
critical material treatment, cellular dissolution, flocculation,
acid and/or base treatment, drying, lysing, and chemical
treatment.
[0039] The biomass may be present at varied concentrations,
depending on the embodiment. For example in one embodiment, the
biomass is present in the compound at a concentration of more than
0.001%, while in other embodiments, the biomass is present in the
mixture at a concentration of more than 0.01%. In still other
embodiments, depending on the make-up of the biomass and the
characteristics of the PHA, greater or lesser concentrations may
also be used.
[0040] The functional characteristics of PHA may also be modified
through the melting and cooling of the PHA polymer in the presence
of a dual-miscible biomass agent and a second polymer by a method
provided in several embodiments herein, the method comprising,
comprising the steps of: (a) providing a first polymer, a biomass,
and a second polymer, wherein the first polymer is a PHA, (b)
subjecting the biomass to a processing step comprising heat,
pressure, solvent washing, filtration, centrifugation, super
critical solvent extraction, and/or shear, wherein the processing
step renders at least a portion of the biomass miscible with the
first polymer and the second polymer, (c) contacting the first
polymer with the biomass and the second polymer to form a compound,
(d) heating the compound to between 50 degrees Celsius and 250
degrees Celsius, thereby causing the biomass to effect a functional
modification of the first polymer, the second polymer, and the
combination of the first polymer and the second polymer, wherein
the functional modification comprises plasticization, nucleation,
compatibilization, melt flow modification, strengthening, and/or
elasticization.
[0041] The biomass may be present at varied concentrations,
depending on the embodiment. For example in one embodiment, the
biomass is present in the compound at a concentration of more than
0.001%, while in other embodiments, the biomass is present in the
mixture at a concentration of more than 0.01%. In still other
embodiments, depending on the make-up of the biomass and the
characteristics of the PHA, greater or lesser concentrations may
also be used. Advantageously, a variety of types of biomass may be
used, for example, one or more of methanotrophic, autotrophic, and
heterotrophic biomass are used in several embodiments.
[0042] Also provided for herein is a method for the synthesis of a
polyhydroxyalkanote (PHA) in a biomass material, comprising the
steps of: (a) providing a medium comprising a biomass capable of
metabolizing a source of carbon, and (b) increasing the
concentration of one or more nutrients in the medium to cause the
biomass to synthesize PHA or increase the synthesis rate of PHA
relative to the synthesis rate of non-PHA material.
[0043] Advantageously, a variety of types of biomass may be used,
for example, one or more of methanotrophic, autotrophic, and
heterotrophic biomass are used in several embodiments.
[0044] In several embodiments, the step of increasing the
concentration of a nutrient in the medium causes a reduction in the
rate of production of non-PHA biomass relative to the rate of
production of the PHA in the biomass. This relative increase in
efficiency (e.g., the reduction of metabolic resources spent
producing non-PHA biomass) advantageously increases the PHA
production capacity of the biomass material (e.g., by increasing
the overall output, increasing the per unit biomass output or
concentration).
[0045] In several embodiments, the nutrient is selected from the
group consisting of: ethylenediaminetetraacetic acid (EDTA), citric
acid, iron, copper, magnesium, manganese, zinc, chromium, nickel,
boron, molybdenum, calcium, potassium, boron, methane, phosphorus,
oxygen, nitrogen, carbon dioxide and combinations thereof.
[0046] There is also provided a method for the synthesis of a
polyhydroxyalkanote (PHA) in a biomass material, comprising the
steps of: (a) providing a medium comprising a biomass and one or
more nutrients, and (b) increasing the concentration of one or more
of the nutrients in the medium to cause the biomass to
metabolically synthesize PHA by using the biomass as a source of
carbon for the production of the PHA. In several embodiments, the
nutrient is selected from the group consisting of magnesium, iron,
copper, zinc, nickel, chromium, phosphorus, oxygen, calcium,
methane, carbon dioxide, hydroxyl ions, hydrogen ions, sulfate,
nitrogen, and combinations thereof. Various types of biomass may be
used, for example, one or more of methanotrophic, autotrophic,
methanogenic and heterotrophic biomass are used in several
embodiments
[0047] Complementary to the methods, processes, and systems for PHA
production, there is also provided herein a process for extracting
a polyhydroxyalkanoate from a PHA-containing biomass slurry
comprising PHA, non-PHA biomass, and a liquid, comprising: a)
controlling the pressure and temperature of the liquid to cause the
non-PHA biomass to become soluble in the liquid, and b) reducing
the amount of the liquid in the slurry.
[0048] Depending on the embodiment, the liquid in the slurry may be
one or more of methanol, water, carbon dioxide, or another a
solvent, super critical fluid, polymer, additive, plasticizer,
and/or other fluid (e.g., methylene chloride, acetone, methanol,
sodium hypochlorite, hypochlorite, chloroform, or dichloroethane).
Various pressures are used, depending on the embodiment, including
pressure above atmospheric pressure and pressure below atmospheric
pressure. In still additional embodiments, phases or sequential
changes between sub-atmospheric and supra-atmospheric pressures are
used. In conjunction with the pressure, temperatures may be varied,
in some embodiments, ranging between 0 and 250 degrees Celsius. In
other embodiments, a broader range of temperatures is used, for
example -40 degrees Celsius to about 500 degrees Celsius, including
about -20, about -4, about 4, about 20, about 37, about 100, about
150 about 200, about 300, or about 400 degrees Celsius. In one
embodiment, the temperature is between 0 and 200 degrees Celsius
and the pressure is between -30 mmHg and 30,000 psi. In several
embodiments, temperatures are maintained between 0 and 400 degrees
Celsius, 20 and 80 degrees Celsius, 10 and 100 degrees Celsius, 5
and 200 degrees Celsius, 100 and 200 degrees Celsius, or 0 and 300
degrees Celsius. It shall be appreciated that different
combinations of temperature and pressure may be used, depending on
the makeup of the slurry, the concentration of PHA in the slurry
and other factors. Also depending on the characteristics of the
slurry and other factors, the step of reducing the amount of the
liquid in the slurry comprises reducing the amount of the liquid in
the biomass slurry before, during, and/or after the step (a).
[0049] Reduction in the amount of the liquid can be achieved in a
variety of ways, used either alone or in combination (e.g.,
sequentially) such as for example, centrifugation, filtration,
distillation, spray drying, flash drying, lyophilization, air
drying, and/or oven drying. These processes can reduce the amount
of liquid in the slurry by about 0.1 to about 100%. In several
embodiments, the reduction is over 50%, over 90%, or over 95%.
Which method is chosen depends, in some embodiments, on the state
of the slurry at that time. Some methods are more efficient at
removal of liquid that others, and as such, may be better suited to
slurries with a higher liquid content.
[0050] In some, embodiments, it may be necessary to increase the
amount of liquid in the slurry (e.g., to effect a more efficient
downstream step), which depending on the embodiment can be done
before, during, and/or after the step (a). Various amounts of
liquid may be added, depending on the embodiment, for example such
that the solids concentration in the slurry of less than about 1
g/L, less than about 5 g/L, less than about 100 g/L, less than
about 250 g/L, less than about 500 g/L, less than about 750 g/L,
less than about 1000 g/L. or about 1300 g/L.
[0051] There is also provided a method for improving the functional
characteristics of a polyhydroxyalkanoate (PHA) material,
comprising the steps of: (a) providing a PHA, a biomass, and a
non-PHA polymer, (b) combining the PHA, the non-PHA polymer, and
the biomass in a mixture to form a compound, (c) heating the
compound to between 100 degrees Celsius and 250 degrees Celsius.
Depending on the embodiment, the biomass is present in the mixture
at a concentration of between about 0.1 and about 0.8%, between
about 0.1 and about 20%, between about 0.1 and about 40%, between
about 0.1 and about 60%, between about 0.1 and about 80%, and
overlapping ranges thereof.
[0052] In several embodiments the biomass is methanotrophic
biomass, while in other embodiments, the biomass is autotrophic
biomass, heterotrophic biomass, in combination, alone or with
methanotrophic and/or methanogenic biomass.
[0053] In several embodiments, the non-PHA polymer is one or more
of the following: polypropylene, polyethylene, polystyrene,
polycarbonate, Acrylonitrile butadiene styrene, Polyethylene
terephthalate, Polyvinyl chloride, Fluoropolymers, Liquid Crystal
Polymers, Acrylic, Polyamide/imide, Polyarylate, Acetal,
Polyetherimide, Polyetherketone, Nylon, Polyphenylene Sulfide,
Polysulfone, Cellulosics, Polyester, Polyurethane, Polyphenylene
oxide, Polyphenylene Ether, Styrene Acrylonitrile, Styrene Maleic
Anhydride, Thermoplastic Elastomer, Ultra High Molecular Weight
Polyethylene, Epoxy, Melamine Molding Compound, Phenolic,
Unsaturated Polyester, Polyurethane Isocyanates, Urea Molding
Compound, Vinyl Ester, Polyetheretherketone, Polyoxymethylene
plastic, Polyphenylene sulfide, Polyetherketone, Polysulphone,
Polybutylene terephthalate, Polyacrylic acid, Cross-linked
polyethylene, Polyimide, Ethylene vinyl acetate, Styrene maleic
anhydride, Styrene-acrylonitrile, Poly(methyl methacrylate),
Polytetrafluoroethylene, Polybutylene. Polylactic acid, Polyvinyl
chloride, Polyvinyl acetate, Polyvinyl acetate
co-Polyvinylpyrrolidone, Polyvinylpyrrolidone, Polyvinyl alcohol,
Cellulose, Lignin, Cellulose Acetate Butryate, Polypropylene,
Polypropylene Carbonate, Propylene Carbonate, Polyethylene, ethyl
alcohol, ethylene glycol, ethylene carbonate, glycerol,
polyethylene glycol, pentaerythritol, polyadipate, dioctyl adipate,
triacetyl glycerol, triacetyl glycerol-co-polyadipate, tributyrin,
triacetin, chitosan, polyglycidyl methacrylate, polyglycidyl
metahcrylate, oxypropylated glycerine, polyethylene oxide, lauric
acid, trilaurin, citrate esters, triethyl citrate, tributyl
citrate, acetyl tri-n-hexyl citrate, saccharin, boron nitride,
thymine, melamine, ammonium chloride, talc, lanthanum oxide,
terbium oxide, cyclodextrin, organophosphorus compounds, sorbitol,
sorbitol acetal, sodium benzoate, clay, calcium carbonate, sodium
chloride, titanium dioxide, metal phosphate, glycerol monostearate,
glycerol tristearate, 1,2-hydroxystearate, cellulose acetate
propionate, polyepichlorohydrin, polyvinylphenol, polymethyl
methacrylate, polyvinylidene fluoride, polymethyl acrylate,
polyepichlorohydrin-co-ethylene oxide, polyvinyl idene
chloride-co-acrylonitrile, polycyclohexyl methacrylate, cellulose
acetate butryate, cellulose, starch, cellulose acetate
butyrate-g-polyethyelene glycol, polyvinylidene chloride
co-acrylonitrile, polyvinyl acetate, polyethylene glycol
b-poly(e-caprolactone), R-PHB-OH, S-PHB-OH, polyphenol
poly(4,4'-dihydroxydiphenyl ester, 4-tert-butylphenol,
polyglutamate, acrylonitrile-butadiene-styrene, polystyrene,
styrene acrylonitrile, polyethylene 2,6-napthalate, polypropylene
oxide, polyethylene terepthalate, polybutylacrylate,
poly-y-benzyl-1-glutamate, starch-b-PPG-urethane, ethylene
propylene rubber-g-sodium acrylate EPR-g-SA, polypropylene
carbonate, polypropylene carbonate-co-polyvinyl acetate, natural
starch, starch adipate, starch-b-polyester-urethane,
starch-b-PEG-urethane, PHBV, polycaprolactone, PLLA,
polyoxymethylene, polyvinyl acetate-co-vinyl alcohol,
ethylene-propylene rubber, ethylene-vinyl-acetate copolymer,
synthetic poly3-hydroxybutyrate,
poly-3-hydroxybutyrate-co-poly-3-hydroxyvalerate,
poly-3-hydroxypropionate, polybutylene succinate-co-butylene
adipate, polybutylene succinate-co-caprolactone, phenol
poly(4,4'-dihydroxydiphenyl ester, and/or Polyvinylidene
chloride.
[0054] There is also provided, in several embodiments, a method for
the synthesis of polyhydroxyalkanote (PHA) in a biomass material,
comprising providing a medium comprising a biomass metabolizing a
source of carbon, and increasing or maintaining above a minimum,
the concentration of an element in the medium to cause the biomass
to synthesize PHA and/or increase the synthesis rate of PHA
relative to the synthesis rate of non-PHA material. In several
embodiments the PHA is polyhydroxybutyrate (PHB), while in other
embodiments other types of PHA are produced. In several
embodiments, the biomass is one or more microorganisms. In one
embodiment, the biomass comprises one or more recycled
microorganisms (e.g., those that have already been processed
through a PHA synthesis process). In one embodiment, the
microorganisms have been processed to remove at least a portion of
the PHA they produced in the prior synthesis process.
[0055] In several embodiments, the increase in the concentration of
an element in the medium above a minimum concentration (or
maintenance above that minimum) causes a reduction in the
concentration or production of sugar, lipids, nucleic acids,
saccharides, polysaccharides, methanobactin, and/or pigments in the
biomass relative to the concentration or production of PHA in the
biomass. In several embodiments, the element that is increased or
maintained is one or more of phosphorus, oxygen, or nitrogen. In
additional embodiments, the element is one or more of EDTA, citric
acid, iron, copper, magnesium, manganese, zinc, calcium, potassium,
boron, methane, or carbon dioxide.
[0056] In still additional embodiments, the PHA synthesis rate is
increased relative to the synthesis rate of PHA in the biomass in
the absence of the increase or maintenance above a minimum the
concentration of an element in the medium.
[0057] There is also provided a method for the synthesis of
polyhydroxyalkanote (PHA) in a biomass material, comprising the
steps of: (a) providing a medium comprising a biomass and an
element, and (b) maintaining above a minimum concentration or
increasing the concentration of the element in the medium to cause
the biomass material to metabolically synthesize PHA at the expense
of alternative biomass energy and/or carbon storage materials.
[0058] In several embodiments, the element that is increased (or
maintained) is one or more of phosphorus, oxygen, magnesium,
calcium, copper, iron, methane, carbon dioxide, hydroxyl ions,
hydrogen ions, or nitrogen. In some embodiments, the amount of
increase (or maintenance) that is required of one element is
altered when more than one element is manipulated. For example, if
phosphorous is increased in combination with another element, the
overall amount of phosphorous needed is reduced as compared to the
addition of phosphorous alone (e.g., the combination of elements
potentiates the effect).
[0059] In several embodiments, the biomass comprises one or more
microorganisms, such as for example, methanotrophic microorganisms,
heterotrophic microorganisms, autotrophic microorganisms,
methanogenic microorganisms, or combinations thereof.
[0060] More specifically, certain embodiments of the invention
provide high efficiency, high density, high PHA concentration
processes for the production of PHA from carbon-containing gases,
comprising the steps of: (a) providing a microorganism culture
comprising PHA-containing biomass, (b) removing a portion of the
PHA-containing biomass from the culture, (c) extracting a portion
of PHA from the removed culture to produce isolated PHA and
PHA-reduced biomass, (d) purifying the isolated PHA, and (e)
returning the PHA-reduced biomass to the culture to cause the
culture to convert the carbon within the PHA-reduced biomass into
PHA. In several embodiments, carbon output from the system is
wholly or substantially only in the form of PHA.
[0061] In several embodiments, a system for using a microorganism
culture to convert a carbon-containing gas into PHA at high
efficiencies is provided. Microorganisms are cultured using a
combination of one or more carbon-containing gases and PHA-reduced
biomass, or derivatives thereof, as sources of carbon to produce
PHA-containing biomass. A portion of the PHA-containing biomass is
then removed from the culture, and PHA is extracted from the
removed PHA-containing biomass to create substantially PHA-reduced
biomass and substantially isolated PHA.
[0062] Typically, PHA is present in the PHA-containing biomass of
gas-utilizing microorganisms at concentrations in the range of
about 5%-60%, and approximately 40-95% of the PHA-containing
biomass is discarded from the system following PHA extraction. In
some cases, PHA is present in gas-utilization microorganisms in the
range of about 1-90%, including at about 1%, 3%, 5%, 7%, 10%, 15%,
20%, 25%, 30%, 35%, 40%, 45%, 50%, 60%, 70%, 80%, or 90%, and
approximately 10-99% of the PHA-containing biomass is discarded
from the system following PHA extraction, including 99%, 97%, 95%,
93%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 40%, 30%, 20%, or
10% of the PHA-containing biomass. Rather than discarding the
remaining, e.g., 40-95% of the PHA-reduced biomass, in one
embodiment of the invention, the PHA-reduced biomass is returned
back to the microorganism culture to be regenerated as PHA by a
microorganism culture capable of utilizing PHA-reduced biomass, or
a derivative thereof, as a source of carbon for PHA production,
thereby creating a regenerative closed-loop polymerization system.
By using PHA-reduced biomass as a source of carbon for PHA
production in microorganisms growing as or in association with
gas-utilizing microorganisms, PHA can be produced from
carbon-containing gases at surprisingly and unexpectedly improved
carbon, energy, and chemical efficiencies, since carbon from
carbon-containing gases that would otherwise be discarded is
regenerated as PHA in a microorganism culture, and microorganisms
that produce PHA from carbon-containing gases at low concentrations
(e.g., 5-60% PHA by weight, or less than 70% PHA by weight) can, in
some embodiments, be utilized to produce PHA at significantly
increased carbon-to-PHA efficiencies. In some embodiments, the
regeneration step is repeated to form an essentially closed-loop
system. Thus, in some embodiments, the carbon output from the
system is at least 1%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%,
90%, 95%, or 99% PHA In other words, at least 1%, 5%, 10%, 20%,
30%, 40%, 50%, 70%, 80%, 90%, 95%, or 99% of the carbon entering
the system is converted into PHA. In other embodiments, 1-5%,
5-10%, 10-20%, 20-30%, 30%-40%, 40%-50%, 50%-60%, 60%-70%, 70%-80%,
80%-90%, 90%-95%, 95%-99% (and overlapping ranges thereof) of the
carbon entering the system is converted to PHA. By regenerating
PHA-reduced biomass as PHA in a microorganism culture, the
percentage of carbon from a carbon containing gas that is converted
to PHA is at least 2-fold, 3-fold, 4-fold, 5-fold, 6-fold, 7-fold,
8-fold, 9-fold, 10-fold, or greater than systems that do not employ
the regenerative or closed-loop system disclosed herein. In some
embodiments, the regeneration (e.g., return and/or recycling of the
PHA-reduced biomass) step is repeated at least 2, 3, 4, 5, 6, 7, 8,
9, or 10 (or more) times. In some embodiments, the regeneration
step is repeated until at least 90% to 95% of the carbon input into
the system is converted into PHA. In some embodiments, the
regeneration step is repeated as many times as desired to reach a
particular percentage conversion of carbon to PHA.
[0063] Several embodiments of the invention provide for the
production of PHA from carbon-containing gases at previously
unattainable energy, carbon, and chemical efficiencies by way of
providing a microorganism culture capable of metabolizing the
carbon within both a carbon-containing gas and PHA-reduced biomass,
manipulating the conditions of the culture to cause the culture to
produce PHA, removing a portion of PHA-containing biomass from the
culture, extracting the PHA within the removed PHA-containing
biomass to create substantially isolated PHA and substantially
PHA-reduced biomass, returning the PHA-reduced biomass to the
culture and contacting the PHA-reduced biomass with the culture to
cause the culture to metabolize the carbon within the PHA-reduced
biomass into PHA, and purifying the isolated PHA. Thus, an
advantage of several embodiments of the invention is the production
of PHA from carbon-containing gases at significantly improved
energy, carbon, and chemical efficiencies.
[0064] The process according to several embodiments disclosed
herein yields a range of surprising benefits over current gas-based
PHA production technologies. To begin, whereas the cell density of
gas-based fermentation processes is traditionally limited by the
mass transfer or diffusion rates of one or more factors, such as
light, oxygen, carbon dioxide, methane, or volatile organic
compounds, several embodiments disclosed herein enable the
generation of cell densities that significantly exceed cell
densities attainable in other current practices (e.g., by more than
1%, 10%, 20%, 30%, 50%, 80%, 100% or more), and thereby enables
cost-efficient system mixing, aeration, heat control, and
dewatering. For example, current methane-based PHA production
systems are known to be capable (based on cell morphology and mass
transfer characteristics) of generating approximately 60 g/L of
biomass with an overall PHA concentration of 55%, or 33 g/L PHA. In
contrast, in several embodiments of the invention, cell densities
of approximately 135 g/L with an overall PHA concentration of 70%,
or 94.5 g/L PHA are generated in a methane-based PHA production
system. In some embodiments, cell densities of approximately 10
g/L, 20 g/L, 30 g/L, 60 g/L, 75 g/L, 100 g/L, 125 g/L, 135 g/L, 150
g/L or greater are achieved. In some embodiments, overall PHA
concentration in such cultures ranges from approximately 1% to 20%,
20% to 30%, 30% to 55%, 55% to 60%, 65% to 70%, 70% to 80%, 80% to
90%, or 95% or greater, (and overlapping ranges thereof) result. In
several embodiments, such PHA concentration ranges represent
significant, unexpected, and surprising improvements over
traditional processes, e.g., processes that are limited to low cell
densities and/or PHA concentrations.
[0065] As a non-limiting example of the impact of this improvement
on energy efficiency, the energy required, on an energy
input-to-PHA output basis, to aerate, mix, and dewater a 135 g/L
solution with a PHA concentration of 70% by weight is 186% less
than the energy required to aerate, mix, and dewater a 60 g/L
microorganism solution comprising 40% PHA by weight. It shall be
appreciated that variations in the energy efficiency gains based on
the systems and processes disclosed herein may occur, depending on
the culture conditions, the strain or organisms used, and the
concentration and/or purity of an initial gas stream or other
carbon source. In several embodiments, even modest increases in
efficiency have substantial benefits. For example, the ability to
efficiently use an input gas having a low carbon concentration that
would not otherwise be useful in PHA production may prevent the
release of such a gas into the environment and/or reaction of the
gas with other atmospheric compounds, thereby reducing the adverse
impact of the low carbon concentration gas on the environment
(e.g., destruction of ozone, greenhouse gas emission, pollution,
etc.).
[0066] Additionally, whereas current gas-based PHA production
systems produce significant carbon losses as a result of the low
PHA inclusion concentrations of gas-utilizing microorganisms (e.g.,
a significant portion of carbon and energy input is lost as
biomass), several embodiments of the invention enable the
generation of overall carbon input yield efficiencies approaching
maximum substrate values; e.g., 100% carbon input-to-PHA yield,
minus respiration and/or downstream processing losses. In some
embodiments, at least 5%, at least 10%, at least 30%, at least 50%,
at least 70%, or at least 90%, carbon input-to-PHA yield is
achieved. It is one important advantage of several embodiments of
the invention that maximum carbon yield efficiencies are
unexpectedly and surprisingly generated in a PHA production system
employing gas-utilizing microorganisms, and particularly, in some
embodiments, in PHA production systems employing gas-utilizing
microorganisms that produce low biomass and/or PHA inclusion
densities.
[0067] In some embodiments, the microorganism culture is a mixed
culture, comprising heterotrophic microorganisms, methanotrophic
microorganisms, autotrophic microorganisms, bacteria, yeast, fungi,
algae, or combinations thereof. In other embodiments, the
microorganism culture may be one or more cultures (e.g., a
plurality of cultures). In some embodiments, the cultures are grown
in one or more bioreactors. In some embodiments, the bioreactors
utilize one or more culture conditions, including both aerobic and
anaerobic conditions. In some embodiments, the microorganism
culture converts PHA-reduced biomass to methane in an anaerobic
process and subsequently to PHA in an aerobic process, such that
PHA-reduced biomass is first anaerobically metabolized to methane
and then used as methane to produce biomass and PHA in a
methanotrophic culture.
[0068] In several embodiments, at least part of the microorganism
culture is a mixed culture capable of metabolizing
carbon-containing gases, including methane, carbon dioxide,
greenhouse gases, and/or various other volatile organic compounds,
into biomass and/or PHA. In some embodiments, the microorganism
culture comprises a two phase system of anaerobic and
anaerobic/aerobic metabolism, whereby carbon-containing gas is
produced in a first substantially anaerobic phase and subsequently
converted into PHA in a second phase, wherein the microorganism
culture in the first phase is substantially anaerobic and the
culture in the second phase is either anaerobic or aerobic, wherein
the two phases may be operated in one single vessel or in multiple
vessels.
[0069] In some embodiments, at least one or more of the
microorganisms are contacted with artificial and/or natural light
during one or more steps of the methods disclosed herein.
[0070] In some embodiments, at least one of more of the
microorganisms is contacted with dissolved oxygen during one or
more steps of the methods disclosed herein.
[0071] In some embodiments, at least one of more of the
microorganisms is cultured at atmospheric, sub-atmospheric, or
above-atmospheric pressures.
[0072] In some embodiments, at least one of more of the
microorganisms can utilize only a carbon-containing gas as a source
of carbon.
[0073] In several embodiments, at least one or more of the
microorganisms can utilize carbon derived from a PHA-reduced
biomass as a source of carbon. In other embodiments, at least one
or more of the microorganisms is a heterotrophic microorganism
capable of converting PHA-reduced biomass into, carbon dioxide,
oxygen, biomass, and/or PHA.
[0074] In several embodiments, at least one or more of the
microorganisms are cultured using carbon derived from both a
carbon-containing gas and a PHA-reduced biomass.
[0075] In some embodiments, the microorganism culture is a pure
culture. In some embodiments, the cultures are maintained in
semi-sterile or sterile conditions.
[0076] In some embodiments, the microorganism culture is a mixed,
non-sterile culture, including a naturally equilibrating consortium
of microorganisms.
[0077] In several embodiments, the microorganism culture is at
least partially comprised of genetically engineered
microorganisms.
[0078] In some embodiments, the microorganism culture is a mixed
culture comprising a combination of naturally occurring and
genetically engineered microorganisms.
[0079] In several embodiments, the PHA is removed from the
microorganism culture by solvent extraction, including solvent
extraction at temperatures ranging from 0.degree. C. to 200.degree.
C. and at pressures ranging from -30 psi to 30,000 psi.
[0080] In several embodiments, the PHA is removed from the
microorganism culture through the utilization of ketones, alcohols,
and/or chlorinated solvents.
[0081] In several embodiments, the PHA is removed from the
microorganism culture by hypochlorite digestion and/or
chlorine-based solvent extraction.
[0082] In several embodiments, the PHA is removed from the
microorganism culture by supercritical carbon dioxide
extraction.
[0083] In several embodiments, the PHA is removed from the
microorganism culture by protonic non-PHA cell material
dissolution.
[0084] In several embodiments, the PHA is partially removed from
the microorganism culture to create a PHA-rich phase and a PHA-poor
phase.
[0085] In several embodiments, the PHA is removed from the
microorganism culture to render the PHA substantially free of
non-PHA material, including substantially 5%, 10%, 20%, 30%-40%,
40%-50%, 50%-60%, 60%-70%, 70%-80%, 80-90%, 90-99% or more pure PHA
by weight.
[0086] In several embodiments, the PHA is removed from the
microorganism culture by manipulating the pH of the microorganism
culture.
[0087] In certain embodiments, at least one or more of the
microorganisms are contacted with methane, carbon dioxide, oxygen,
and/or a combination thereof.
[0088] In several embodiments, multiple culture vessels are
employed, such that microorganism growth, PHA synthesis,
PHA-reduced biomass metabolism, and PHA removal are carried out in
separate vessels.
[0089] In other embodiments, microorganism growth, PHA-reduced
biomass metabolism, and PHA synthesis occurs in a single
vessel.
[0090] In still other embodiments, microorganism growth and PHA
synthesis occur in a single vessel and PHA extraction is carried
out in one or more separate vessels.
[0091] In several embodiments of the process as disclosed herein,
PHA synthesis is regulated by manipulating, increasing, decreasing,
maintaining below a maximum threshold, or maintaining above a
minimum threshold the concentration of a material in the process,
wherein the material is one or more of oxygen, methane, carbon
dioxide, nitrogen, phosphorus, copper, iron, manganese, carbon,
magnesium, potassium, cobalt, aluminum, sulfate, chlorine, boron,
citric acid, and EDTA.
[0092] In several embodiments, the microorganism culture comprises
one or more strains of microorganisms collectively capable of
converting the carbon within a carbon-containing gas into cellular
biomass and the carbon from cellular biomass or methane into
PHA.
[0093] In several embodiments, the microorganisms are subjected to
filtration, centrifugation, settling, and/or density
separation.
[0094] In several embodiments, the isolated PHA and/or the
PHA-reduced biomass is subjected to filtration, centrifugation,
settling, and/or density separation.
[0095] In some embodiments, the processes disclosed herein further
comprise washing the recovered PHA with water or other liquid-based
agents or solvents to purify the PHA.
[0096] In several embodiments, the process further comprises
oxidizing the recovered PHA to purify the PHA.
[0097] In several embodiments, the process further comprises drying
the recovered PHA to remove volatiles such as water and/or one or
more solvents.
[0098] In several embodiments of the invention, methods for the
production of PHA are provided. In one embodiment, the method
comprises: (a) providing a microorganism culture comprising
PHA-containing biomass, (b) removing a portion of the
PHA-containing biomass from the culture, (c) extracting a portion
of the PHA from the removed PHA-containing biomass to produce
isolated PHA and PHA-reduced biomass, (d) returning the PHA-reduced
biomass to the culture to cause the culture to convert the carbon
within the PHA-reduced biomass into PHA, and (e) purifying the
isolated PHA.
[0099] In one embodiment, the microorganism culture utilizes the
PHA-reduced biomass, or derivatives thereof, such as carbon
dioxide, methane, or volatile organic acids, volatile fatty acids,
volatile organic compounds, non-methane organic compounds, and one
or more carbon-containing gas as a source of carbon. In one
embodiment, the gas is selected from the group consisting of
methane, carbon dioxide, volatile organic compounds, hydrocarbons,
and combinations thereof. In one embodiment, the gas is derived
from one or more sources from the group consisting of: landfills,
wastewater treatment plants, power production facilities or
equipment, agricultural digesters, oil refineries, natural gas
refineries, cement production facilities, and/or anaerobic organic
waste digesters.
[0100] In some embodiments, the carbon in the PHA-reduced biomass
is derived from one or more gases from the group consisting of:
methane, biogas, carbon dioxide, volatile organic compounds,
natural gas, wastewater treatment methane and VOCs, and
hydrocarbons.
[0101] In some embodiments, natural and/or artificial light is
utilized to induce the metabolism of the carbon dioxide by the
culture.
[0102] In some embodiments, the microorganism culture comprises one
strain, or a consortium of strains, of microorganisms, including
one or more microorganisms selected from the group consisting of:
bacteria, fungi, yeast, and algae, and combinations thereof.
[0103] In some embodiments, the microorganism culture comprises one
or more microorganisms from the group consisting of: methanotrophic
microorganisms, carbon-dioxide utilizing microorganisms, anaerobic
microorganisms, methanogenic microorganisms, acidogenic
microorganisms, acetogenic microorganisms, heterotrophic
microorganisms, autotrophic microorganisms, cyanobacteria, and
biomass-utilizing microorganisms, and combinations thereof.
[0104] In some embodiments, at least a portion of the microorganism
culture is naturally occurring. In some embodiments, at least a
portion of the microorganism culture is genetically engineered. In
some embodiments, naturally occurring and genetically engineered
microorganisms are both used in the culture. As used herein, the
term genetically engineered shall be given its ordinary meaning and
shall also refer to microorganisms which have been manipulated to
contain foreign (e.g., not from that microorganism) genetic
material and/or foreign proteins. In certain embodiments,
microorganisms are genetically manipulated to express one or more
enzymes or enzymatic pathways useful in PHA production. In certain
embodiments, microorganisms are genetically manipulated to express
a marker, enzyme, or protein useful allowing the selective
identification of the genetically engineered microorganisms.
[0105] In some embodiments, the microorganism culture is at least
partially maintained under above-atmospheric pressure.
[0106] In some embodiments, the PHA-containing biomass includes one
or more microorganism-derived materials selected from the group
consisting of: intracellular, cellular, and/or extracellular
material, including a polymer, amino acid, nucleic acid,
carbohydrate, lipid, sugar, polyhydroxyalkanoate, chemical, and/or
metabolic derivative, intermediary, and/or end-product. In some
embodiments, the PHA-containing biomass includes one or more
microorganism-derived materials selected from the group consisting
of: methane, volatile organic compounds, carbon dioxide, and
organic acids.
[0107] In one embodiment, the PHA-containing biomass contains less
than about 95% water, including less than about 90%, about 85%,
about 80%, about 75%, or about 70% water.
[0108] In some embodiments, the PHA-containing biomass is mixed
with one or more chemicals, including one or more chemicals from
the group consisting of: methylene chloride, acetone, ethanol,
methanol, ketones, alcohols, chloroform, and dichloroethane, or
combinations thereof.
[0109] In one embodiment, the PHA-containing biomass is processed
through homogenization, heat treatment, pH treatment, enzyme
treatment, solvent treatment, spray drying, freeze drying,
sonication, and microwave treatment, or combinations thereof.
[0110] In one embodiment, the PHA-reduced biomass includes the
PHA-containing biomass wherein at least a portion of the PHA has
been removed from the PHA-containing biomass. In another
embodiment, the PHA-reduced biomass includes methane, carbon
dioxide, and organic compounds produced from the PHA-reduced
biomass.
[0111] In some embodiments, the PHA-reduced biomass is subject to
dewatering, chemical treatment, sonication, additional PHA
extraction, homogenization, heat treatment, pH treatment,
hypochlorite treatment, microwave treatment, microbiological
treatment, including both aerobic and anaerobic digestion, solvent
treatment, water washing, solvent washing, and/or drying, including
simple or fractional distillation, spray drying, freeze drying,
and/or oven drying, or combinations thereof.
[0112] In several embodiments, the microorganism culture is
maintained in a sterile, semi-sterile, or non-sterile
environment.
[0113] In one embodiment, the PHA includes one or more PHA selected
from the group consisting of: polyhydroxybutyrate (PHB),
polyhydroxyvalerate (PHV), polyhydroxybutyrate-covalerate (PHB/V),
polyhydroxyhexanoate (PHHx), and short chain length (SCL), medium
chain length (MCL), and long chain length (LCL) PHAs.
[0114] In several embodiments, the metabolism, growth,
reproduction, and/or PHA synthesis of the culture is controlled,
manipulated, and/or affected by a growth medium. In some
embodiments, the bioavailable and/or total concentration of
nutrients within the growth medium, such as copper, iron, oxygen,
methane, carbon dioxide, nitrogen, magnesium, potassium, calcium,
phosphorus, EDTA, calcium, sodium, boron, zinc, aluminum, nickel,
sulfur, manganese, chlorine, chromium, molybdenum, and/or
combinations thereof are manipulated (e.g., increased, decreased,
or maintained) in order to control the metabolism, growth,
reproduction, and/or PHA synthesis of the culture In some
embodiments, a single nutrient in the growth medium is manipulated,
while in some embodiments, more than one nutrient in the growth
medium is manipulated to achieve the desired effect on the culture.
It shall be appreciated that manipulation of a nutrient (or other
component of a culture medium) is performed, in several
embodiments, in order to maintain the overall concentration of that
nutrient in the medium over time within a certain desired range
(e.g., if a nutrient is consumed by the microorganisms, a
"replacement" amount of that nutrient is added to the medium).
[0115] In one embodiment, the conversion of the PHA-reduced biomass
into the PHA is induced and/or controlled by manipulating the
composition of the medium. As discussed herein, the conversion of
PHA-reduced biomass into the PHA can be controlled in a
time-dependent manner to maximize the efficiency of conversion. In
some embodiments, conversion to PHA production is induced about
1-12 hours, about 5-15 hours, or about 8-24 hours after PHA-reduced
biomass is re-introduced into the culture. In some embodiments,
longer times, e.g., about 24 hours to several days or weeks, are
employed.
[0116] In one embodiment, the conversion of the PHA-reduced biomass
into the PHA is effected by manipulating the concentration one or
more elements within a medium selected from the group consisting
of: nitrogen, methane, carbon dioxide, phosphorus, oxygen,
magnesium, potassium, iron, copper, hydrogen, hydrogen ions,
hydroxyl, hydroxyl ions, sulfate, manganese, calcium, chlorine,
boron, zinc, aluminum, nickel, and/or sodium, and combinations
thereof.
[0117] Methods used in several embodiments disclosed herein to
control the concentration of elements within the medium include,
but are not limited to, automatic, continuous, batch, semi-batch,
manual, injection, solid feed, liquid, or other methods of
inputting one or more chemical into the medium, wherein the total
and/or bioavailable concentration of elements is increased,
decreased, maintained, adjusted, or otherwise controlled at one or
more time and/or physical chemical adjustment points.
[0118] According to several embodiments, additional methods to
adjust the total or bioavailable concentration of one or more
elements within a mineral media include, but are not limited to,
the directed precipitation, chelation, de-chelation, and
de-precipitation of elements. In one embodiment, the directed
precipitation or chelation of one or more element is utilized to
reduce the total or bioavailable concentration of one or more
element within a medium and thereby i) induce or increase PHA
production in a biomass and/or ii) control the metabolism of
microorganisms within a medium, including for the purpose of
controlling the specification and/or functionality of PHA. In one
embodiment, methanobactin is produced and/or utilized to chelate
copper and/or iron in order to impact the metabolism of
methanotrophic microorganisms.
[0119] In several embodiments, the concentration of one or more
elements within a growth culture medium is increased, controlled,
manipulated, or otherwise managed to induce or increase the rate of
PHA production in biomass, including a microorganism culture. In
one embodiment, the concentration of phosphorus within the medium
is increased to induce or increase the rate of PHA production in a
microorganism culture. In one embodiment, the concentration of an
element, e.g., phosphorus, carbon dioxide, iron, copper, oxygen,
methane, hydroxyl ions, hydrogen ions, and/or magnesium, within the
medium is manipulated or increased to cause a metabolic shift in
the microorganism culture, such that the production of non-PHA
materials by the culture using carbon and/or nitrogen sources
(e.g., nitrate, ammonia, ammonium, dinitrogen, urea, or amino
acids) is reduced, inhibited, or otherwise impacted to enhance PHA
production. In one embodiment, the concentration of phosphorus
within the medium is manipulated or increased to reduce the
utilization of nutrients, including nitrogen, oxygen, and/or
carbon, for the production of non-PHA materials by the culture. In
one embodiment, the concentration of phosphorus within the medium
is manipulated or increased to reduce the utilization of nutrients
for the production of non-PHA materials by the culture and induce
or increase the rate of PHA production in the culture.
[0120] In several embodiments, an increase in the concentration of
phosphorus causes a metabolic shift that favors the production of
PHA at the expense of other non-PHA materials, including a
reduction in the production of protein, nucleic acids,
polysaccharides, sugars, methanobactin, lipids, particularly but
not necessarily under growth-limiting conditions, including
nitrogen (e.g., nitrate, ammonia, ammonium, dinitrogen, urea, or
amino acids), oxygen, magnesium, potassium, iron, copper, or other
nutrient-limiting conditions.
[0121] In several embodiments, depending on the strain of
microorganism, an increase in the concentration of phosphorus above
about 0.00 ppm, 0.01 ppm, 0.02 ppm, 0.05 ppm, 0.10 ppm, 0.20 ppm,
0.50 ppm, 1.00 ppm, 1.25 ppm, 1.50 ppm, 1.75 ppm, 2.00 ppm, 2.20
ppm, 2.40 ppm, 3 ppm, 4 ppm 5 ppm, 6 ppm, 8 ppm, 20 mM, 30 mM, 40
mM, 50 mM, 60 mM, 70 mM, 80 mM, 90 mM, 100 mM, 110 mM, 120 mM, 140
mM, 200 mM, 400 mM, 600 mM, 800 mM, or 1000 mM, or overlapping
ranges between these concentrations, causes a reduction in the
utilization of carbon and/or nitrogen sources for the production of
non-PHA material, including proteins, non-PHA polymers, nucleic
acids, lipids, pigments, polysaccharides, methanobactin, and/or
carbon dioxide, and, under growth-limiting conditions, an increase
in the utilization of carbon sources for the production of PHA
material, as a result of metabolic changes in the culture and/or
chemical interactions between chemicals within the media and/or
culture induced by augmented concentrations of phosphorus. The
elevation of phosphorus concentrations as a method to induce or
increase the rate of PHA production in a biomass culture is
contrary to the conventional wisdom in the field, which suggests
that PHA production is induced or enhanced by reducing or
eliminating the concentration of elements, such as, e.g.,
phosphorus in the mineral medium. The addition or controlled
elevation of an element, such as, e.g., phosphorus to a biomass
system to induce or increase PHA production produces an unexpected
and surprising increase in PHA production in a biomass system. An
element such as, e.g., phosphorus may be added to the mineral media
using a variety of phosphorus sources, including phosphorus,
phosphate, phosphoric acid, sodium phosphate, disodium phosphate,
monosodium phosphate, and/or potassium phosphate, dissolved carbon
dioxide, Fe(II) iron, Fe(III) iron, copper sulfate, Fe-EDTA,
dissolved oxygen, dissolved methane, and/or magnesium sulfate,
among other potential sources. In one embodiment, copper
concentrations are manipulated or maintained above a minimum
concentration, for at least a period of time, in order to reduce
the concentration of methanobactin in the medium in order to
increase the purity of PHA produced by and/or extraction from a
methanotrophic microorganism culture.
[0122] In several embodiments of the invention, the concentrations
of dissolved gases, such as methane, oxygen, carbon dioxide, and/or
nitrogen, are manipulated to increase the rate of PHA production
relative to the rate of cellular production of non-PHA materials
and, specifically, to cause a reduction in the utilization of
carbon or nitrogen sources for the production of non-PHA material,
including proteins, non-PHA polymers, enzymes, nucleic acids,
lipids, pigments, polysaccharides, methanobactin, and/or carbon
dioxide, and, under some conditions, including growth-limiting
conditions, further cause an increase in the utilization of carbon
sources for the production of PHA material, as a result of
metabolic changes in the culture and/or chemical interactions
between chemicals within the media and/or culture induced by
augmented concentrations of one or more of such dissolved gases. In
one embodiment, the concentration of methane or dissolved methane
is manipulated to above at least 0.01 ppm, 0.05 ppm, 0.1 ppm, 0.5
ppm, 1.0 ppm, 1.5 ppm, 1.75 ppm, 2.0 ppm, 2.5 ppm, 3.0 ppm, 3.5
ppm, 4.0 ppm, 4.5 ppm, 5.0 ppm, 6.0 ppm, 7.0 ppm, 8.0 ppm, 10 ppm,
15 ppm, 20 ppm, 30 ppm, 50 ppm, 100 ppm, 200 ppm, 300 ppm, 500 ppm,
or 1000 ppm, or overlapping ranges between these concentrations to
reduce the production of non-PHA materials relative to the
production of PHA materials in a culture. In some embodiments, the
concentration of oxygen or dissolved oxygen is manipulated to above
at least 0.0001 ppm, 0.01 ppm, 0.05 ppm, 0.1, 0.2 ppm, 0.3 ppm, 0.4
ppm, 0.5 ppm, 0.6 ppm, 0.7 ppm, 0.8 ppm, 0.9 ppm, 1.0 ppm, 1.1 ppm,
1.2 ppm, 1.3 ppm, 1.4 ppm 1.5 ppm, 1.75 ppm, 2.0 ppm, 2.5 ppm, 3.0
ppm, 3.5 ppm, 4.0 ppm, 4.5 ppm, 5.0 ppm, 6.0 ppm, 7.0 ppm, 8.0 ppm,
10 ppm, 15 ppm, 20 ppm, 30 ppm, 50 ppm, 100 ppm, 200 ppm, 300 ppm,
500 ppm, 750 ppm, or 1000 ppm to reduce the production of non-PHA
materials relative to the production of PHA materials in a culture.
In one embodiment, the concentration of carbon dioxide or dissolved
carbon dioxide is manipulated to at least 0.01 ppm, 0.05 ppm, 0.1
ppm, 0.5 ppm, 1.0 ppm, 1.5 ppm, 1.75 ppm, 2.0 ppm, 2.5 ppm, 3.0
ppm, 3.5 ppm, 4.0 ppm, 4.5 ppm, 5.0 ppm, 6.0 ppm, 7.0 ppm, 8.0 ppm,
10 ppm, 15 ppm, 20 ppm, 30 ppm, 50 ppm, 100 ppm, 200 ppm, 500 ppm,
1000 ppm, 1500 ppm, 2000 ppm, 3000 ppm, 5000 ppm, 10,000 ppm,
20,000 ppm, or overlapping ranges of these concentrations to reduce
the production of non-PHA materials relative to the production of
PHA materials in a culture. In some embodiments, the concentration
of nitrogen or dissolved nitrogen is manipulated to above at least
0.01 ppm, 0.05 ppm, 0.1 ppm, 0.5 ppm, 1.0 ppm, 1.5 ppm, 1.75 ppm,
2.0 ppm, 2.5 ppm, 3.0 ppm, 3.5 ppm, 4.0 ppm, 4.5 ppm, 5.0 ppm, 6.0
ppm, 7.0 ppm, 8.0 ppm, 10 ppm, 15 ppm, 20 ppm, 30 ppm, or 50 ppm or
ranges between these concentrations to reduce the production of
non-PHA materials relative to the production of PHA materials in a
culture. In several embodiments, an increase in the concentration
of methane, oxygen, carbon dioxide, and/or nitrogen causes a
metabolic shift that favors the production of PHA at the expense of
other non-PHA materials, including a reduction in the production of
protein, nucleic acids, polysaccharides, sugars, and/or lipids,
particularly, but not necessarily, under growth-limiting, that is,
PHA synthesis, conditions.
[0123] In some embodiments, the PHA is at least partially removed
from the PHA-containing biomass or otherwise purified using one or
more extraction agents or mechanisms selected from the group
consisting of: methylene chloride, acetone, ethanol, methanol,
dichloroethane, supercritical carbon dioxide, sonication,
homogenization, water, heat, distillation, spray drying, freeze
drying, centrifugation, filtration, enzymes, polymers, surfactants,
co-solvents, hydrolyzers, acids, bases, hypochlorite, peroxides,
bleaches, ozone, EDTA, miscible agents, and/or combinations
thereof.
[0124] In one embodiment, the extraction process is substantially
carried out at intracellular temperatures less than 100.degree. C.
In other embodiments, temperatures for extraction range from about
10.degree. C. to 30.degree. C., from about 30.degree. C. to
50.degree. C., from about 50.degree. C. to 70.degree. C., from
about 70.degree. C. to 90.degree. C., from about 90.degree. C. to
about 120.degree. C., from about 100.degree. C. to about
140.degree. C., from about 20.degree. C. to 150.degree. C., or from
about 120.degree. C. to about 200.degree. C., or higher. In another
embodiment, cells are reused for polymerization following the
extraction process as viable cells.
[0125] In some embodiments, PHA-containing biomass is treated with
one or more chemical treatment steps to control, modify, or
increase the concentration or functional characteristics (e.g.,
molecular weight, monomer composition, melt flow profile, purity,
non-PHA residuals concentration, protein concentration, DNA
concentration, antibody concentration, antioxidant concentration)
of PHA in a PHA-containing material or biomass.
[0126] As used herein, the terms "functional properties" and
"functional characteristics" shall be given their ordinary meanings
and shall also refer to the specification, features, qualities,
traits, or attributes of PHA. The functional characteristics of the
generated PHA include, but are not limited to molecular weight,
polydispersity and/or polydispersity index, melt flow and/or melt
index, monomer composition, co-polymer structure, melt index,
non-PHA material concentration, purity, impact strength, density,
specific viscosity, viscosity resistance, acid resistance,
mechanical shear strength, flexular modulus, elongation at break,
freeze-thaw stability, processing conditions tolerance,
shelf-life/stability, hygroscopicity, and color. As used herein,
the term "polydispersity index" (or PDI), shall be given its
ordinary meaning and shall be considered a measure of the
distribution of molecular mass of a given polymer sample
(calculated as the weight average molecular weight divided by the
number average molecular weight). Advantageously, several
embodiments of the processes disclosed herein may be carried out in
sterile, semi-sterile, or non-sterile conditions. In several
embodiments, consistency in more than one of these functional
properties is achieved. For example, in some embodiments,
consistent molecular weight, polydispersity, and combinations
thereof are achieved. In one embodiment, temperature is used to
control, modify, reduce, or optimize the molecular weight,
polydispersity, melt flow, and other characteristics of PHA. In one
embodiment, temperature and/or time is used to control the
molecular weight of PHA between the range of about 5,000,000 and
about 10,000 Daltons. In several embodiments the molecular weight
of PHA ranges between about 5,000,000 and about 2,500,000 Daltons,
between about 2,500,000 and about 1,000,000 Daltons, between about
1,000,000 and about 750,000 Daltons, between about 750,000 and
about 500,000 Daltons, between about 500,000 and about 250,000
Daltons, between about 250,000 and about 100,000 Daltons, between
about 100,000 and about 50,000 Daltons, between about 50,000 and
about 10,000 Daltons, and overlapping ranges thereof. In one
embodiment, a slurry comprising PHA-containing biomass and a
culture media is subject to one or more water removal steps or
water addition steps to increase the concentration of PHA in a
PHA-containing biomass. In one embodiment, the water removal step
is a dewatering step or combination of dewatering steps, such as
centrifugation, filtration, spray drying, flash drying, and/or
chemical dewatering (e.g., with acetone, ethanol, or methanol, or
combinations thereof), wherein at least a portion of the water
concentration relative to the concentration of PHA-containing
biomass in the slurry is reduced. In one embodiment, a temperature
and/or pressure control step is carried out under atmospheric (0
psi), sub-atmospheric (-100-0 psi), or above-atmospheric pressure
(e.g., 0-30,000 psi) and at temperature conditions wherein the
PHA-containing biomass, or the liquid in and/or around the
PHA-containing biomass, is maintained, for at least a period of
time, at a temperature ranging from -30 to 10 degrees Celsius, 10
degrees Celsius to 100 degrees Celsius, 10 degrees Celsius to 150
degrees Celsius, 20 degrees Celsius to 250 degrees Celsius, and/or
100 to 200 degrees Celsius, including overlapping ranges thereof.
In one embodiment, the PHA-containing biomass is subject to a
dewatering step before or after the temperature and/or pressure
control step, wherein the dewatering step is centrifugation,
filtration, and/or spray drying, to produce a fully or partially
de-watered PHA-containing biomass or PHA-containing biomass slurry,
wherein the water concentration of the dried slurry is less than
99%, 95%, 80%, 60%, 40%, 30%, 20%, 10%, 5%, 3%, 2%, or 1% water. In
one embodiment, the PHA-containing biomass is subject to a
temperature control step, wherein the water or liquid chemicals
within and/or around the biomass is controlled and maintained at a
temperature of at least -30, -10, -5, -4, -3, -2, -1, 0, 10, 20,
30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170,
180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300
degrees Celsius or ranges between those temperatures. In one
embodiment, the PHA-biomass is not dried prior to such temperature
control step. In one embodiment, the PHA-containing biomass is
dried or de-watered prior to such temperature control step. In one
embodiment, the PHA-containing biomass is filtered or centrifuged
following the temperature control step. In one embodiment, the
PHA-containing cell slurry is not dewatered, for example, by
centrifugation or other drying mechanism, prior to the temperature
control step. In one embodiment, a mechanism to impart shear onto
or into the PHA-containing biomass is coupled with a temperature
control step; such shear may be imparted in the form of one or more
shear induction mechanisms including, but not limited to e.g., a
centrifugal pump, agitator, blender, high shear mixer, vortex
mixer, etc. In one embodiment, the PHA-containing biomass is
dewatered in one step and the treated PHA-containing biomass is
further dewatered in one or more additional steps. In one
embodiment, the PHA-containing biomass is dewatered, water and/or
other chemicals are added and temperature and/or pressure is
controlled, and the treated PHA-containing biomass is further
dewatered and/or purified. In one embodiment, the water and/or
chemicals within, around, and/or added to the PHA-containing
biomass is temperature and/or pressure controlled, and the treated
PHA-containing biomass is further purified in one or more
purification steps. In one embodiment, the temperature control step
process time is approximately 1 second, 5 seconds, 10 seconds, 25
seconds, 60 seconds, 2 minutes, 5 minutes, 20 minutes, 45 minutes,
1 hour, 2 hours, 5 hours, 6 hours, 7 hours, 12 hours, 15 hours, 24
hours, 36 hours, or 48 hours, or ranges between those times. In one
embodiment, inorganic materials may be used to effect PHA
modification, purification, or extraction, including carbon dioxide
and dinitrogen. In one embodiment, the PHA-containing slurry or
biomass is treated with carbon dioxide under elevated temperatures
and pressures, including supercritical ranges, to induce PHA
extraction or functional modification of PHA. In one embodiment,
solvents, including methylene chloride, enzymes, super critical
fluids, acetone, chloroform, dichloroethane, ethanol, plasticizers,
acids, bases, polymers, and/or methanol are used, alone or in
combination, in conjunction with any of the above steps to improve
efficiency, including increasing purity, recovery, extractability,
solubility, reaction speed, odor, color, recyclability,
biodegradability, toxicity, endotoxin removal rate, and the like.
In one embodiment, solvents or extraction materials may be used or
recycled for biomass production, biogas production, and/or PHA
synthesis.
[0127] In one embodiment, chemicals are added to a PHA-containing
biomass to cause the crystallization of PHA. In one embodiment,
methylene chloride, carbon dioxide, acetone, water, dichloroethane,
or methanol may be added to a PHA-containing biomass in order to
induce the crystallization of PHA in the PHA-containing biomass. In
some embodiments, this step may be useful for the downstream
processing of PHA, wherein crystallized PHA is less prone than
amorphous PHA to degradation, including molecular weight loss, when
contacted with extraction chemicals, including solvents, enzymes,
acids, bases, and bleach. In one embodiment, silicon, silica,
derivatives thereof, and/or chemicals containing silicon may be
added to the PHA-containing biomass in order to impact the
metabolic status of the culture, and thereby control the functional
characteristics of the PHA produced by the culture, including one
or more of the following: molecular weight, monomer composition,
co-polymer structure, melt index, and polydispersity.
[0128] In one embodiment, the removal of the PHA from the culture
causes the culture to be temporarily deactivated, such that the
culture, or elements thereof, may be further used for the synthesis
of PHA. In certain embodiments, deactivation is beneficial because
it allows for the delay of PHA production, transfer of material to
another production area, and the like. In some embodiments,
deactivation allows a tailored PHA production time frame. In some
embodiments, the reuse of cells for polymerization is beneficial
because it avoids or reduces the need to produce new biomass prior
to polymerization, thereby reducing the carbon, chemical, and
energy requirement of PHA production.
[0129] In one embodiment, a PHA produced according to the several
embodiments described herein is provided.
[0130] In several embodiments, processes for the production of PHA
from a carbon-containing gas are provided. In one embodiment, the
process comprises the steps of: a) providing a growth medium
comprising a microorganism culture capable of utilizing the carbon
within one or more carbon-containing gas and PHA-reduced biomass,
b) manipulating the medium to cause the culture to produce PHA, c)
removing at least a portion of the PHA within the culture to create
substantially isolated PHA and substantially PHA-reduced biomass,
d) purifying the isolated PHA, and e) returning the PHA-reduced
biomass to the culture to cause the culture to metabolize the
carbon within the PHA-reduced biomass into PHA.
[0131] In one embodiment, the carbon-containing gas is selected
from the group consisting of: methane, carbon dioxide, toluene,
xylene, butane, ethane, methylene chloride, acetone, ethanol,
propane, methanol, vinyl chloride, volatile organic compounds,
hydrocarbons, and combinations thereof. As discussed herein, in
some embodiments, non-gaseous carbon-containing material can be
used, at least in part, for the production of PHA.
[0132] In one embodiment, the invention comprises manipulating the
concentration of elements, e.g., copper, iron, phosphorus, oxygen,
methane, carbon dioxide, in the culture medium to control the
concentration of sMMO and/or pMMO produced by a methanotrophic
culture in order to control the relative ratio of sMMO to pMMO in
the culture, including over time and over multiple growth and
polymerization cycles, and thereby control one or more of the
growth conditions, metabolic status, metabolic disposition, and/or
specification of PHA (e.g., molecular weight, polydispersity, melt
flow, monomer composition, etc.) produced by the culture, including
over time. In some embodiments, sMMO is expressed in a range
between about 0% and 100% of a methanotrophic culture by dry cell
weight, as a percentage of microorganisms expressing sMMO, or as a
percentage of total MMO expressed by one or more methanotrophic
cells, including between 0% and 1%, between about 1% and about 2%,
between about 2% and about 3%, between about 3% and about 5%,
between about 5% and about 10%, between about 10% and about 20%,
between about 20% and about 30%, between about 30% and about 50%,
between about 50% and about 70%, between about 70% and about 80%,
between about 80% and about 90%, between about 90% and about 95%,
between about 95% and about 100%, and overlapping ranges thereof.
Simultaneously, or independently, in some embodiments, pMMO is
expressed in a range between about 0% and 100% of a methanotrophic
culture by dry cell weight, as a percentage of microorganisms
expressing pMMO, or as a percentage of total MMO expressed by one
or more methanotrophic cells, including between 0% and 1%, between
about 1% and about 2%, between about 2% and about 3%, between about
3% and about 5%, between about 5% and about 10%, between about 10%
and about 20%, between about 20% and about 30%, between about 30%
and about 50%, between about 50% and about 70%, between about 70%
and about 80%, between about 80% and about 90%, between about 90%
and about 95%, between about 95% and about 100%, and overlapping
ranges thereof. In some embodiments, the ratio of sMMO to pMMO
produced in a methanotrophic culture is controlled to control the
specification of PHA produced by a culture. In some embodiments,
the relative weight ratio of sMMO to pMMO in a methanotrophic
culture is at least or approximately 0 to 1, approximately
0.0000001 to 1, approximately 0.0001 to 1, approximately 0.001 to
1, approximately 0.01 to 1, approximately 0.1 to 1, approximately 1
to 1, approximately 2 to 1, approximately 3 to 1, approximately 5
to 1, approximately 10 to 1, approximately 15 to 1, approximately
20 to 1, approximately 25 to 1, approximately 30 to 1,
approximately 35 to 1, approximately 50 to 1, approximately 65 to
1, approximately 70 to 1, approximately 80 to 1, approximately 90
to 1, approximately 95 to 1, approximately 98 to 1, approximately
99 to 1, approximately 100 to 1, approximately 1000 to 1,
approximately 10,000 to 1, approximately 100,000 to 1, or
approximately 1,000,000 to 1, respectively. In some embodiments,
the relative weight ratio of pMMO to sMMO in a methanotrophic
culture is approximately 0 to 1, approximately 0.0000001 to 1,
approximately 0.0001 to 1, approximately 0.001 to 1, approximately
0.01 to 1, approximately 0.1 to 1, approximately 1 to 1,
approximately 2 to 1, approximately 3 to 1, approximately 5 to 1,
approximately 10 to 1, approximately 15 to 1, approximately 20 to
1, approximately 25 to 1, approximately 30 to 1, approximately 35
to 1, approximately 50 to 1, approximately 65 to 1, approximately
70 to 1, approximately 80 to 1, approximately 90 to 1,
approximately 95 to 1, approximately 98 to 1, approximately 99 to
1, approximately 100 to 1, approximately 1000 to 1, approximately
10,000 to 1, approximately 100,000 to 1, or approximately 1,000,000
to 1.
[0133] In some embodiments, by controlling the relative
concentrations of sMMO and pMMO produced by a culture of
methanotrophic microorganisms, it is possible to control the
metabolic status of the culture and thereby control the type (and
characteristics) of PHA and other cellular material produced by the
culture, particularly in the presence of one or more of the
following: volatile organic compounds, fatty acids, volatile fatty
acids, methanol, formate, acetone, acetate, acetic acid, formic
acid, dissolved carbon dioxide, dissolved methane, dissolved
oxygen, carbon-containing materials, ammonia, ammonium, and other
elements or compounds that impact the metabolism of a culture of
methanotrophic microorganisms in a certain manner according to the
relative concentration of sMMO or pMMO in such a culture. In some
embodiments, sMMO and/or pMMO is expressed in a range between about
0% and 100% of a methanotrophic culture by dry cell weight, as a
percentage of microorganisms expressing sMMO or pMMO, or as a
percentage of total MMO expressed by one or more methanotrophic
cells, including between 0% and 1%, between about 1% and about 2%,
between about 2% and about 3%, between about 3% and about 5%,
between about 5% and about 10%, between about 10% and about 20%,
between about 20% and about 30%, between about 30% and about 50%,
between about 50% and about 70%, between about 70% and about 80%,
between about 80% and about 90%, between about 90% and about 95%,
between about 95% and about or 100%, and overlapping ranges thereof
prior to, during, throughout, or after a PHA production phase.
[0134] In one embodiment, sMMO is not expressed, or is expressed in
low amounts (e.g., less than about 35%, about 25%, about 15%, about
5%, about 3% or about 1%), in a methanotrophic culture prior to,
during, throughout, or after a PHA production phase. In some
embodiments, the directed or controlled absence or reduction of
sMMO in a methanotrophic culture producing PHA, particularly in the
presence of non-methane organic compounds that can be metabolized
by methanotrophic microorganisms, engenders PHA production
stability, consistency, and control by selectively shielding
against the metabolism of one or some or many non-methane organic
compounds that might otherwise be metabolized in the presence of
sMMO, which enables the metabolism of a larger group of non-methane
compounds than pMMO. Similarly, in one embodiment, pMMO is not
expressed, or is expressed in low amounts (e.g., less than about
35%, about 25%, about 15%, about 5%, about 3% or about 1%), in a
methanotrophic culture prior to, during, throughout, or after a PHA
production phase. In some embodiments, the directed or controlled
absence or reduction of pMMO in a methanotrophic culture producing
PHA, particularly in the presence of non-methane organic compounds
that can be metabolized by methanotrophic microorganisms, engenders
PHA production stability, consistency, and control by selectively
inducing or promoting the metabolism of one or some or many
non-methane organic compounds that might otherwise be metabolized
using pMMO. Further, in some methanotrophic cultures, sMMO promotes
PHA synthesis at high intracellular concentrations by reducing
cellular production of non-PHA materials, particularly as compared
to PHA synthesis using pMMO. By controlling the concentration of
sMMO relative to pMMO in a methanotrophic microorganism culture in
the presence of methane and/or non-methane organic compounds,
including VOCs, volatile fatty acids, acetone, formate, ethane,
propane, it is possible to control the specification or type of PHA
produced by the culture, including the molecular weight,
polydispersity, and other similar functional characteristics as
disclosed herein. In some embodiments, it is preferable to maintain
the concentration of copper in the culture media in order to
promote sMMO production. In some embodiments, the production of
sMMO in many, most, or substantially all of the methanotrophic
cells enables the culture to produce more PHA when subject to a
nutrient limiting step than would otherwise be produced if the
relative ratio of pMMO in the culture was higher prior to the
nutrient limiting step. In some embodiments, it is preferable to
maintain the concentration of copper in the culture media in order
to promote pMMO production. In some embodiments, the production of
pMMO in many, most, or substantially all of the methanotrophic
cells enables the culture to produce more PHA when subject to a
nutrient limiting step than would otherwise be produced if the
relative ratio of sMMO in the culture was higher prior to the
nutrient limiting step. In one embodiment, one or more
methanotrophic cells or cultures are subject to repeated growth and
PHA synthesis cycles or steps, wherein the relative concentration
of sMMO to pMMO in the cells or cultures is controlled or caused to
remain approximately similar or substantially the same (e.g.,
within about 5% to about 10%, with about 10% to about 20%, within
about 20% to about 30%, within about 30% to about 40%, within about
40% to about 50%, within about 50 to about 75%) or the same in each
new cycle or step in order to control or keep substantially the
same (e.g., within about 5% to about 10%, with about 10% to about
20%, within about 20% to about 30%, within about 30% to about 40%,
within about 40% to about 50%, within about 50% to about 75% across
production runs) the specification, characteristics, and/or
functionality (e.g., molecular weight, monomer composition, melt
flow index, polydispersity, non-PHA material concentration, and/or
purity) of the PHA produced by or extractable from the culture or
cultures in each new or repetitive cycle with the same or new
cells.
[0135] In one embodiment, the invention comprises a PHA comprising
carbon derived from PHA-reduced biomass, wherein the PHA-reduced
biomass comprises carbon derived from one or more carbon-containing
gasses and/or one or more additional sources of carbon (either
gaseous or non-gaseous). In one embodiment, PHA is co-mingled
and/or melted with PHA-reduced biomass to improve the functional
characteristics of the PHA. In one embodiment, PHA is co-mixed
and/or melted with PHA-removed biomass and/or microorganism biomass
to improve the functional characteristics of PHA. In one
embodiment, the percentage of non-PHA microorganism biomass
included in a PHA, PHA compound, or PHA mixture is about 0.00001%
to about 0.001%, about 0.001% to about 0.01%, about 0.01% to about
0.1%, to about 0.1% to about 0.5%, about 0.5% to about 1%, about
1%, to about 2%, about 2% to about 3%, about 3% to about 5%, about
5% to about 7%, about 7% to about 10%, about 10% to about 15%,
about 15% to about 20%, about 20% to about 30%, about 30% to about
40%, about 40% to about 50%, about 50% to about 60%, about 60% to
about 70%, about 70% to about 80%, about 80% to about 90%, about
90% to about 98%, about 98% to about 99.99%, and overlapping ranges
thereof. In some embodiments, the inclusion of microorganism
biomass to a PHA improves the functional characteristics of a PHA
by acting as one or more of the following: nucleating agent,
plasticizer, compatibilizer, melt flow modifier, mold release
agent, filler, strength modifier, elasticity modifier, or density
modifier. In some embodiments, the microscopic size of
microorganism biomass, including nucleic acids and proteins, is
particularly and surprisingly effective as a functionalization
agent for PHA. In some embodiments, microorganism biomass acts as a
surprisingly effective compatibilizer for PHA and non-PHA polymers,
such as polypropylene and polyethylene. In one embodiment, the
biomass is subject to a processing step in order to make the
biomass, or at least a portion of the biomass, miscible with the
PHA and/or non-PHA polymer, which yields unexpected and surprising
functional improvement of the biomass as a blend component. Such
processing step may include: heat, shear, pressure, solvent
extraction, washing, filtration, centrifugation, sonication,
enzymatic treatment, super critical material treatment, cellular
dissolution, flocculation, acid and/or base treatment, drying,
lysing, and/or chemical treatment, wherein said chemicals may
include solvents, cell dissolution agents, cell metabolizing
agents, polymers, plasticizers, compatibilization agents,
nucleating agents, including processing steps that enable PHA
contained in said biomass to become miscible with said biomass
and/or other materials, including a second polymer or carrier
agent. In one embodiment, microorganism biomass is mixed with a PHA
to modify one or more of the nucleation, plasticization,
compatibilization, melt flow, density, strength, elongation,
elasticity, mold strength, mold release, and/or bulk density
characteristics of a PHA, which may be melted, extruded, film
blown, die cast, pressed, injection molded, or otherwise processed.
In one embodiment, PHA is partially or not removed from
PHA-containing microorganism biomass prior to melt processing,
e.g., extrusion, injection molding, etc. In one embodiment, non-PHA
biomass parts or materials are caused to remain with PHA derived
from a PHA-containing biomass in order to modify or control the
functional characteristics of a PHA material. In one embodiment,
PHA is present in PHA-containing biomass at a concentration ranging
from 1-99.99999%, 1-99.99%, 1-99%, 5-99%, 10-99%, 20-99%, 30-99%,
50-99%, 70-99%, 80-99%, 90-99%, 95-99%, 98-99%, and overlapping
ranges thereof. In one embodiment, PHA, microorganism biomass,
and/or one or more non-PHA material, polymer, or thermoplastic are
mixed, melted, or processed together. In one embodiment, the
non-PHA polymer or material consists of one or more of the
following solvents, cell dissolution agents, cell metabolizing
agents, polymers, plasticizers, compatibilization agents, miscible
agents, and nucleating agents: polypropylene, polyethylene,
polystyrene, polycarbonate, Acrylonitrile butadiene styrene,
Polyethylene terephthalate, Polyvinyl chloride, Fluoropolymers,
Liquid Crystal Polymers, Acrylic, Polyamide/imide, Polyarylate,
Acetal, Polyetherimide, Polyetherketone, Nylon, Polyphenylene
Sulfide, Polysulfone, Cellulosics, Polyester, Polyurethane,
Polyphenylene oxide, Polyphenylene Ether, Styrene Acrylonitrile,
Styrene Maleic Anhydride, Thermoplastic Elastomer, Ultra High
Molecular Weight Polyethylene, Epoxy, Melamine Molding Compound,
Phenolic, Unsaturated Polyester, Polyurethane Isocyanates, Urea
Molding Compound, Vinyl Ester, Polyetheretherketone,
Polyoxymethylene plastic, Polyphenylene sulfide, Polyetherketone,
Polysulphone, Polybutylene terephthalate, Polyacrylic acid,
Cross-linked polyethylene, Polyimide, Ethylene vinyl acetate,
Polyvinyl chloride, Polyvinyl acetate, Polyvinyl acetate
co-Polyvinylpyrrolidone, Polyvinylpyrrolidone, Polyvinyl alcohol,
Cellulose, Lignin, Cellulose Acetate Butryate, Polypropylene,
Polypropylene Carbonate, Propylene Carbonate, Polyethylene, ethyl
alcohol, ethylene glycol, ethylene carbonate, glycerol,
polyethylene glycol, pentaerythritol, polyadipate, dioctyl adipate,
triacetyl glycerol, triacetyl glycerol-co-polyadipate, tributyrin,
triacetin, chitosan, polyglycidyl methacrylate, polyglycidyl
metahcrylate, oxypropylated glycerine, polyethylene oxide, lauric
acid, trilaurin, citrate esters, triethyl citrate, tributyl
citrate, acetyl tri-n-hexyl citrate, saccharin, boron nitride,
thymine, melamine, ammonium chloride, talc, lanthanum oxide,
terbium oxide, cyclodextrin, organophosphorus compounds, sorbitol,
sorbitol acetal, sodium benzoate, clay, calcium carbonate, sodium
chloride, titanium dioxide, metal phosphate, glycerol monostearate,
glycerol tristearate, 1,2-hydroxystearate, cellulose acetate
propionate, polyepichlorohydrin, polyvinylphenol, polymethyl
methacrylate, polyvinylidene fluoride, polymethyl acrylate,
polyepichlorohydrin-co-ethylene oxide, polyvinyl idene
chloride-co-acrylonitrile, polycyclohexyl methacrylate, cellulose
acetate butryate, cellulose, starch, cellulose acetate
butyrate-g-polyethyelene glycol, polyvinylidene chloride
co-acrylonitrile, polyvinyl acetate, polyethylene glycol
b-poly(e-caprolactone), R-PHB-OH, S-PHB-OH, polyphenol
poly(4,4'-dihydroxydiphenyl ester, 4-tert-butylphenol,
polyglutamate, acrylonitrile-butadiene-styrene, polystyrene,
styrene acrylonitrile, polyethylene 2,6-napthalate, polypropylene
oxide, polyethylene terepthalate, polybutylacrylate,
poly-y-benzyl-1-glutamate, starch-b-PPG-urethane, ethylene
propylene rubber-g-sodium acrylate EPR-g-SA, polypropylene
carbonate, polypropylene carbonate-co-polyvinyl acetate, natural
starch, starch adipate, starch-b-polyester-urethane,
starch-b-PEG-urethane, PHBV, polycaprolactone, PLLA,
polyoxymethylene, polyvinyl acetate-co-vinyl alcohol,
ethylene-propylene rubber, ethylene-vinyl-acetate copolymer,
synthetic poly3-hydroxybutyrate,
poly-3-hydroxybutyrate-co-poly-3-hydroxyvalerate,
poly-3-hydroxypropionate, polybutylene succinate-co-butylene
adipate, polybutylene succinate-co-caprolactone, phenol
poly(4,4'-dihydroxydiphenyl ester, Styrene maleic anhydride,
Styrene-acrylonitrile, Poly(methyl methacrylate),
Polytetrafluoroethylene, Polybutylene. Polylactic acid,
Polyvinylidene chloride, and/or other similar materials or
combinations of these materials, including mold release agents,
plasticizers, solvents, solvent-grafted polymer, salts, nucleating
agents, cross-linking agents, filaments, water, antioxidants,
compatibilizers, co-polymers, peroxides, alcohols, ketones,
polyolefins, chlorinated solvents, non-chlorinated solvents,
aliphatic hydrocarbons, hydrophilic agents, hydrophobic agents,
enzymes, PHA miscible agents, pigments, stabilizers, and/or
rubbers. In several embodiments, the additional of one or more of
such non-PHA polymer or material advantageously improves the
post-production handling of PHA. In one embodiment, PHA,
methanotrophic, autotrophic, and/or heterotrophic microorganism
biomass, and a non-PHA polymer are mixed and melted together. In
one embodiment, the concentration of non-PHA microorganism biomass
in such a mixture ranges from 0.0001% to 90%, 0.1% to 30%, 0.1% to
10%, or 0.5% to 8%, and overlapping ranges thereof. In one
embodiment, the concentration of methanobactin in PHA is controlled
to modify the functional characteristics of the PHA, including
color, odor, brittleness, flexibility, antioxidant activity,
antiviral activity, and/or antibacterial activity. In one
embodiment, reducing the concentration of methanobactin in the PHA
reduces the brown or yellow shade of the PHA and increases the
flexibility of the PHA. In another embodiment, increasing the
concentration of methanobactin in the PHA increases the
antimicrobial (e.g., antibacterial, antiviral) and/or antioxidant
activity or potential activity or the PHA. In one embodiment, a
method is provided for improving the functional characteristics of
a PHA polymer through the melting and cooling of the PHA polymer in
the presence of a dual-miscible biomass agent and a second polymer,
comprising the steps of: (a) providing a first polymer, a biomass,
and a second polymer, wherein the first polymer is a PHA, (b)
subjecting the biomass to a processing step comprising heat,
pressure, solvent washing, filtration, centrifugation, super
critical solvent extraction, and/or shear, wherein the processing
step renders at least a portion of the biomass miscible with the
first polymer and the second polymer, (c) contacting the first
polymer with the biomass and the second polymer to form a compound,
(d) heating the compound to between 50 degrees Celsius and 250
degrees Celsius, and (d) causing the biomass to effect a functional
modification of the first polymer, the second polymer, and the
combination of the first polymer and second polymer, wherein the
functional modification comprises plasticization, nucleation,
compatibilization, melt flow modification, strengthening, and/or
elasticization.
[0136] In one embodiment, a PHA derived from a carbon-containing
greenhouse gas, or greenhouse gas emission including methane,
carbon dioxide, or combinations thereof, is provided. In some
embodiments, use of such a gas is particularly advantageous, as it
allows for the simultaneous production of PHA at lower energy costs
and higher efficiencies, but also removes a portion of a
destructive gas from the atmosphere, or prevents a destructive gas
from entering the atmosphere. In some embodiments, processes and
systems as disclosed herein are particularly well suited for use
near sources of such gases (e.g., landfills, power production
plants, anaerobic digesters, etc.) for onsite conversion of harmful
gasses to a commercially valuable product.
[0137] In several embodiments, processes for the oxidation of
methane are provided. In one embodiment, the process comprises:
providing a culture of methanotrophic and autotrophic
microorganisms, providing a growth culture medium comprising
dissolved methane and carbon dioxide, and contacting the culture
with light to cause the culture to convert the carbon dioxide into
oxygen, whereby the culture utilizes the oxygen to oxidize the
methane, thereby reducing or eliminating the need for an extraneous
source of oxygen to drive methanotrophic metabolism.
[0138] In some embodiments, the light used to contact the culture
is artificial light. In some embodiments, the light used to contact
the culture is natural light. In other embodiments, combinations of
natural and artificial light are used. In some such embodiments,
wavelengths of artificial light are specifically filtered out or
controlled such that the culture is exposed to a broader or more
controlled overall spectrum of light (e.g., the sum of wavelengths
of natural light and artificial light). In some embodiments, the
source of light also functions to generate heat, which can be used
to maintain optimal culture temperatures. In other embodiments,
light input is regulated by time, such that specific cultures of
autotrophic and/or heterotrophic microorganisms are selected for or
optimized according to the duration and/or pattern of light
injection (e.g., 0-12 or 12-24 hours light injection, 0-12 or 12-24
hours dark incubation, multi-second pulsation, etc.).
[0139] In one embodiment, the addition of light reduces the need
for exogenous oxygen sources. While such embodiments provide an
advantage in reducing costs of input materials, in some
embodiments, an exogenous source of oxygen, including air, is added
to the culture.
[0140] In some embodiments, the addition of autotrophic
microorganisms to the culture impacts the metabolism of the
culture. In such an embodiment, the timed and planned addition,
activation, or metabolic enhancement of autotrophic organisms can
be based on the desire for changing the rate of methane
oxidation.
[0141] In some embodiments, a system is used for PHA production
comprising providing i) a culture of autotrophic, methanotrophic,
methanogenic, and/or heterotrophic microorganisms and ii) a first
gas comprising carbon dioxide, methane, volatile organic compounds,
oxygen, and/or other gas, whereby the culture of microorganisms are
caused to used the first gas to generate a second gas comprising
carbon dioxide, methane, oxygen, volatile organic compounds, and/or
other gas, whereby the culture subsequently is caused to utilize
the second gas for the generation of PHA, which can then be
isolated and purified according to several embodiments disclosed
herein. In some embodiments, the first gas can be methane, carbon
dioxide, oxygen, or volatile organic compounds. In other
embodiments, the second gas can be oxygen, methane, carbon dioxide,
or other volatile organic compounds. In some embodiments,
microorganisms can be used to convert carbon dioxide to biomass
which can in turn be used to produce methane, which can be
subsequently used to produce PHA. In other embodiments,
microorganisms can be used to convert carbon dioxide to oxygen
which can in turn be used to produce PHA. As disclosed herein, the
products generated at each of these steps may be recycled (e.g.,
splitting a portion of the autotrophic culture and recycling it to
generate additional biomass, generating reduced-PHA biomass and
recycling it into the methanotrophic culture to generate additional
biomass and additional PHA).
[0142] In several embodiments, processes for producing autotrophic
microorganisms using only methane as a carbon input are provided.
In one embodiment, the process comprises: adding methane, oxygen,
and methane-utilizing microorganisms to a culture of autotrophic
microorganisms, whereby the methane-utilizing microorganisms
convert the methane into carbon dioxide, and whereby the
autotrophic microorganisms utilize the carbon dioxide as a source
of carbon, thereby reducing or eliminating the need for an
extraneous source of carbon dioxide to drive autotrophic
metabolism. In some embodiments, addition of methanotrophic and/or
heterotrophic microorganisms to the culture impacts the metabolism
of the autotrophic microorganisms. As discussed herein, the
purposeful addition of such microorganisms at particular times
allows for specific levels of control over the overall output and
operation of the system.
[0143] In several embodiments, processes for oxidizing methane at
low concentrations are provided. In one embodiment, the process
comprises: culturing methanotrophic microorganisms in a medium
comprising water, dissolved methane, dissolved oxygen, and mineral
salts, adding methanol to the medium at a rate and volume
sufficient to cause the microorganisms to reduce the concentration
of the methane in the medium, whereby substantially all of the
methane within the medium is utilized, thereby enabling
methanotrophic microorganisms to metabolize methane present at low
bioavailable concentrations. In some embodiments, gas containing
less than 20% methane by volume is contacted with the medium. In
some embodiments, gas containing less than 1% methane by volume is
contacted with the medium. In some embodiments, the methanol is
produced by microorganism metabolism.
[0144] In several embodiments, processes for separating water from
microorganism biomass are provided. In one embodiment, the process
comprises: providing biomass mixed with water in a liquid medium,
mixing the medium with a liquid agent selected from the group
consisting of ketones, alcohols, chlorinated solvents, derivatives
thereof, or combinations thereof, and subjecting the mixture to a
filtration step. In several embodiments, this enables the efficient
separation of biomass from water. In some embodiments, such methods
reduce or eliminate the need for centrifugation in the separation
process. In some embodiments, the liquid agent is acetone, ethanol,
isopropanol, and/or methanol. In other embodiments, other liquid
agents that are miscible with water are used to separate the
biomass from the aqueous portion of the mixture. In several
embodiments separation is achieved by centrifugation (high-speed,
low-speed), gravity separation, multi-stage filtration, or
combinations thereof.
[0145] In several embodiments, processes for extracting a
polyhydroxyalkanoate from a PHA-containing biomass are provided. In
one embodiment, the process comprises the steps of: (a) providing a
PHA-containing biomass comprising PHA and water, (b) mixing said
biomass with a solvent at a temperature sufficient to dissolve at
least a portion of said PHA into said solvent and at a pressure
sufficient to enable substantially all or part of said solvent to
remain in liquid phase, thereby producing a PHA-lean biomass phase
and a PHA-rich solvent phase comprising water, PHA and solvent (c)
separating said PHA-rich solvent phase from said PHA-lean biomass
phase at a temperature and pressure sufficient to enable
substantially all or part of said solvent to remain in liquid phase
and prevent substantially all or part of said PHA within said
PHA-rich solvent phase from precipitating into said water, (d)
reducing the pressure or increasing the temperature of said
PHA-rich solvent phase to cause said PHA-rich solvent to vaporize
and said PHA to precipitate or otherwise become a solid PHA
material while maintaining the temperature and/or pressure of the
PHA-rich solvent phase to prevent all or part of the
temperature-dependent precipitation of said PHA into said water,
and (e) collecting said solid PHA material, including optionally
separating said solid PHA material from said solvent and/or said
water.
[0146] In some embodiments, solvents include acetone, ethanol,
methanol, dichloroethane, and/or methylene chloride. Depending on
the solvent selected, in some embodiments, separating the solid PHA
material from solvent and/or water is achieved by increasing the
temperature of the mixture. In other embodiments, separation is
achieved through reducing the pressure of the solvent, PHA, and/or
water. In some embodiments, combinations of temperature changes and
pressure changes are used to optimally separate solid PHA material
from solvent and/or water. In some embodiments, evaporation of
solvent and/or water occurs in a rapid fashion, thereby reducing
the need for temperature or pressure changes. Advantageously,
certain embodiments of the processes disclosed herein may
optionally be carried out in a batch, semi-continuous, or
continuous manner. Thus, the process can be tailored to the needs
of the producer at any given time.
[0147] In several embodiments, processes for modifying the
functional characteristics of a PHA are provided. In one
embodiment, the process comprises providing a first PHA and a
second PHA, wherein the molecular weight of said second PHA is
greater than the molecular weight of said first PHA, and combining
said first PHA with said second PHA to modify the functional
characteristics of both said first PHA and second PHA. In some
embodiments, both the first PHA and the second PHA are PHB, and in
some embodiments, one or more of the first and second PHA comprises
PHBV. In one embodiment the first PHA and the second PHA is PHB or
PHBV.
[0148] In some embodiments, the molecular weight of the first PHA
is greater than about 500,000 Daltons and the molecular weight of
the second PHA is less than about 500,000 Daltons. However, in some
embodiments, the molecular weight can be adjusted. For example, in
some embodiments, a first PHA is subjected to a temperature
sufficient to reduce the molecular weight of the first PHA.
Thereafter, it can be combined with the second PHA. It shall be
appreciated that the second PHA could also optionally be exposed to
temperature in order to adjust its molecular weight. In some
embodiments, the molecular weight of the second PHA is greater than
about 800,000 Daltons. In certain embodiments, the molecular weight
of said second PHA is greater than about 1,000,000 Daltons. In some
embodiments, the molecular weights of the first and second PHA are
specifically tailored relative to one another, (e.g., a ratio of
1:2, 1:4, 1:6, 1:8, 1:10, etc.) in order to maximize the
alterations in functional characteristics.
[0149] In several embodiments, processes for increasing the
penetration depth of light in a liquid are provided. In one
embodiment, the process comprises the steps of (a) directing light
into a liquid medium in the form of a light path and (b) reducing
the density of liquid in the light path.
[0150] In several embodiments, the density of the liquid in the
light path is reduced by adding gas to said liquid in the light
path. In some embodiments, the gas is air, oxygen, methane, carbon
dioxide, nitrogen, and/or a combination thereof. In some
embodiments, the gas is simultaneously added along with the light.
In certain embodiments, the gas and the light are emitted or
injected into the liquid through a common material, such as a
permeable or semi-permeable membrane through which light and/or gas
traverse. In other embodiments, the light and the gas are added
separately. In such embodiments, customization of the addition is
possible. For example, gas can be added in pulses (e.g., on/off
sequences), continuously, or in bracketed time frames around the
addition of light. In some embodiments, the addition of light and
gas are coordinated to maximize the penetration of the light. For
example a burst of gas followed by a burst of light (or overlapping
to some degree) may advantageously increase the penetration of the
light.
[0151] In several embodiments, processes for modifying the pH in a
microorganism culture medium are provided. In one embodiment, the
process comprises the steps of: (a) providing a culture medium
comprising water and microorganisms, (b) adding a first source of
nitrogen to the medium to cause the microorganisms to metabolize
the nitrogen and thereby increase the concentration of either
hydroxyl ions or protons, respectively, in the medium, and/or (c)
adding a second source of nitrogen to the medium to cause the
microorganisms to metabolize the nitrogen and thereby increase the
concentration of either protons or hydroxyl ions, respectively, in
the medium. In other embodiments, a source of nitrogen is added to
the culture that increases the pH of the medium, wherein the
metabolism of the nitrogen source causes the pH of the medium to
decrease, thereby reducing or eliminating the need for an
additional pH adjustment step. In one embodiment, nitrogen fixation
is used to add hydroxyl ions to the culture medium, which may or
may not be counterbalanced by the addition of protons from either
biological or chemical sources. In one embodiment, nitrate fixation
is used to add hydroxyl ions to the culture medium, which may or
may not be counterbalanced by the addition of protons from either
biological or chemical sources. In one embodiment, ammonia or
ammonium fixation is used to add protons to the culture medium,
which may or may not be counterbalanced by the addition of hydroxyl
ions from either biological or chemical sources.
[0152] In several embodiments, low shear processes for adding gas
to a microorganism culture medium are provided. In one embodiment,
the process comprises the steps of: (a) providing a liquid medium
and a gas, (b) contacting the medium with the gas in a first
container to cause at least a portion of the gas to dissolve in the
medium, (c) providing a second container, and (d) transferring at
least a portion of the liquid comprising the gas within the first
container to the second container. In some embodiments, a mixer is
also provided, in order to dissolve a portion of the gas in the
medium. In some embodiments, the mixer is a pump or agitator or
high shear mixer. In some embodiments, the mixer comprises a
centrifugal pump. In still other embodiments, the gas itself
provides a mixing function. For example, the injection of gas into
a medium will result in gas bubbles, which, if released at the
bottom of a container comprising medium, will not only promote the
dissolution of gas into the medium, but mix the medium as the
bubbles rise.
[0153] In several embodiments, processes for injecting gas into a
pressurized microorganism culture vessel are provided. In one
embodiment, the process comprises the steps of: providing a vessel
comprising a medium comprising microorganisms, adding a gas into
the vessel that can be metabolized by the microorganisms, and
adjusting the flow rate of the gas into the vessel according to the
rate of change of pressure within the vessel. In some embodiments,
the gas is oxygen, methane, carbon dioxide, or combinations
thereof. Choice of the gas depends on the vessel used and the
culture within the vessel. In some embodiments, backpressure
monitoring allows for optimal gas injection for a given culture
(e.g., if certain cultures react more quickly to administration of
a gas and rapidly increase pressure, flow can be coordinately
reduced).
[0154] In one embodiment, a process for producing light in a liquid
medium is provided. In one embodiment, the process comprises the
steps of: a) providing a liquid, b) providing a light-emitting unit
or material comprising two conductive leads and a light-emitting
conjuncture between the conductive leads, or a material that will
emit light when contacted with electrons and c) inducing a voltage
in the liquid, thereby inducing the movement of electrons in the
conductive leads of the light-emitting unit or inducing electrons
to contact the material, thereby causing the light-emitting unit or
material to emit light. In some embodiments, the material is a
phosphor, phosphoric, and/or luminescent material, including an
electroluminescent phosphor.
[0155] In one embodiment, AC voltage is induced in a liquid by
inserting the two leads of a 115V AC power source into a liquid.
Without being bound by theory, it is believed that a liquid
carrying an AC voltage is capable of inducing the movement of
electrons into and through a light-emitting device suspended in the
liquid and not contacting the two 115V AC power source leads due to
the oscillating nature of electrons in an AC circuit, such that AC
voltage in a liquid causes electrons to fill conductive paths
connected to the liquid, in spite of the resistance of the
conductive paths relative to the liquid, and will oscillate as an
AC current in those conductive paths, thereby performing work,
e.g., generating light in a light emitting diode. As a non-limiting
example, light is produced in a liquid medium by a) placing a
light-emitting diode in a liquid comprising water and electrolytic
ions, and b) inducing an AC voltage in the liquid, wherein c) the
induction of AC voltage in the electrolytic liquid causes the
light-emitting diode to generate light.
[0156] Through experimentation, Applicant unexpectedly discovered
that one or multiple light emitting units will emit light in a
liquid when AC voltage is applied to the liquid and when the
light-emitting units are rated for voltages and amp draws
commensurate with available electrical energy. The production of
autotrophic microorganisms is fundamentally constrained by the
ability of light to penetrate through a liquid and thereby enable
photosynthesis. Prior to Applicant's invention as disclosed herein,
no methods were believed to be known to produce light in a liquid
through the utilization of light-emitting devices physically
unconnected to an electrical voltage source vis-a-vis solid
conductive material. In one embodiment, the utilization of one or
more, and preferably many, free-floating light-emitting units in an
electrically charged liquid comprising autotrophic microorganisms
enables a very high light transmission efficiency, wherein previous
light penetration constraints are largely overcome and high
autotrophic microorganism densities are fully enabled.
[0157] In several embodiments, a method for producing a
polyhydroxyalkanoate (PHA) in a microorganism culture is provided.
In some embodiments, the method comprises the steps of: a)
subjecting said culture to a growth period comprising exposing said
culture to growth conditions to cause said culture to reproduce,
(b) subjecting said culture to a polymerization period comprising
exposing said culture to polymerization conditions to cause said
culture to produce intracellular PHA, and (c) repeating step (a)
and then second step (b) two or more times.
[0158] In some embodiments the growth period comprises a period in
which the culture reproduces or otherwise produces biomass and/or
reproduces. In some embodiments, the polymerization period
comprises a period in which the culture synthesizes PHA. In some
embodiments, the growth period and the polymerization period are
induced by the culture media (e.g., the extracellular media around
the culture). In some embodiments, alterations in the media
conditions induce a transition (partial or complete) between growth
and polymerization periods. In some embodiments, a culture is
cycled between growth and polymerization periods two, three, four,
or more times, in order to produce PHA and then reproduce biomass,
which is subsequently used to generate additional PHA.
[0159] In some embodiments, the culture is exposed to non-sterile
conditions. In certain such embodiments, input carbon is
non-sterile. However, in some embodiments, sterile conditions
exist. In some embodiments, the culture is dynamic over time in
that it may be exposed to extraneous microorganisms. In certain
embodiments, this is due to a non-sterile culture environment. In
some embodiments, extraneous microorganisms potentiate the
production of PHA.
[0160] In several embodiments, a process for the reduction of
pigmentation in a microorganism culture is provided. In one
embodiment, the process comprises the steps of: providing a medium
comprising a microorganism culture comprising dissolved oxygen, and
increasing the concentration of dissolved oxygen over successive
periods to select for light-colored or low-level pigmentation
microorganisms.
[0161] PHA, while able to be treated post-production to reduce
pigmentation, is less expensive to produce when lower levels of
pigmentation exist. Some microorganisms are more pigmented than
others, and therefore in several embodiments, selection against the
more pigmented microorganisms results in a less pigmented PHA,
which reduces production costs. In some embodiments, the
microorganisms cultured and selected for are methanotrophic
microorganisms. By manipulating the culture conditions, which
benefit certain varieties of microorganisms, a less pigmented
culture (and hence a less pigmented PHA) result. In some
embodiments, increases in concentration of dissolved oxygen over
periods ranging from 1-3 hours, 3-5 hours, 5-7 hours, 7-10 hours,
10-15 hours, or 15-24 hours are used to select for less pigmented
microorganisms. As discussed herein, in several embodiments,
various compounding agents are optionally added to the produced PHA
(either during the production phase or after production phase).
Many such compounding agents, however, adversely affect the quality
and/or performance (or other characteristic) of the final PHA
product. In several embodiments, certain compounding agents, or
combinations thereof, are added in order to improve one or more
characteristics of the final PHA product. In some embodiments, such
agents aid in the reduction of pigmentation of the PHA. In some
embodiments, compounding agents reduce the degree of filtration,
centrifugation, settling (or other techniques disclosed herein to
separate solids from liquid phases). Advantageously and
unexpectedly, the addition of certain compounding agents, viewed in
the art as harmful to the quality or to a certain characteristic of
the PHA, the result achieve with the methods disclosed herein is a
higher quality PHA that is not adversely affected by the
compounding agents, but rather is enhanced by the addition of such
compounds. [113] In several embodiments, a process for the
conversion of a gas into a polyhydroxyalkanoate (PHA) is provided,
wherein the process comprises the steps of: a) providing i) a first
gas and ii) a culture of microorganisms, b) contacting the first
gas with the culture to cause the culture to convert the first gas
into a second gas c) contacting the second gas with the culture,
and d) causing the culture to use the second gas to produce
PHA.
[0162] In some embodiments, the microorganisms are autotrophic,
methanogenic, heterotrophic, or combinations thereof.
[0163] In one embodiment the first gas is carbon dioxide. In one
embodiment the first gas is oxygen. In one embodiment the first gas
is methane. In one embodiment the first gas is a volatile organic
compound.
[0164] In one embodiment the second gas is carbon dioxide. In one
embodiment the second gas is oxygen. In one embodiment the second
gas is methane. In one embodiment the second gas is a volatile
organic compound.
[0165] It shall be appreciated that the selection of the first and
the second gas is based on the type of microorganism or
microorganisms being cultured.
BRIEF DESCRIPTION OF THE DRAWING
[0166] FIG. 1 is a block flow diagram comprising the steps of:
microorganism fermentation and PHA synthesis, PHA-containing
biomass removal, PHA-reduced biomass and isolated PHA production,
PHA-reduced biomass recycling and fermentation, and isolated PHA
purification.
DETAILED DESCRIPTION
[0167] While PHAs have significant environmental advantages
compared to fossil fuel-based plastics, the cost of PHA production
is generally viewed as a significant limitation to the industrial
production and commercial adoption of PHAs. Generally, the overall
cost of PHA production is determined by three major inputs: 1)
carbon, 2) chemicals, and 3) energy. Accordingly, efforts to reduce
the cost of PHA production must address one or more of these areas,
specifically by: i) reducing carbon input costs, ii) increasing
carbon-to-PHA yields, iii) reducing the volume of chemicals
required for PHA production, and/or iv) increasing energy-to-PHA
yields.
[0168] As discussed above, food crop derived sugars in genetically
engineered microorganism-based aqueous fermentation systems are
widely regarded as the most carbon, chemical, energy, and, thus,
cost efficient PHA production method. Despite these efficiencies,
sugar-based PHA production remains many times more expensive than
fossil fuel-based plastics production. Attempts to reduce the
carbon input cost of the PHA production process, by utilizing
carbon-containing industrial off-gases, such as carbon dioxide and
methane, have been previously limited by technical challenges and
stoichiometric limitations that render the gas-to-PHA production
process significantly more energy and chemical intensive, and thus
more costly, than the food crop-based PHA production process.
[0169] Specifically, these technical challenges and stoichiometric
limitations include: low mass transfer rates, low microorganism
growth rates, extended polymerization times, low cell densities,
high oxygen demand (relative to solid substrates), and low PHA
cellular inclusion concentrations. Whereas sugar-based fermentation
systems have the ability to generate high cellular densities and
PHA inclusion concentrations, carbon-containing gas-based
fermentation processes typically cannot, based on fundamental cell
morphology and mass transfer constraints, generate cellular and PHA
densities exceeding 10-30% of densities possible in sugar-based
processes. As a result, the ratio of energy-to-PHA required to
carry out upstream carbon injection, oxygen injection, system
cooling, and culture mixing, as well as downstream PHA
purification, significantly exceeds the energy-to-PHA ratio
required for sugar-based PHA production methods, thereby rendering
the emissions-based process uncompetitive when compared to both
petroleum-based plastics and sugar-based PHAs.
[0170] Several embodiments of the present invention therefore
relate to a novel method for the production of PHA using
carbon-containing gases as a source of carbon (alone or in
combination with a non-gaseous source of carbon), wherein the
energy input-to-PHA production ratio, carbon input-to-PHA
production ratio, and cost efficiency of the process is
significantly improved over previous gas-based PHA production
processes.
[0171] In several embodiments, this process may be accomplished by
a) culturing a first microorganism culture capable of metabolizing
the carbon within both a carbon-containing gas and biomass, or a
derivative thereof, b) manipulating the conditions of the culture
to cause the culture to produce PHA-containing biomass, c) removing
a portion of the PHA-containing biomass; d) extracting at least a
portion of the PHA within the removed PHA-containing biomass to
create substantially isolated PHA and substantially PHA-reduced
biomass, e) purifying the isolated PHA, and f) returning the
PHA-reduced biomass to the microorganism culture to cause the
microorganism culture to metabolize the carbon within the
PHA-reduced biomass into PHA.
[0172] According to some embodiments, the steps of this process are
as follows: (a) providing a microorganism culture comprising
biomass and PHA; (b) removing a portion of the PHA-containing
biomass from the culture, and extracting PHA from the removed
PHA-containing biomass to produce isolated PHA and PHA-reduced
biomass; (c) purifying the isolated PHA, and (d) returning the
PHA-reduced biomass to be mixed with the culture to cause the
culture to convert the carbon within the PHA-reduced biomass into
PHA. Each of the above recited steps in the process are discussed
in more detail below.
Providing a Microorganism Culture Comprising Biomass and PHA
[0173] The terms "microorganism", "microorganisms", "culture",
"cultures", and "microorganism cultures", as used herein, shall be
given their ordinary meanings and shall include, but not be limited
to, a single strain of microorganism and/or consortium of
microorganisms, including, among others, genetically-engineered
bacteria, fungi, algae, and/or yeast. In some embodiments,
microorganisms are naturally occurring and in some embodiments
microorganisms are genetically-engineered. In some embodiments,
both naturally occurring and genetically-engineered microorganisms
are used. In some embodiments, a mixed culture of microorganisms
may be used. In some embodiments, microorganisms or cultures shall
include a microorganism metabolism system, including the
interactions and/or multiple functions of multiple cultures in one
or more conditions.
[0174] The terms "biomass" and "biomass material" shall be given
their ordinary meaning and shall include, but not be limited to,
microorganism-derived material, including intracellular, cellular,
and/or extracellular material, such materials including, but not
limited to, a polymer or polymers, amino acids, nucleic acids,
carbohydrates, lipids, sugars, PHA, volatile fatty acids,
chemicals, gases, such as carbon dioxide, methane, volatile organic
acids, and oxygen, and/or metabolic derivatives, intermediaries,
and/or end-products. In several embodiments, biomass is dried or
substantially dried.
[0175] In some embodiments, the biomass contains less than about
99% water. In other embodiments, the biomass contains between about
99% to about 75% water, including about 95%, 90%, 85%, and 80%. In
some embodiments, the biomass contains between about 75% and about
25% water, including 75%-65%, 65%-55%, 55%-45%, 45%-35%, 35%-25%,
and overlapping ranges thereof. In additional embodiments, the
biomass contains from about 25% water to less than about 0.1%
water, including 25%-20%, 20%-15%, 15%-10%, 10%-5%, 5%-1%, 1%-0.1%,
and overlapping ranges thereof. In still other embodiments, the
biomass contains no detectable amount of water. Depending on the
embodiment, water is removed from the biomass by one or more of
freeze drying, spray drying, fluid bed drying, ribbon drying,
flocculation, pressing, filtration, and/or centrifugation. In some
embodiments, the biomass may be mixed with one or more chemicals
(including, but not limited to solvents), such as methylene
chloride, acetone, methanol, and/or ethanol, at various
concentrations. In other embodiments, the biomass may be processed
through homogenization, heat treatment, pH treatment, enzyme
treatment, solvent treatment, spray drying, freeze drying,
sonication, or microwave treatment. As used herein, the term
"PHA-reduced biomass" shall be given its ordinary meaning and shall
mean any biomass wherein at least a portion of PHA has been removed
from the biomass through a PHA extraction process. As used herein,
the term "PHA-containing biomass" shall be given its ordinary
meaning and shall mean any biomass wherein at least a portion of
the biomass is PHA.
[0176] Microorganism cultures useful for the invention described
herein include a single strain, and/or a consortium of strains,
which are individually and/or collectively capable of using carbon
containing gases and biomass, including PHA-reduced biomass, as a
source of carbon for the production of biomass and PHA. In some
embodiments, a microorganism culture according to several
embodiments, comprises a microorganism culture that utilizes
PHA-reduced biomass, or any derivative thereof, including
methanotrophic microorganisms, anaerobic digestion cultures, and
other heterotrophic microorganisms, as a source of carbon for the
production of biomass, or metabolic derivatives including, and in
particular, the production of PHA, protein, methane, and/or carbon
dioxide (herein, "biomass-utilizing microorganisms"). As used
herein, the terms "microorganism", "culture", "microorganism
culture," "microorganism system," "microorganism consortium," and
"consortium of microorganisms" are used interchangeably.
Additionally, any of these terms may refer to one, two, three, or
more microorganism cultures and/or strains, including a
microorganism system that is collectively capable of carrying out a
complex metabolic function (e.g., conversion of PHA-reduced biomass
to methane, carbon dioxide, protein, and/or PHA). In several
embodiments, the microorganism culture comprises of a consortium of
carbon-containing gas-utilizing microorganisms and a consortium of
biomass-utilizing microorganisms. In some embodiments, the gases
metabolized by such cultures comprise methane, carbon dioxide,
and/or a combination thereof.
[0177] In some embodiments, the microorganism culture comprises a
consortium of acidogenic, acetogenic, methanogenic, methanotrophic,
and/or autotrophic microorganisms in one or more individual
bioreactors. As such, in some embodiments, the cultures are grown
in one or more distinct culture conditions. In some embodiments,
the conditions are either aerobic or anaerobic conditions. In some
embodiments, culture conditions are varied over time (e.g.
initially aerobic with a transition to anaerobic, or vice versa).
As used herein, the term "bioreactor" shall be given its ordinary
meaning and shall also refer to a tank, vessel, or any container or
device suitable for growth and culturing of microorganisms.
[0178] In some embodiments, the microorganism culture is contained
within a single vessel, wherein the steps of converting PHA-reduced
biomass to biomass, converting biomass to PHA, and converting
carbon-containing gases to biomass and/or PHA occur simultaneously
or sequentially.
[0179] In other embodiments, the microorganism culture is contained
within multiple vessels, which are designed to carry out specific
and unique functions. For example, one embodiment includes the
steps of (a) converting PHA-reduced biomass to PHA-reduced
biomass-derived materials such volatile organic acids, methane,
and/or carbon dioxide, which is carried out in a first vessel and
(b) synthesizing PHA from PHA-reduced biomass-derived materials
which is carried out in a second, separate tank under independent
conditions. In some embodiments, one or more of the tanks is an
anaerobic digestion tank and one or more other tank is an aerobic
fermentation tank.
[0180] As used herein, the term "gas-utilizing microorganisms"
shall be given its ordinary meaning and shall refer to
microorganisms capable of utilizing gases containing carbon for the
production of biomass, including the production of PHA. Similarly,
the terms "methanotrophic microorganisms" and "methane-utilizing
microorganisms" shall be given their ordinary meanings and shall
refer to microorganisms capable of utilizing methane as a source of
carbon for the production of biomass. Further, the terms
"autotrophic microorganisms" and "carbon dioxide-utilizing
microorganisms" shall be given their ordinary meaning and shall
refer to microorganisms capable of utilizing carbon dioxide as a
source of carbon for the production of biomass, including
microorganisms that utilize natural and/or synthetic sources of
light to carry out the metabolism of carbon dioxide into biomass.
The term "heterotrophic microorganisms", as used herein, shall be
given its ordinary meaning and shall include methanotrophic,
methanogenic, acidogenic, acetogenic and biomass-utilizing
microorganisms, including microorganisms that convert sugar,
volatile fatty acids, or other carbon substrates to biomass. The
term "methanogenic microorganisms" shall be given its ordinary
meaning and shall refer to microorganisms that convert biomass to
methane, including the consortium of microorganisms required to
carry out such a process, including, but not limited to, acidogenic
and acetogenic microorganisms.
[0181] As discussed herein, in several embodiments,
carbon-containing gases are used as a source of carbon by
microorganism cultures. In some embodiments, other sources of
carbon are used (e.g., PHA-reduced biomass), either alone or in
combination with carbon-containing gases. In some embodiments, the
carbon-containing gases used include, but are not limited to,
carbon dioxide, methane, ethane, butane, propane, benzene, xylene,
acetone, methylene chloride, chloroform, volatile organic
compounds, hydrocarbons, and/or combinations thereof. The source of
the carbon-containing gases depends on the embodiment. For example,
carbon-containing gas sources used in some embodiments include
landfills, wastewater treatment plants, anaerobic metabolism, power
production facilities or equipment, agricultural digesters, oil
refineries, natural gas refineries, cement production facilities,
and/or anaerobic organic material digesters, including both solid
and liquid material digesters.
[0182] In several embodiments described herein, microorganisms may
include, but are not limited to, yeast, fungi, algae, and bacteria
(including combinations thereof). Suitable yeasts include, but are
not limited to, species from the genera Candida, Hansenula,
Torulopsis, Saccharomyces, Pichia, 1-Debaryomyces, Lipomyces,
Cryptococcus, Nematospora, and Brettanomyces. Suitable genera
include Candida, Hansenula, Torulopsis, Pichia, and Saccharomyces.
Non-limiting examples of suitable species include, but are not
limited to: Candida boidinii, Candida mycoderma, Candida utilis,
Candida stellatoidea, Candida robusta, Candida claussenii, Candida
rugosa, Brettanomyces petrophilium, Hansenula minuta, Hansenula
satumus, Hansenula californica, Hansenula mrakii, Hansenula
silvicola, Hansenula polymorpha, Hansenula wickerhamii, Hansenula
capsulata, Hansenula glucozyma, Hansenula henricii, Hansenula
nonfermentans, Hansenula philodendra, Torulopsis candida,
Torulopsis bolmii, Torulopsis versatilis, Torulopsis glabrata,
Torulopsis molishiana, Torulopsis nemodendra, Torulopsis
nitratophila, Torulopsis pinus, Pichia farinosa, Pichia polymorpha,
Pichia membranaefaciens, Pichia pinus, Pichia pastoris, Pichia
trehalophila, Saccharomyces cerevisiae, Saccharomyces fragilis,
Saccharomyces rosei, Saccharomyces acidifaciens, Saccharomyces
elegans, Saccharomyces rouxii, Saccharomyces lactis, and/or
Saccharomyces fractum.
[0183] Suitable bacteria include, but are not limited to, species
from the genera Bacillus, Mycobacterium, Actinomyces, Nocardia,
Pseudomonas, Methanomonas, Protaminobacter, Methylococcus,
Arthrobacter, Methylomonas, Brevibacterium, Acetobacter,
Methylomonas, Brevibacterium, Acetobacter, Micrococcus,
Rhodopseudomonas, Corynebacterium, Rhodopseudomonas,
Microbacterium, Achromobacter, Methylobacter, Methylosinus, and
Methylocystis. Preferred genera include Bacillus, Pseudomonas,
Protaminobacter, Micrococcus, Arthrobacter and/or Corynebacterium.
Non-limiting examples of suitable species include, but are not
limited to: Bacillus subtilis, Bacillus cereus, Bacillus aureus,
Bacillus acidi, Bacillus urici, Bacillus coagulans, Bacillus
mycoides, Bacillus circulans, Bacillus megaterium, Bacillus
licheniformis, Pseudomonas ligustri, Pseudomonas orvilla,
Pseudomonas methanica, Pseudomonas fluorescens, Pseudomonas
aeruginosa, Pseudomonas oleovorans, Pseudomonas putida, Pseudomonas
boreopolis, Pseudomonas pyocyanea, Pseudomonas methylphilus,
Pseudomonas brevis, Pseudomonas acidovorans, Pseudomonas
methanoloxidans, Pseudomonas aerogenes, Protaminobacter ruber,
Corynebacterium simplex, Corynebacterium hydrocarbooxydans,
Corynebacterium alkanum, Corynebacterium oleophilus,
Corynebacterium hydrocarboclastus, Corynebacterium glutamicum,
Corynebacterium viscosus, Corynebacterium dioxydans,
Corynebacterium alkanum, Micrococcus cerificans, Micrococcus
rhodius, Arthrobacter rufescens, Arthrobacter parafficum,
Arthrobacter citreus, Methanomonas methanica, Methanomonas
methanooxidans, Methylomonas agile, Methylomonas albus,
Methylomonas rubrum, Methylomonas methanolica, Mycobacterium
rhodochrous, Mycobacterium phlei, Mycobacterium brevicale, Nocardia
salmonicolor, Nocardia minimus, Nocardia corallina, Nocardia
butanica, Rhodopseudomonas capsulatus, Microbacterium
ammoniaphilum, Archromobacter coagulans, Brevibacterium butanicum,
Brevibacterium roseum, Brevibacterium flavum, Brevibacterium
lactofermentum, Brevibacterium paraffinolyticum, Brevibacterium
ketoglutamicum, and/or Brevibacterium insectiphilium.
[0184] In several embodiments, more than one type or species of
microorganism is used. For example, in some embodiments, both algae
and bacteria are used. In some embodiments, several species of
yeast, algae, fungi, and/or bacteria are used. In some embodiments,
a single yeast, algae, fungi, and/or bacteria species is used. In
some embodiments, a consortium of cyanobacteria is used. In some
embodiments, a consortium of methanotrophic microorganisms is used.
In still additional embodiments, a consortium of both
methanotrophic bacteria and cyanobacteria are used. In several
embodiments, methanotrophic, heterotrophic, methanogenic, and/or
autotrophic microorganisms are used.
[0185] In several embodiments of the invention, the microorganism
culture comprises a consortium of methanotrophic, autotrophic,
and/or heterotrophic microorganisms, wherein methane and/or carbon
dioxide is individually, interchangeably, or simultaneously
utilized for the production of biomass. In some embodiments,
PHA-reduced biomass is used as a source of carbon by heterotrophic,
autotrophic, and/or methanotrophic microorganisms. In several
embodiments of the invention, the microorganism culture comprises
methanotrophic microorganisms, cyanobacteria, and
non-methanotrophic heterotrophic microorganisms, wherein methane
and carbon dioxide are continuously utilized as sources of carbon
for the production of biomass and PHA.
[0186] In some embodiments, microorganisms are employed in a
non-sterile, open, and/or mixed environment. In other embodiments,
microorganisms are employed in a sterile and/or controlled
environment.
[0187] The terms "PHA", "PHAs", and "polyhydroxyalkanoate", as used
herein, shall be given their ordinary meaning and shall include,
but not be limited to, polymers generated by microorganisms as
energy and/or carbon storage vehicles; biodegradable and
biocompatible polymers that can be used as alternatives to
petrochemical-based plastics such as polypropylene, polyethylene,
and polystyrene; polymers produced by bacterial fermentation of
sugars, lipids, or gases; and/or thermoplastic or elastomeric
materials derived from microorganisms. PHAs include, but are not
limited to, polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV),
polyhydroxybutyrate-covalerate (PHBV), and polyhydroxyhexanoate
(PHHx), as well as both short chain length (SCL), medium chain
length (MCL), and long chain length (LCL) PHAs.
[0188] The terms "growth-culture medium", "growth medium",
"growth-culture media", "medium", and "media", as used herein shall
be given their ordinary meaning and shall also refer to materials
affecting the growth, metabolism, PHA synthesis, and/or
reproductive activities of microorganisms. Non-limiting examples of
growth-culture media used in several embodiments include a mineral
salts medium, which may comprise water, nitrogen, vitamins, iron,
phosphorus, magnesium, and various other nutrients suitable to
effect, support, alter, modify, control, constrain, and/or
otherwise influence the metabolism and metabolic orientation of
microorganisms. A growth-culture medium may comprise water filled
with a range of mineral salts. For example, each liter of a liquid
growth-culture medium may be comprised of about 0.7-1.5 g
KH.sub.2PO.sub.4, 0.7-1.5 g K.sub.2HPO.sub.4, 0.7-1.5 g KNO.sub.3,
0.7-1.5 g NaCl, 0.1-0.3 g MgSO.sub.4, 24-28 mg
CaCl.sub.2*2H.sub.2O, 5.0-5.4 mg EDTA Na.sub.4(H.sub.2O).sub.2,
1.3-1.7 mg FeCl.sub.2*4H.sub.2O, 0.10-0.14 mg CoCl.sub.2*6H.sub.2O,
0.08-1.12 mg MnCl.sub.2*2H.sub.2O, 0.06-0.08 mg ZnCl.sub.2,
0.05-0.07 mg H.sub.3BO.sub.3, 0.023-0.027 mg NiCl.sub.2*6H.sub.2O,
0.023-0.027 mg NaMoO.sub.4*2H.sub.2O, and 0.011-0.019 mg
CuCl.sub.2*2H.sub.2O. A growth-culture medium can be of any form,
including a liquid, semi-liquid, gelatinous, gaseous, foam, or
solid substrate.
[0189] In several embodiments of the invention, a microorganism
culture is produced in a liquid growth medium, wherein carbon
dioxide and methane are utilized as a gaseous source of carbon for
the production of methanotrophic and/or autotrophic biomass. In
some embodiments, PHA-reduced methanotrophic and/or PHA-reduced
autotrophic biomass is utilized as a source of carbon for the
production of heterotrophic biomass and heterotrophically-produced
PHA. In some embodiments, the growth medium is manipulated to
effect the growth, reproduction, and PHA synthesis of the
microorganism culture. Methods for the production of methanotrophic
microorganisms are disclosed in the art, and are described by
Herrema, et al., in U.S. Pat. No. 7,579,176, which is hereby
incorporated by reference in its entirety. Methods for the
production of cyanobacteria are described by Lee, et al.
("High-density algal photobioreactors using light-emitting diodes,"
Biotechnology and Bioengineering, Vol. 44, Issue 10, pp.
1161-1167), which is hereby incorporated by reference in its
entirety. Methods for the production of methane from biomass are
described by Deublein, et al. ("Biogas from Waste and Renewable
Resources, WILEY-VCH Verlag GmbH & Co. KgaA, 2008), which is
hereby incorporated by reference in its entirety. In some
embodiments, PHA synthesis may be effected through the manipulation
of one of more elements of the culture medium, including through
the reduction, increase, or relative change in either the total or
bioavailable concentration of one or more of the following elements
(also referred to as essential nutrients): carbon, oxygen,
magnesium, phosphorus, phosphate, potassium, sulfate, sulfur,
calcium, boron, aluminum, chromium, cobalt, iron, copper, nickel,
manganese, molybdenum, sodium, nitrogen, nitrate, ammonia,
ammonium, urea, amino acids, methane, carbon dioxide, and/or
hydrogen. Methods for the production of PHA are described by
Herrema, et al., in U.S. Pat. No. 7,579,176. It shall be
appreciated that all of the various components (including elements,
compounds, liquids, gases, solids, and other compositions) of a
culture medium can be considered essential nutrients, given that
they support the growth of the microorganisms.
[0190] In one embodiment, the conversion of the PHA-reduced biomass
into the PHA is effected by manipulating the concentration one or
more elements within a growth medium selected from the group
consisting of: nitrogen, methane, carbon dioxide, phosphorus,
oxygen, magnesium, potassium, iron, copper, sulfate, manganese,
calcium, chlorine, boron, zinc, aluminum, nickel, and/or sodium,
and combinations thereof. Methods to control the concentration of
elements within the medium include, but are not limited to,
automatic, continuous, batch, semi-batch, manual, injection, solid
feed, liquid, or other methods of inputting one or more chemical
into the medium, wherein the total and/or bioavailable
concentration of elements is increased, decreased, maintained,
adjusted, or otherwise controlled at one or more time and/or
physical chemical adjustment points. Additional methods to adjust
the total or bioavailable concentration of one or more elements
within a mineral media include, but are not limited to, the
directed precipitation, chelation, de-chelation, and
de-precipitation of elements. In one embodiment, the directed
precipitation or chelation of one or more element is utilized to
reduce the total or bioavailable concentration of one or more
element within a medium and thereby induce or increase PHA
production in a biomass. In one embodiment, an ion exchange system,
including one or more reversible ion exchange resins, is used to
control the concentration of ions with the medium and/or control
the precipitation or solubilization of elements within the medium.
In one embodiment, the medium is passed through an ion exchange
resin in order to induce the reduction or increase of a specific
ion in the medium in order to induce or preclude PHA production in
a biomass.
[0191] In one embodiment, the concentration of one or more elements
within a growth culture medium is increased, controlled,
manipulated, or managed to induce or increase the rate of PHA
production in biomass, including a microorganism culture. As used
herein, the terms "control", "manipulate", "adjust", "maintain",
"manage" and the like shall be given their ordinary meaning and
shall also refer to steps which are taken to keep or achieve
concentrations of certain nutrients, compounds or elements of a
culture within a desired range. For example, in one context
controlling the concentration of an element may result in the
maintenance of the concentration of that element within a certain
range, that concentration being achieved by the addition of that
element and/or dilution of the culture to reduce the concentration
of that element. In one embodiment, the concentration of phosphorus
within the medium is increased to induce or increase the rate of
PHA production in a microorganism culture. In another embodiment,
the concentration of an element, e.g., phosphorus, carbon dioxide,
iron, copper, oxygen, methane, and/or magnesium, within the medium
is manipulated or increased to cause a metabolic shift in the
microorganism culture, such that the production of non-PHA
materials by the culture using nitrogen sources (e.g., nitrate,
ammonia, ammonium, dinitrogen, urea, or amino acids) is reduced,
inhibited, or otherwise impacted to enhance PHA production. In one
embodiment, the concentration of phosphorus within the medium is
manipulated or increased to reduce the utilization of nutrients,
including nitrogen, oxygen, and/or carbon, for the production of
non-PHA materials by the culture. In another embodiment, the
concentration of phosphorus within the medium is manipulated or
increased to reduce the utilization of nutrients for the production
of non-PHA materials by the culture and induce or increase the rate
of PHA production in the culture. In some embodiments, an increase
in the concentration of phosphorus causes a metabolic shift that
favors the production of PHA at the expense of other non-PHA
materials, including a reduction in the production of protein,
nucleic acids, polysaccharides, sugars, lipids, particularly but
not necessarily under growth-limiting conditions, including
nitrogen (e.g., nitrate, ammonia, ammonium, dinitrogen, urea, or
amino acids), oxygen, magnesium, potassium, iron, copper, or other
nutrient-limiting conditions. In some embodiments, an increase in
the concentration of phosphorus above 0.00 ppm, 0.01 ppm, 0.02 ppm,
0.05 ppm, 0.10 ppm, 0.20 ppm, 0.50 ppm, 1.00 ppm, 1.25 ppm, 1.50
ppm, 1.75 ppm, 2.00 ppm, 2.20 ppm, 2.40 ppm, 3 ppm, 4 ppm 5 ppm, 6
ppm, 8 ppm, 20 mM, 30 mM, 40 mM, 50 mM, 60 mM, 70 mM, 80 mM, 90 mM,
100 mM, 110 mM, or 120 mM, and particularly above 40 mM or 80 mM,
causes a reduction in the utilization of carbon and nitrogen
sources for the production of non-PHA material, including proteins,
non-PHA polymers, nucleic acids, lipids, pigments, polysaccharides,
methanobactin, and/or carbon dioxide, and, under growth-limiting
conditions, an increase in the utilization of carbon sources for
the production of PHA material, as a result of metabolic changes in
the culture and/or chemical interactions between chemicals within
the media and/or culture induced by augmented concentrations of
phosphorus. The elevation of phosphorus concentrations as a method
to induce or increase the rate of PHA production in a biomass
culture is contrary to the teachings of the prior art, which
teaches that PHA production is induced or enhanced by reducing or
eliminating the concentration of elements, such as, e.g.,
phosphorus in the mineral medium. The addition or controlled
elevation of an element, such as, e.g., phosphorus to a biomass
system to induce or increase PHA production produces an unexpected
and surprising increase in PHA production in a biomass system. An
element such as, e.g., phosphorus may be added to the mineral media
using a variety of phosphorus sources, including phosphorus,
phosphate, phosphoric acid, sodium phosphate, disodium phosphate,
monosodium phosphate, and/or potassium phosphate; other elements,
such as dissolved carbon dioxide, Fe(II) iron, Fe(III) iron, copper
sulfate, Fe-EDTA, dissolved oxygen, dissolved methane, and/or
magnesium sulfate, hydrogen sulfide, and sodium hydroxide are among
other potential sources of elements that may be added to the
mineral media.
[0192] In one embodiment of the invention, the concentrations of
dissolved gases, such as methane, oxygen, carbon dioxide, and/or
nitrogen, are manipulated to increase the rate of PHA production
relative to the rate of cellular production of non-PHA materials
and, specifically, to cause a reduction in the utilization of
carbon or nitrogen sources for the production of non-PHA material,
including proteins, non-PHA polymers, enzymes, nucleic acids,
lipids, pigments, polysaccharides, and/or carbon dioxide, and,
under some conditions, including growth-limiting conditions,
further cause an increase in the utilization of carbon sources for
the production of PHA material, as a result of metabolic changes in
the culture and/or chemical interactions between chemicals within
the media and/or culture induced by augmented concentrations of one
or more of such dissolved gases. In one embodiment, the
concentration of methane or dissolved methane is manipulated to
between about 0.01 ppm and about 0.05 ppm, between about 0.05 ppm
and about 0.1 ppm, between about 0.1 ppm and about 0.5 ppm, between
about 0.5 ppm and about 1.0 ppm, between about 1.0 ppm and about
1.5 ppm, between about 1.5 ppm and about 1.75 ppm, between about
1.75 ppm and about 2.0 ppm, between about 2.0 ppm and about 2.5
ppm, between about 2.5 ppm and about 3.0 ppm, between about 3.0 ppm
and about 3.5 ppm, between about 3.5 ppm and about 4.0 ppm, between
about 4.0 ppm and about 4.5 ppm, between about 4.5 ppm and about
5.0 ppm, between about 5.0 ppm and about 6.0 ppm, between about 6.0
ppm and about 7.0 ppm, between about 7.0 ppm and about 8.0 ppm,
between about 8.0 ppm and about 10 ppm, between about 10 ppm and
about 15 ppm, between about 15 ppm and about 20 ppm, between about
20 ppm and about 30 ppm, or between about 30 ppm and about 50 ppm
(and overlapping ranges thereof) to reduce the production of
non-PHA materials relative to the production of PHA materials in a
culture. In one embodiment, the concentration of oxygen or
dissolved oxygen is manipulated to between about 0.01 ppm and about
0.05 ppm, between about 0.05 ppm and about 0.1 ppm, between about
0.1 ppm and about 0.5 ppm, between about 0.5 ppm and about 1.0 ppm,
between about 1.0 ppm and about 1.5 ppm, between about 1.5 ppm and
about 1.75 ppm, between about 1.75 ppm and about 2.0 ppm, between
about 2.0 ppm and about 2.5 ppm, between about 2.5 ppm and about
3.0 ppm, between about 3.0 ppm and about 3.5 ppm, between about 3.5
ppm and about 4.0 ppm, between about 4.0 ppm and about 4.5 ppm,
between about 4.5 ppm and about 5.0 ppm, between about 5.0 ppm and
about 6.0 ppm, between about 6.0 ppm and about 7.0 ppm, between
about 7.0 ppm and about 8.0 ppm, between about 8.0 ppm and about 10
ppm, between about 10 ppm and about 15 ppm, between about 15 ppm
and about 20 ppm, between about 20 ppm and about 30 ppm, or between
about 30 ppm and about 50 ppm (and overlapping ranges thereof) to
reduce the production of non-PHA materials relative to the
production of PHA materials in a culture. In another embodiment,
the concentration of carbon dioxide or dissolved carbon dioxide is
manipulated to between about 0.01 ppm and about 0.05 ppm, between
about 0.05 ppm and about 0.1 ppm, between about 0.1 ppm and about
0.5 ppm, between about 0.5 ppm and about 1.0 ppm, between about 1.0
ppm and about 1.5 ppm, between about 1.5 ppm and about 1.75 ppm,
between about 1.75 ppm and about 2.0 ppm, between about 2.0 ppm and
about 2.5 ppm, between about 2.5 ppm and about 3.0 ppm, between
about 3.0 ppm and about 3.5 ppm, between about 3.5 ppm and about
4.0 ppm, between about 4.0 ppm and about 4.5 ppm, between about 4.5
ppm and about 5.0 ppm, between about 5.0 ppm and about 6.0 ppm,
between about 6.0 ppm and about 7.0 ppm, between about 7.0 ppm and
about 8.0 ppm, between about 8.0 ppm and about 10 ppm, between
about 10 ppm and about 15 ppm, between about 15 ppm and about 20
ppm, between about 20 ppm and about 30 ppm, or between about 30 ppm
and about 50 ppm between about 50 ppm and about 100 ppm, between
about 100 ppm and about 200 ppm, between about 200 ppm and about
500 ppm, between about 500 ppm and about 1000 ppm, between about
100 ppm and about 1500 ppm, between about 1500 ppm and about 2000
ppm, between about 2000 ppm and about 3000 ppm, between about 3000
ppm and about 5000 ppm, between about 5000 ppm and about 10,000
ppm, between about 10,000 ppm and about 20,000 ppm (and overlapping
ranges thereof) to reduce the production of non-PHA materials
relative to the production of PHA materials in a culture. In
another embodiment, the concentration of nitrogen or dissolved
nitrogen is manipulated to above at least between about 0.01 ppm
and about 0.05 ppm, between about 0.05 ppm and about 0.1 ppm,
between about 0.1 ppm and about 0.5 ppm, between about 0.5 ppm and
about 1.0 ppm, between about 1.0 ppm and about 1.5 ppm, between
about 1.5 ppm and about 1.75 ppm, between about 1.75 ppm and about
2.0 ppm, between about 2.0 ppm and about 2.5 ppm, between about 2.5
ppm and about 3.0 ppm, between about 3.0 ppm and about 3.5 ppm,
between about 3.5 ppm and about 4.0 ppm, between about 4.0 ppm and
about 4.5 ppm, between about 4.5 ppm and about 5.0 ppm, between
about 5.0 ppm and about 6.0 ppm, between about 6.0 ppm and about
7.0 ppm, between about 7.0 ppm and about 8.0 ppm, between about 8.0
ppm and about 10 ppm, between about 10 ppm and about 15 ppm,
between about 15 ppm and about 20 ppm, between about 20 ppm and
about 30 ppm, or between about 30 ppm and about 50 ppm, and
overlapping ranges thereof, to reduce the production of non-PHA
materials relative to the production of PHA materials in a culture.
Without being limited by theory, it is believed that, in some
metabolic pathways, an increase in the concentration of methane,
oxygen, carbon dioxide, and/or nitrogen causes a metabolic shift
that favors the production of PHA at the expense of other non-PHA
materials, including a reduction in the production of protein,
nucleic acids, polysaccharides, sugars, and/or lipids,
particularly, but not necessarily, under growth-limiting, that is,
PHA synthesis, conditions. In one embodiment, the synthesis of
polyhydroxyalkanote (PHA) in a biomass material is effected,
comprising the steps of: (a) providing a medium comprising a
biomass metabolizing a source of carbon, and (b) increasing or
maintaining above a minimum the concentration of an element in the
medium to cause the biomass to synthesize PHA or increase the
synthesis rate of PHA relative to the synthesis rate of non-PHA
material. In one embodiment, the PHA is polyhydroxybutyrate (PHB).
In one embodiment, the biomass is one or more microorganisms. In
one embodiment, the step of increasing the concentration of the
element in the medium causes a reduction in the concentration of
sugar, lipids, nucleic acids, saccharides, polysaccharides, and/or
pigments in the biomass relative to the concentration of PHA in the
biomass. In one embodiment, the element is one or more of the
following: phosphorus, phosphate, phosphoric acid, sodium
phosphate, disodium phosphate, monosodium phosphate, or potassium
phosphate, methane, oxygen, carbon dioxide, hydroxyl ions, hydrogen
ion, nitrogen. In one embodiment, the element is one or more of the
following: EDTA, citric acid, iron, copper, magnesium, manganese,
zinc, calcium, potassium, boron. In one embodiment, the PHA
synthesis rate is increased relative to the synthesis rate of PHA
in said biomass in the absence of said. In one embodiment, the
synthesis of polyhydroxyalkanote (PHA) in a biomass material is
effected, comprising the steps of: (a) providing a medium
comprising a biomass and an element, and (b) maintaining above a
minimum concentration or increasing the concentration of the
element in the medium to cause the biomass material to
metabolically synthesize PHA at the expense of alternative biomass
energy and/or carbon storage materials. In one embodiment, the
element is phosphorus, oxygen, magnesium, calcium, copper, iron,
methane, carbon dioxide, or nitrogen. In one embodiment, the
element is phosphorus. In one embodiment, the element is oxygen. In
one embodiment, the element is magnesium. In one embodiment, the
element is calcium. In one embodiment, the element is copper. In
one embodiment, the element is iron. In one embodiment, the biomass
comprises one or more microorganisms. In one embodiment, one or
more microorganisms comprise methanotrophic microorganisms. In one
embodiment, one or more microorganisms comprise heterotrophic
microorganisms. In one embodiment, one or more microorganisms
comprise autotrophic microorganisms. In one embodiment, one or more
microorganisms comprise methanogenic microorganisms.
[0193] In one embodiment, the invention comprises manipulating the
concentration of elements, e.g., copper, iron, phosphorus, oxygen,
methane, carbon dioxide, in the culture medium to control the
concentration of sMMO and/or pMMO produced by a methanotrophic
culture in order to control the relative ratio of sMMO to pMMO in
the culture and thereby control the growth conditions, metabolic
status, metabolic disposition, and/or specification of PHA produced
by the culture. In some embodiments, sMMO is expressed in a range
between about 0% and 100% of a methanotrophic culture by dry cell
weight, as a percentage of microorganisms expressing sMMO, or as a
percentage of total MMO expressed by one or more methanotrophic
cells, including between 0% and 1%, between about 1% and about 2%,
between about 2% and about 3%, between about 3% and about 5%,
between about 5% and about 10%, between about 10% and about 20%,
between about 20% and about 30%, between about 30% and about 50%,
between about 50% and about 70%, between about 70% and about 80%,
between about 80% and about 90%, between about 90% and about 95%,
between about 95% and about or 100%, and overlapping ranges
thereof. Simultaneously, or independently, in some embodiments,
pMMO is expressed in a range between about 0% and 100% of a
methanotrophic culture by dry cell weight, as a percentage of
microorganisms expressing pMMO, or as a percentage of total MMO
expressed by one or more methanotrophic cells, including between 0%
and 1%, between about 1% and about 2%, between about 2% and about
3%, between about 3% and about 5%, between about 5% and about 10%,
between about 10% and about 20%, between about 20% and about 30%,
between about 30% and about 50%, between about 50% and about 70%,
between about 70% and about 80%, between about 80% and about 90%,
between about 90% and about 95%, between about 95% and about or
100%, and overlapping ranges thereof. In some embodiments, the
ratio of sMMO to pMMO produced in a methanotrophic culture is
controlled to control the specification of PHA produced by a
culture In some embodiments, the relative weight ratio of sMMO to
pMMO in a methanotrophic culture is at least or approximately 0 to
1, approximately 0.0000001 to 1, approximately 0.0001 to 1,
approximately 0.001 to 1, approximately 0.01 to 1, approximately
0.1 to 1, approximately 1 to 1, approximately 2 to 1, approximately
3 to 1, approximately 5 to 1, approximately 10 to 1, approximately
15 to 1, approximately 20 to 1, approximately 25 to 1,
approximately 30 to 1, approximately 35 to 1, approximately 50 to
1, approximately 65 to 1, approximately 70 to 1, approximately 80
to 1, approximately 90 to 1, approximately 95 to 1, approximately
98 to 1, approximately 99 to 1, approximately 100 to 1,
approximately 1000 to 1, approximately 10,000 to 1, approximately
100,000 to 1, or approximately 1,000,000 to 1, respectively. In
some embodiments, the relative weight ratio of pMMO to sMMO in a
methanotrophic culture is approximately 0 to 1, approximately
0.0000001 to 1, approximately 0.0001 to 1, approximately 0.001 to
1, approximately 0.01 to 1, approximately 0.1 to 1, approximately 1
to 1, approximately 2 to 1, approximately 3 to 1, approximately 5
to 1, approximately 10 to 1, approximately 15 to 1, approximately
20 to 1, approximately 25 to 1, approximately 30 to 1,
approximately 35 to 1, approximately 50 to 1, approximately 65 to
1, approximately 70 to 1, approximately 80 to 1, approximately 90
to 1, approximately 95 to 1, approximately 98 to 1, approximately
99 to 1, approximately 100 to 1, approximately 1000 to 1,
approximately 10,000 to 1, approximately 100,000 to 1, or
approximately 1,000,000 to 1. In some embodiments, controlling the
relative concentrations of sMMO and pMMO produced by a culture of
methanotrophic microorganisms, it is possible to control the
metabolic status of the culture and thereby control the type of PHA
and other cellular material produced by the culture, particularly
in the presence of volatile organic compounds, fatty acids,
volatile fatty acids, methanol, formate, acetate, dissolved carbon
dioxide, dissolved methane, dissolved oxygen, and other elements or
compounds that impact the metabolism of a culture of methanotrophic
microorganisms in a certain manner according to the relative
concentration of sMMO or pMMO in such a culture. In some
embodiments, sMMO and/or pMMO is expressed in a range between about
0% and 100% of a methanotrophic culture by dry cell weight, as a
percentage of microorganisms expressing sMMO or pMMO, or as a
percentage of total MMO expressed by one or more methanotrophic
cells, including between 0% and 1%, between about 1% and about 2%,
between about 2% and about 3%, between about 3% and about 5%,
between about 5% and about 10%, between about 10% and about 20%,
between about 20% and about 30%, between about 30% and about 50%,
between about 50% and about 70%, between about 70% and about 80%,
between about 80% and about 90%, between about 90% and about 95%,
between about 95% and about or 100%, and overlapping ranges thereof
prior to, during, throughout, or after a PHA production phase. In
one embodiment, sMMO is not expressed, or is expressed in low
concentrations, in a methanotrophic culture prior to, during,
throughout, or after a PHA production phase. Without being limited
by theory, it is believed that the directed or controlled absence
or reduction of sMMO in a methanotrophic culture producing PHA,
particularly in the presence of non-methane organic compounds that
can be metabolized by methanotrophic microorganisms, engenders PHA
production stability, consistency, and control by selectively
shielding against the metabolism of one or some or many non-methane
compounds that might otherwise be metabolized in the presence of
sMMO, which enables the metabolism of a larger group of non-methane
compounds than pMMO. Similarly, in one embodiment, pMMO is not
expressed, or is expressed in low concentrations, in a
methanotrophic culture prior to, during, throughout, or after a PHA
production phase. In some embodiments, the directed or controlled
absence or reduction of pMMO in a methanotrophic culture producing
PHA, particularly in the presence of non-methane organic compounds
that can be metabolized by methanotrophic microorganisms, engenders
PHA production stability, consistency, and control by selectively
inducing or promoting the metabolism of one or some or many
non-methane compounds that might otherwise be not be metabolized
using pMMO. In some embodiments, in some methanotrophic cultures,
sMMO promotes PHA synthesis at high intracellular concentrations by
reducing cellular production of non-PHA materials, particularly as
compared to PHA synthesis using pMMO. By controlling the
concentration of sMMO relative to pMMO in a methanotrophic
microorganism culture in the presence of methane and/or non-methane
organic compounds, including VOCs and other carbon-containing
materials, such as volatile fatty acids, acetone, acetic acid,
acetate, formate, formic acid, chloroform, methylene chloride,
carbon dioxide, ethane, and/or propane, it is possible to control
the specification or type of PHA produced by the culture, including
the molecular weight, polydispersity, melt flow, impact strength,
and other similar functional characteristics. In some embodiments,
it is preferable to maintain the concentration of copper in the
culture media in order to promote sMMO production. In some
embodiments, in some methanotrophic cultures, the production of
sMMO in many, most, or substantially all of the methanotrophic
cells enables the culture to produce more PHA when subject to a
nutrient limiting step than would otherwise be produced if the
relative ratio of pMMO in the culture was higher prior to the
nutrient limiting step. Conversely, in some embodiments, it is
preferable to maintain the concentration of copper in the culture
media in order to promote pMMO production. In some embodiments, in
some methanotrophic cultures, the production of pMMO in many, most,
or substantially (e.g., more than 50%, more than 60%, more than
70%, more than 80%, more than 90%, or more) all of the
methanotrophic cells enables the culture to produce more PHA when
subject to a nutrient limiting step than would otherwise be
produced if the relative ratio of sMMO in the culture was higher
prior to the nutrient limiting step. In one embodiment, one or more
methanotrophic cells or cultures are subject to repeated growth and
PHA synthesis cycles or steps, wherein the relative concentration
of sMMO to pMMO in the cells or cultures are caused to remain
approximately similar or the same in each new cycle or step in
order to control the specification and/or functionality of the PHA
produced by the culture. In several embodiments, the relative
concentration of sMMO to pMMO is variable across the repetitions.
In some embodiments, the ratio of relative concentrations decreases
(e.g., there is progressively less sMMO and progressively more pMMO
with each repetition). In one embodiment, the functional
characteristics of PHA produced by a methanotrophic culture exposed
to methane emissions comprising methane, carbon dioxide, and one or
more volatile organic compounds are controlled and optimized,
wherein the method comprises: (a) providing a methanotrophic
culture in a mineral medium comprising nutrients, (b) controlling
the concentration of one or more of nutrients in the medium to
cause the culture to produce a defined relative ratio of sMMO to
pMMO, (c) and controlling the concentration of the nutrients in the
medium to cause the culture to produce PHA. In one embodiment, the
culture produces essentially only pMMO. As used herein, the term
"essentially only" shall be given its ordinary meaning and shall
also refer to production of pMMO or sMMO in an amount greater than
about 50%, greater than about 55%, greater than about 60%, greater
than about 65%, greater than about 70%, greater than about 75%,
greater than about 80%, greater than about 85%, greater than about
90%, greater than about 95%, greater than about 97%, or greater
than about 99% of the monooxygenase produced by a culture. In other
embodiments, essentially only shall refer to the ratio of
production of pMMO to sMMO. In some embodiments wherein a culture
is producing essentially only pMMO, the ration of pMMO to sMMO is
about 2:1, about 5:1, about 10:1 about 50:1, about 100:1, about
250:1, about 500:1, about 1000:1, about 2500:1, about 5000:1, about
10,000:1, or greater. In still additional embodiments, the culture
may produce both sMMO and pMMO, but with respect to the activity of
the enzymes, the culture produces PHA essentially only through the
pMMO-mediated pathway. In one embodiment, therefore, even if the
culture comprises an equal concentration of sMMO and pMMO, PHA may
be preferentially produced via pMMO. In other embodiments,
depending on the culture conditions and/or the microorganism
strain, the inverse can occur (e.g., the culture produces
essentially only sMMO). In one embodiment, the concentration of
sMMO in the culture is more than 2 times greater than the
concentration of pMMO in the culture. In one embodiment, the
concentration of sMMO is more than 5 times greater than the
concentration of pMMO in the culture. In one embodiment, the
concentration of sMMO is more than 10 times greater than the
concentration of pMMO in culture. In one embodiment, the
concentration of pMMO is more than 2 times greater than the
concentration of sMMO in said culture. In one embodiment, the
concentration of pMMO is more than 5 times greater than the
concentration of sMMO in said culture. In one embodiment, steps (a)
through (c) are repeated, wherein the concentration of sMMO
relative to pMMO in the culture is substantially the same (e.g.,
within 5%, 10%, 25%, 50% or 75% relative proportion by weight) in
step (c) in at least two repetitions.
[0194] In one embodiment, a method is provided for converting a
carbon-containing gas or material into a polyhydroxyalkanoate (PHA)
at high efficiency, comprising: (a) providing a methanotrophic
culture, (b) providing a medium comprising one or more nutrient
comprising a carbon-containing material that can be metabolized by
the culture, (c) controlling the concentration of the one or more
nutrient in the medium to cause the cellular replication of one or
more microorganisms in the culture wherein the gene encoding the
soluble methane monooxygenase enzyme is absent in the one or more
microorganisms, (d) controlling the concentration of the one or
more nutrients in the medium to cause the culture to produce PHA,
and (e) repeating steps (a) through (d). Copper is a critical
component of many methanotrophic systems, including both sMMO and
pMMO, and copper typically controls the switch between sMMO and
pMMO production. Reducing copper concentration (below 0.1, 1, 2, 4,
10, 20, 40, 100 micromolar, below 0.001, 0.01, 0.1, 1, 2, 4, 8, 10,
15, 20, 40, 100, 200 mg/L, or below 0.001, 0.01, 0.1, 1, 2, 4, 10,
100 mg/g dry weight of microorganism biomass) typically increases
sMMO production, while increasing copper concentration (above 0.1,
1, 2, 4, 10, 20, 40, 100 micromolar, above 0.001, 0.01, 0.1, 1, 2,
4, 8, 10, 15, 20, 40, 100, 200 mg/L, or, or above 0.001, 0.01, 0.1,
1, 2, 4, 10, 100 mg/g dry weight of microorganism biomass)
typically increases pMMO production. Copper is generally added to a
culture each time water or mineral media is added to a culture,
since trace copper is difficult to remove from even purified water,
and copper is needed for methanotrophic cellular
replication/growth, since MMO generally drives the oxidation of
methane to biomass, and MMO is a copper-containing enzyme.
Applicant has surprisingly discovered that microorganisms that do
not possess or express the gene for sMMO unexpectedly produce PHA
at high efficiency, and can be selectively cultured, using culture
selection pressures, to out-compete microorganisms that do possess
or express the gene for sMMO (particularly in non-sterile systems,
wherein new microorganisms are periodically introduced to the
culture) by limiting, controlling, or reducing copper
concentrations and simultaneously subjecting the culture to
growth-polymerization-growth repetitions, as described herein. In
one embodiment, microorganisms that possess higher concentrations
of PHA switch from polymerization to growth mode (wherein the
microorganisms produce soluble and/or particulate methane
monooxygenase) more quickly and efficiently than microorganisms
that possess lower concentrations of PHA, and/or carry out cellular
replication more efficiently in general; by reducing copper
concentrations to levels that would traditionally cause the culture
to express sMMO (e.g., less than 0.001, 0.01, 0.1, 1, 10, or 100
mg/L, or less than 0.01, 0.1, 1, 10, or 100 micromolar, or less
than 0.001, 0.01, 0.1, 1, 10, or 100 mg per gram microorganism dry
weight) while also cycling between growth and polymerization
cycles, microorganisms that produce high concentrations of PHA and
also grow quickly in low copper concentrations out-compete
microorganisms that produce less PHA and grow slower in low copper
concentrations. Since pMMO renders a faster metabolism than sMMO,
by reducing the copper concentration in the medium (permanently or
temporarily) to traditionally sMMO-generating concentrations, and
concurrently subjecting a culture to growth-polymerization-growth
repetitions which select for microorganisms that generate high PHA
concentrations and metabolize efficiently in transitioning from
polymerization mode to growth mode, Applicant has discovered that a
high-efficiency microorganism can be selectively produced and
maintained, including in non-sterile conditions, that does not
contain or express the genetic coding for sMMO, accumulates high
concentrations of PHA, and out-competes microorganisms that produce
sMMO. The ability to cause a methanotrophic culture to generate
microorganisms that do not possess or express the gene encoding
sMMO by reducing copper concentrations is a surprising and
unexpected result, and offers a range of advantages, including
superior process stability (microorganisms produce only pMMO,
regardless of copper concentration), PHA consistency (the metabolic
pathway, pMMO, is unchanging, thereby controlling the
characteristics of PHA produced, such as monomer composition,
molecular weight, polydispersity, elongation, modulus, viscosity),
and increased metabolic efficiency (e.g., rate, oxidation,
metabolism, copper requirements). In addition to copper, other
nutrients can be used, either individually or in combination, in
similar fashion to control for the selective production of
microorganisms that do not possess or express the gene encoding
soluble methane monooxygenase, such nutrients including: methane,
oxygen, phosphorus, magnesium, iron, boron, aluminum, calcium,
cobalt, chloride, chromium, EDTA, manganese, molybdenum, sulfur,
nickel, zinc, and/or potassium. In one embodiment, more than 10%,
25%, 50%, 75%, or 80% of the culture does not contain or express
the gene encoding soluble methane monooxygenase.
[0195] In one embodiment, a method is provided for converting a
carbon-containing material (e.g., methane, carbon dioxide, propane,
ethane, acetone, acetate, formaldehyde, a volatile organic
compound, a non-methane organic compound, carbon dioxide) into a
polyhydroxyalkanoate (PHA), the method comprising: (a) providing a
methanotrophic culture, (b) providing a medium comprising one or
more nutrient comprising a carbon-containing material that can be
metabolized by the culture, (c) controlling the concentration of
the one or more nutrient in the medium to cause the cellular
replication of the culture w wherein the gene encoding the
ethylmalonyl-CoA pathway is present or expressed in one or more
microorganism in said culture, (d) controlling the concentration of
said one or more nutrients in said medium to cause said culture to
produce PHA, and (e) repeating steps (a) through (d). Applicant has
surprisingly discovered that the ethylmalonyl-CoA (EMC) pathway,
combined with required and controlled conditions, enables the
production of over 50%, 55%, 60%, 65%, 70%, 80%, 85%, 90%, and 95%
intracellular PHA concentrations. Applicant has also surprisingly
discovered that the ethylmalonyl-CoA (EMC) pathway can switch from
growth to PHA polymerization and back to growth at high efficiency,
even when intracellular PHA concentrations exceed over 50%, 55%,
60%, 65%, 70%, 80%, 85%, 90%, and 95% by weight, whereas many
cultures with PHA concentrations exceeding 50%, 60%, or 70% cannot
effectively return to growth mode following a polymerization
period. Thus, by subjecting a culture to
growth-polymerization-growth cycling, Applicant has found that it
is possible to select for microorganisms that possess the gene
encoding the EMC pathway. In addition, Applicant has surprisingly
discovered that it is possible to selectively produce a culture of
microorganisms that express the EMC pathway in sterile or
non-sterile conditions, including in the presence of methane,
non-methane carbon-containing materials, or other materials that
influence the metabolism of the microorganisms, by simultaneously
subjecting the culture to growth-PHA polymerization-growth cycling,
as described herein, while also controlling the concentration one
or more nutrients available to the culture. In one embodiment, the
concentration of a nutrient, such as copper, is controlled to
selectively favor the production of EMC-pathway microorganisms. In
some embodiments, microorganisms that do not possess or express the
genetic material encoding soluble methane monooxygenase also
possess the genes encoding the EMC-pathway. Thus, as described
herein, by subjecting the culture to growth-polymerization-growth
(GPG) cycling while also controlling or reducing the concentration
of copper, or other nutrients that impact the switch between sMMO
and pMMO production, it is possible to selectively produce
microorganisms that do not possess or express the genetic material
encoding soluble methane monooxygenase but do possess the gene
encoding the EMC pathway. The ability to selectively produce
microorganisms that contain or express the genes encoding the EMC
pathway and/or do not contain or express the genes encoding sMMO
offers significant process advantages, including process stability
(microorganisms produce consistent concentrations of PHA and
produce only pMMO, regardless of copper concentration or
microorganism contamination), PHA consistency (the metabolic
pathway is unchanging, thereby controlling the characteristics of
PHA produced, such as monomer composition, molecular weight,
polydispersity, elongation, modulus, viscosity), and increased
metabolic efficiency (e.g., rate, oxidation, metabolism, nutrient
requirements). In some embodiments, such microorganisms and
processes may be combined with other microorganisms and processes,
wherein a culture may contain microorganisms containing genes
encoding or expressing both sMMO and pMMO and genetic packages that
do not encode or express the EMC pathway; in some embodiments,
microorganisms that do not possess or express one or more gene
encoding sMMO comprise less than 1%, less than 5%, less than 10%,
less than 20%, less than 50%, less than 75%, more than 75% of a
culture; in other embodiments, microorganisms that contain or
express genetic material encoding the EMC pathway comprise less
than 1%, less than 5%, less than 10%, less than 20%, less than 50%,
less than 75%, more than 75% of a culture.
[0196] In one embodiment, a method is provided for converting a
carbon-containing gas or material into a polyhydroxyalkanoate (PHA)
at high efficiency, comprising: (a) providing a methanotrophic
culture, (b) providing a medium comprising one or more nutrient
comprising a carbon-containing material that can be metabolized by
the culture, (c) controlling the concentration of the one or more
nutrient in the medium to cause the cellular replication of one or
more microorganisms in the culture wherein the gene encoding the
soluble methane monooxygenase enzyme is absent in the one or more
microorganisms, (d) controlling the concentration of the one or
more nutrients in the medium to cause the culture to produce PHA,
and (e) repeating steps (a) through (d). Copper is a critical
component of many methanotrophic systems, including both sMMO and
pMMO, and copper typically controls the switch between sMMO and
pMMO production. In several embodiments, reducing copper
concentration (below about 0.1, about 1, about 2, about 4, about
10, about 20, about 40, about 100 micromolar, below about 0.001,
about 0.01, about 0.1, about 1, about 2, about 4, about 8, about
10, about 15, about 20, about 40, about 100, about 200 mg/L, or
below about 0.001, about 0.01, about 0.1, about 1, about 2, about
4, about 10, about 100 mg/g dry weight of microorganism biomass)
typically increases sMMO production. In contrast, increasing copper
concentration (above about 0.1, about 1, about 2, about 4, about
10, about 20, about 40, about 100 micromolar, above about 0.001,
about 0.01, about 0.1, about 1, about 2, about 4, about 8, about
10, about 15, about 20, about 40, about 100, about 200 mg/L, or, or
above about 0.001, about 0.01, about 0.1, about 1, about 2, about
4, about 10, about 100 mg/g dry weight of microorganism biomass)
typically increases pMMO production. Copper is generally added to a
culture each time water or mineral media is added to a culture,
since trace copper is difficult to remove from even purified water,
and copper is needed for methanotrophic cellular
replication/growth, since MMO generally drives the oxidation of
methane to biomass, and MMO is a copper-containing enzyme.
[0197] In accordance with several embodiments, Applicant has
surprisingly discovered that selective culture conditions can be
employed that allow for the dominance of a culture by
microorganisms that utilize the pMMO pathway, even at low or
reduced copper concentrations. In some embodiments, the pMMO
pathway or enzyme is the exclusive pathway or enzyme expressed or
used in the microorganism for the production of methane
monooxygenase (e.g., the selective pressures of the processes
disclosed herein induce a loss of the genetic material encoding the
sMMO gene in the culture or microorganism over time, or the
selective pressures result in the dominance or growth or metabolic
success of microorganisms that do not possess or express the
genetic material used for sMMO production). In some embodiments,
the pMMO pathway is either preferentially expressed or
preferentially active in the culture, such that the microorganisms
still retain the genetic material necessary to produce sMMO, but
sMMO is either not produced, produced but not used, produced and
functionally blocked (e.g., negative feedback mechanisms), produced
and functionally deficient under the culture conditions, and/or
produced but metabolically outcompeted for substrate by pMMO
enzymes. Thus, in several embodiments, microorganisms that have
reduced sMMO expression or function unexpectedly produce PHA at
high efficiency, and can be selectively cultured, using culture
selection pressures, to out-compete microorganisms that do express
sMMO (particularly in non-sterile systems, wherein new
microorganisms are periodically introduced to the culture) by
limiting, controlling, or reducing copper concentrations and
simultaneously subjecting the culture to
growth-polymerization-growth repetitions, as described herein.
[0198] In one embodiment, microorganisms that possess higher
concentrations of PHA switch from polymerization to growth mode
(wherein the microorganisms produce soluble and/or particulate
methane monooxygenase) more quickly and efficiently than
microorganisms that possess lower concentrations of PHA, and/or
carry out cellular replication more efficiently in general. By
reducing copper concentrations to levels that would cause or
enable, or traditionally cause or enable, the culture, or at least
one or more methanotrophic microorganisms, to express sMMO (e.g.,
less than about 0.001, about 0.01, about 0.1, about 1, about 10, or
about 100 mg/L, or less than about 0.01, about 0.1, about 1, about
10, or about 100 micromolar, or less than about 0.001, about 0.01,
about 0.1, about 1, about 10, or about 100 mg per gram
microorganism dry weight) while also cycling between growth and
polymerization cycles, microorganisms that produce high
concentrations of PHA and also grow quickly in low copper
concentrations out-compete microorganisms that produce less PHA and
grow slower in low copper concentrations. Since pMMO renders a
faster metabolism than sMMO, by reducing the copper concentration
in the medium (permanently or temporarily) as compared to
traditionally pMMO-generating copper concentrations (e.g., to
concentrations that could enable or induce one or more
methanotrophic microorganisms to produce sMMO if present in the
medium), and concurrently (or subsequently) subjecting a culture to
growth-polymerization-growth repetitions which select for
microorganisms that generate high PHA concentrations and metabolize
efficiently in transitioning from polymerization mode to growth
mode, Applicant has discovered that a high-efficiency microorganism
can be selectively produced and maintained (even in non-sterile
conditions) that either does not contain, does not express, does
not produce, or expresses or produces at reduced levels sMMO,
accumulates high concentrations of PHA, and out-competes
microorganisms that produce sMMO. The ability to cause a
methanotrophic culture to generate microorganisms that do not
possess the genetic material encoding sMMO or express sMMO at
reduced levels (or reduced functionality) by reducing copper
concentrations is a surprising and unexpected result, and offers a
range of advantages. For example, superior process stability
(microorganisms produce only pMMO, regardless of copper
concentration), PHA consistency (the metabolic pathway, pMMO, is
unchanging, thereby controlling the characteristics of PHA
produced, such as monomer composition, molecular weight,
polydispersity, elongation, modulus, viscosity), and increased
metabolic efficiency (e.g., rate, oxidation, metabolism, copper
requirements) are achieved. In addition to copper, other nutrients
can be used, either individually or in combination, in similar
fashion to control for the selective production of microorganisms
that do not possess or express the gene encoding soluble methane
monooxygenase, such nutrients including: methane, oxygen,
phosphorus, magnesium, iron, boron, aluminum, calcium, cobalt,
chloride, chromium, EDTA, manganese, molybdenum, sulfur, nickel,
zinc, and/or potassium. In one embodiment, more than 10%, 25%, 50%,
75%, or 80% of the culture does not contain the gene encoding
soluble methane monooxygenase.
[0199] In one embodiment, a method is provided for converting a
carbon-containing material (e.g., methane, carbon dioxide, propane,
ethane, acetone, acetate, formaldehyde, a volatile organic
compound, a non-methane organic compound, carbon dioxide) into a
polyhydroxyalkanoate (PHA), the method comprising: (a) providing a
methanotrophic culture, (b) providing a medium comprising one or
more nutrient comprising a carbon-containing material that can be
metabolized by the culture, (c) controlling the concentration of
the one or more nutrient in the medium to cause the cellular
replication of the culture wherein the genetic material encoding
the ethylmalonyl-CoA (EMC) pathway (e.g., the various enzymes or
co-factors that are involved in the pathway) is present in one or
more microorganism in said culture, (d) controlling the
concentration of said one or more nutrients in said medium to cause
said culture to produce PHA, and (e) repeating steps (a) through
(d). Applicant has surprisingly discovered that the EMC pathway,
combined with required and controlled conditions, enables the
production of over 50%, 55%, 60%, 65%, 70%, 80%, 85%, 90%, and 95%
intracellular PHA concentrations. Applicant has also surprisingly
discovered that the microorganisms using the EMC pathway can be
switched from growth conditions or metabolism to PHA polymerization
conditions or metabolism and back to growth conditions or
metabolism at high efficiency, even when intracellular PHA
concentrations exceed over 50%, 55%, 60%, 65%, 70%, 80%, 85%, 90%,
and 95% by weight, whereas many cultures with PHA concentrations
exceeding 50%, 60%, or 70% cannot effectively return to growth mode
following a polymerization period. Thus, by subjecting a culture to
growth-polymerization-growth cycling, Applicant has found that it
is possible to select for microorganisms that possess the gene
encoding the EMC pathway. In addition, Applicant has surprisingly
discovered that it is possible to selectively produce a culture of
microorganisms that express the EMC pathway in sterile or
non-sterile conditions, including in the presence of methane,
non-methane carbon-containing materials, or other materials that
influence the metabolism of the microorganisms, by simultaneously
subjecting the culture to growth-PHA polymerization-growth cycling,
as described herein, while also controlling the concentration one
or more nutrients available to the culture. In one embodiment, the
concentration of a nutrient, such as copper, is controlled to
selectively favor the production of EMC-pathway microorganisms. In
some embodiments, microorganisms that do not possess the genetic
material encoding soluble methane monooxygenase (or have the
genetic material but express at reduced levels or at reduced levels
of activity) also possess the genes encoding the EMC-pathway. Thus,
as described herein, by subjecting the culture to
growth-polymerization-growth (GPG) cycling while also controlling
or reducing the concentration of copper, or other nutrients that
impact the switch between sMMO and pMMO production, it is possible
to selectively produce microorganisms that do not possess the gene
encoding soluble methane monooxygenase (or have the genetic
material but express sMMO at reduced levels or at reduced levels of
activity) but do possess the gene encoding the EMC pathway. The
ability to selectively produce microorganisms that contain the
genetic material for and express the gene encoding the EMC pathway
and/or do not contain the genetic material for or do not express
the gene encoding sMMO offers significant process advantages,
including process stability (microorganisms produce consistent
concentrations of PHA and produce only pMMO, regardless of copper
concentration or microorganism contamination), PHA consistency (the
metabolic pathway, is unchanging, thereby controlling the
characteristics of PHA produced, such as monomer composition,
molecular weight, polydispersity, elongation, modulus, viscosity),
and increased metabolic efficiency (e.g., rate, oxidation,
metabolism, nutrient requirements). In some embodiments, such
microorganisms and processes may be combined with other
microorganisms and processes, wherein a culture may contain
microorganisms containing genes encoding both sMMO and pMMO and
genetic material that does not include material encoding the EMC
pathway; in some embodiments, microorganisms that do not possess
gene(s) encoding sMMO comprise less than about 1%, less than about
5%, less than about 10%, less than about 20%, less than about 50%,
less than about 75%. In other embodiments, microorganisms that
contain genetic material encoding the EMC pathway comprise less
than about 1%, less than about 5%, less than about 10%, less than
about 20%, less than about 50%, or less than about 75%. In some
embodiments, microorganisms and processes may be combined with
other microorganisms and processes, wherein a culture may contain
microorganisms containing genes encoding both sMMO and pMMO and
genetic material that does not include material encoding the EMC
pathway. It shall be appreciated that additional selection methods,
and/or "spiking" of a culture with microorganisms of a certain type
or genetic makeup can be used to achieve microorganism cultures
with desired characteristics/demographics. [0146] In several
embodiments of the invention, methanol is added to a culture of
methanotrophic microorganisms utilizing a closed loop recycling gas
stream comprising methane. In some embodiments, methanotrophic
microorganisms are enabled to grow under conditions of, and
consume, very low concentrations of methane by co-utilizing
methanol as a carbon substrate. In the past, the growth of
methanotrophic microorganisms was significantly reduced under low
methane concentrations due to, among other things, low mass
transfer rates. In some embodiments, by the addition of methanol in
a closed loop gas recycling system, it is possible to effect the
substantially complete elimination of methane by methanotrophic
microorganisms.
[0200] In several embodiments of the invention, the diffusion of
light is increased in a liquid growth culture media by reducing the
density of the liquid in a light path. In some embodiments the
culture comprises autotrophic microorganisms. In some embodiments,
the application of gas bubbles into the media decreases the
relative solids density of the light path, thus enabling an
increased diffusion of light into a liquid culture media from a
given light intensity energy.
[0201] In several embodiments of the invention, a series of
submerged light rods are placed into a liquid culture to manipulate
or adjust the culture conditions. In some embodiments, the culture
comprises autotrophic microorganisms. In some embodiments, the
light rods function to diffuse light, diffuse gas, act as static or
dynamic mixers, assist in the circulation of a liquid culture
media, and/or facilitate heat exchange through the circulation of a
gas, liquid, and/or combination thereof.
[0202] Traditionally, pH control in a microorganism growth system
is difficult and/or costly to maintain. In some embodiments, pH is
controlled by varying the nitrogen source supplied to a
microorganism growth system between pH-increasing and pH-reducing
nitrogen sources, e.g., NO.sub.3.sup.+ and NH.sub.3.sup.+,
respectively. In some embodiments, nitrogen sources are utilized
that do not significantly affect the pH of the system, including,
when applicable, complex nitrogen sources such as biomass. In
additional embodiments, a closed loop system is employed to reduce
changes in pH. In some embodiments, respiration-generated carbon
dioxide counterbalances increases in pH caused by the utilization
of pH-increasing nitrogen sources, such as nitrates. In one
embodiment, nitrogen fixation is used to add hydroxyl ions to the
culture medium, which may or may not be counterbalanced by the
addition of protons from either biological or chemical sources. In
one embodiment, nitrate fixation is used to add hydroxyl ions to
the culture medium, which may or may not be counterbalanced by the
addition of protons from either biological or chemical sources. In
one embodiment, ammonia or ammonium fixation is used to add protons
to the culture medium, which may or may not be counterbalanced by
the addition of hydroxyl ions from either biological or chemical
sources.
[0203] A number of methods are known for the induction of gas into
liquid, including static mixing, ejector mixing, propeller mixing,
and/or a combination thereof. Simultaneously, it is also known that
shear can be highly detrimental to microorganism growth, and can
often impede or permanently deactivate microorganism metabolism.
Thus, mass transfer in a gas-based system is often limited by the
need to counterbalance sufficient mixing with shear considerations.
In several embodiments of the invention, a vessel comprising liquid
culture media is mixed with a gas, e.g. methane, under relatively
high shear conditions, and then subsequently transferred to a
vessel comprising liquid culture media maintained under relatively
low shear conditions. In some embodiments, microorganism growth is
primarily induced in the low shear vessel. In some embodiments,
high gas transfer rates are effected in the first high shear vessel
by mixing while performed in the low shear vessel by gaseous
diffusion.
[0204] In another embodiment, a closed loop gas recycling system is
maintained, wherein a vessel comprising gas-utilizing
microorganisms is supplied with gas, wherein the gas is utilized by
gas-utilizing microorganisms, and wherein the rate at which gas is
added to the system is determined by the rate at which the pressure
in the vessel changes in accordance with the conversion of gases
into metabolic derivatives (such as biomass, carbon dioxide, and
water). For example, a vessel containing methane-utilizing
microorganisms may be pressurized to 60 psi with a combination of
methane and oxygen; as the pressure in the system drops in
accordance with the metabolism of the methane-utilizing
microorganisms, additional methane and oxygen is added to the
system such that the pressure of the vessel remains at 60 psi. It
shall be appreciated that, in certain embodiments, higher or lower
pressures are maintained. In some embodiments, the system is
periodically flushed to remove carbon dioxide. In some embodiments,
autotrophic microorganisms and a light injection system may be
added to the system in order to convert carbon dioxide into
additional oxygen, thereby substantially reducing or eliminating
the need to flush the system and/or introduce oxygen.
[0205] In several embodiments, PHA synthesis is induced in a
microorganism culture comprising methane-utilizing, heterotrophic,
and/or carbon dioxide-utilizing microorganisms wherein a PHA
inclusion concentration (by dry biomass weight) is generated of
between about 0.01% and about 95%. In some embodiments, the
inclusion concentration is between about 25% and about 80%,
including about 25 to about 35%, about 35% to about 50%, about 50%
to about 65%, about 65% to about 80%, and overlapping ranges
thereof. In some embodiments, the inclusion concentration is
between about 0.01% and about 55%, including, about 0.01% to about
1%, about 1% to about 5%, about 5% to about 10%, about 10% to about
15%, about 15% to about 20%, about 20%, to about 25%, about 25% to
about 30%, about 30% to about 35%, about 35% to about 40%, about
40% to about 45%, about 45% to about 50%, about 50% to about 55%,
and overlapping ranges thereof. In some embodiments, these
inclusion ratios are achieved with reduced carbon input, reduced
energy expenditure, or reduced numbers of microorganisms (thereby
representing a more efficient generation of PHA). In some
embodiments, PHA synthesis is induced in a methanotrophic,
heterotrophic, and/or autotrophic microorganism culture wherein a
PHA inclusion concentration (by dry biomass weight) is generated of
between about 20% and about 80%, between about 30% and about 70%,
between about 40% and about 60%, between about 50% and about 70%,
including about 50% to about 55%, about 55 to about 60%, about 60%
to about 65%, about 65% to about 70%, and overlapping ranges
thereof. In some embodiments of the invention, PHA synthesis is
induced in microorganism culture comprising methanotrophic,
autotrophic, and heterotrophic microorganisms, wherein an average
PHA inclusion concentration (by dry biomass weight) is greater than
about 5%, greater than about 20%, greater than about 40%, greater
than about 65%, or greater than about 70% by dry cell weight.
[0206] In some embodiments, the growth culture media is manipulated
to induce both i) microorganism growth and ii) PHA synthesis within
one or more open, non-sterile, or sterile vessels using a
feast-famine culture regime. In some embodiments, the
microorganisms are subject to successive alternating periods of
nutrient/carbon availability and nutrient/carbon unavailability to
encourage the reproductive success of microorganisms that are
capable of synthesizing PHA, particularly at high inclusion
concentrations. Feast-famine regimes useful for the selection of
PHA producing microorganisms, including PHA-producing
methanotrophic microorganisms, over microorganisms that either
cannot produce PHA, produce PHA slowly, or produce PHA at
relatively low concentrations are described in the art (Verlinden,
et al., "Bacterial synthesis of biodegradable
polyhydroxalkanoates," Journal of Applied Microbiology, 102 (2007),
p. 1437-1449, Frigon, et al., "rRNA and Poly-Hydroxybutyrate
Dynamics in Bioreactors Subjected to Feast and Famine Cycles,"
Applied and Environmental Microbiology, April 2006, p. 2322-2330;
Muller, et al., "Adaptive responses of Ralstonia eutropha to feast
and famine conditions analysed by flow cytometry," J Biotechnol.
1999 Oct. 8; 75(2-3):81-97; Reis, et al., "Production of
polyhydroxyalkanoates by mixed microbial cultures," Bioprocess and
Biosystems Engineering, Volume 25, Number 6, 377-385, DOI:
10.1007/s00449-003-0322-4.)
[0207] In some embodiments of the invention, the classical
feast-famine regime is modified to reduce PHA losses. Specifically,
in the past, feast-famine regimes were thought to be effective by
passing a microorganism culture through a period wherein carbon or
nutrients were unavailable or relatively limited for metabolism,
thereby forcing the culture to accumulate and/or consume
intracellular PHA as a source of carbon to survive, and thereby
selecting for microorganisms with the capacity to synthesize and
store PHA. Applicant has surprisingly discovered that, some
microorganisms with higher concentrations of intracellular PHA
reproduce more efficiently than microorganisms with lower
concentrations of intracellular PHA in periods of carbon
availability and nutrient balance. Thus, in one embodiment, a novel
PHA production regime is employed in one or more vessel wherein
microorganisms are subjected to two successive and recurring
phases: 1) growth, wherein carbon and nutrient availability is
optimized for reproduction, and 2) PHA synthesis, wherein carbon is
available in excess, and one or more nutrient is reduced or
increased relative to the growth period to induce PHA synthesis. In
some embodiments, a fraction of the vessel media is removed for
downstream PHA extraction and processing after the PHA synthesis
period, and that fraction is replaced with lower cell density
media, which simultaneously returns carbon and nutrient
concentrations to reproductively favorable levels, e.g., the growth
phase or growth conditions, and causes microorganisms to enter into
a reproductive phase without consuming significant portions of
intracellular PHA. As such, efficient PHA producing microorganisms
selectively reproduce over inefficient or non-PHA producing
microorganisms. As a result, some embodiments, i) increase the
speed of the microorganism selection process by removing the PHA
consumption step typical to previous feast famine models and ii)
reduce the loss of PHA to cellular metabolism. According to such
embodiments, the feast famine model is converted to a
feast-polymerization-feast process. In several embodiments
methanotrophic, autotrophic, and/or heterotrophic cultures are used
in the feast-polymerization-feast process.
Removing a Portion of the PHA-Containing Biomass from the Culture,
and Extracting PHA from the Removed PHA-Containing Biomass to
Produce Isolated PHA and PHA-Reduced Biomass
[0208] In several embodiments, following the production of a
microorganism culture comprising biomass and PHA (discussed above),
at least a portion of the PHA-containing biomass is removed from
the culture. In several embodiments, a portion ranging from about
20% to about 80% of the PHA-containing biomass is removed,
including about 30% to about 70%, about 40% to about 60%, about 45%
to about 55%, and overlapping ranges thereof. Removal of
PHA-containing biomass may be performed by a number of methods,
including centrifugation, filtration, density separation,
flocculation, agglomeration, spray drying, or other separation
technique. In some embodiments, dewatering (e.g., by
centrifugation) results in a biomass having a desirable water
content that facilitates downstream processing of the biomass. For
example, in some embodiments, centrifugation of the PHA-containing
biomass reduces the amount of culture media (increases the relative
biomass concentration) to a concentration range between about 100
and about 500 grams of biomass per liter of culture media. In some
embodiments, the concentration is of the biomass is adjusted to
about 100 to about 200 g/L, about 200 to about 300 g/L, about 300
to about 400 g/L, about 400 to about 500 g/L, and overlapping
ranges thereof. Advantageously, such an approach also produces, as
an effective by-product, clarified culture media that can be
optionally treated, measured, or recycled into one or more culture
vessels.
[0209] In some embodiments, after a portion of the PHA-containing
biomass is removed from the culture, PHA is extracted from the
removed PHA-containing biomass to produce isolated PHA and
PHA-reduced biomass.
[0210] As used herein, the terms "extraction" and "PHA extraction"
shall be given their ordinary meaning and shall be used
interchangeably to describe the removal and/or separation of PHA
from biomass. PHAs may be extracted from biomass by several
processes, including, but not limited to, the use of chemicals
(e.g., solvents) alone or in combination with mechanical means
and/or enzymes. These processes include the use of: solvents, such
as acetone, ethanol, methanol, methylene chloride, dichloroethane,
with and/or without the application of pressure and/or elevated
temperatures, supercritical carbon dioxide, enzymes, such as
proteases, surfactants, pH adjustment, including the protonic or
hydroxide-based dissolution of non-PHA biomass, and/or hypochlorite
(or another solvent) to dissolve non-PHA biomass, including the use
of hypochlorite in conjunction with another solvent, such as
methylene chloride or with, carbon dioxide, enzymes, acids, bases,
polymers, or surfactants, or combinations thereof. In some
embodiments of the invention, PHA is extracted by solvent
extraction from a PHA-containing biomass comprising gas-utilizing
microorganisms and/or biomass-utilizing microorganisms to produce
isolated PHA and PHA-reduced biomass. In some solvent-based
embodiments, solvents suitable for dissolving the PHA are used,
including carbon dioxide, acetone, methylene chloride, chloroform,
water, ethanol, and methanol. In some embodiments, particular
ratios of solvent to PHA provide optimal dissolution of PHA from
the culture, and therefore lead to improved extraction and
isolation efficiency and yield. For example, in some embodiments,
ratios of solvent to PHA (in grams) of about 500:1 are used. In
some embodiments, ratios of about 0.01:1 are used. In some
embodiments, ratios ranging from between about 500:1 and about
0.01:1 are used, such as about 0.05:1, about 1.0:1, about 1.5:1,
about 20:1, about 250:1, about 300:1, about 350:1, about 400:1, or
about 450:1.
[0211] As discussed above, changes in temperature and/or pressure
may also be used to facilitate the extraction of PHA from the
PHA-containing biomass. In some embodiments, the extraction solvent
chosen dictates the limits of temperature, pressure, and/or
incubation times that are used. In some embodiments, solvent is
combined with PHA-containing biomass and incubated for several
minutes up to several hours. For example, in some embodiments,
incubation is for about 10 minutes, while in other embodiments,
overnight incubation times are used. In some embodiments,
incubation times range from 30 minutes to about 1 hour, about 1
hour to about 2 hours, about 2 hours to about 4 hours, about 4
hours to about 6 hours, about 6 hours to about 8 hours, about 8
hours to about 10 hours, and from about 10 hours to overnight.
Choice of incubation time is determined by solvent, culture density
(e.g., number of microorganisms), type of organisms, expected PHA
yield, and other similar factors.
[0212] Incubation temperature is also tailored to the
characteristics of a given culture. Incubation temperatures can
range from below room temperature to elevated temperatures of up to
about 150.degree. C. or about 200.degree. C. For example, depending
the solvent and other variables of the culture, temperatures are
used that range from about 10.degree. C. to 25.degree. C., from
about 25.degree. C. to about 40.degree. C., from about 40.degree.
C. to about 55.degree. C., from about 55.degree. C. to about
60.degree. C., from about 60.degree. C. to about 75.degree. C.,
from about 75.degree. C. to about 90.degree. C., from about
90.degree. C. to about 105.degree. C., from about 105.degree. C. to
about 120.degree. C., from about 120.degree. C. to about
135.degree. C., from about 135.degree. C. to about 150.degree. C.,
from about 150.degree. C. to about 200.degree. C., and overlapping
ranges thereof.
[0213] As can be appreciated, if changes in temperature are made to
a culture in a closed vessel, changes in pressure result. In some
embodiments, increased pressure provides a shearing effect that
aids in the liberation of PHA from the microorganisms. In some
embodiments, pressure is regulated within a particular range. For
example, in some embodiments, pressure of the reaction of the
PHA-containing biomass with solvent occurs between about 40 and
30,000 psi, including about 50 to about 60 psi, about 60 to about
70 psi, about 70 to about 80 psi, about 80 to about 90 psi, about
90 to about 100 psi, about 100 to about 125 psi, about 125 to about
150 psi, about 150 to about 175 psi, about 175 to about 200 psi,
about 200 to about 1000 psi, about 1000 to about 5000 psi, about
5000 psi to about 10,000 psi, about 10,000 to about 20,000 psi,
about 20,000 to about 30,000 psi, and overlapping ranges thereof.
Additional sources of shear (e.g., agitation, pumping, stirring
etc.) are optionally used in some embodiments to enhance the
extraction of PHA. Any one, or combination, of the PHA extraction
methods described herein, or disclosed in the art, may be utilized
as a method to carry out PHA extraction and remove PHA from the
PHA-containing biomass.
[0214] In several embodiments, a solvent-based extraction system is
utilized to carry out PHA extraction. In some embodiments, solvents
are utilized to carry out PHA extraction at high temperatures,
wherein PHA extraction occurs simultaneous with a
temperature-enhanced breakdown or dissolution of PHA-containing
biomass. In some embodiments, one or more solvent is utilized that
is biodegradable and metabolically assimilable by the culture, such
that PHA-reduced biomass comprising biomass and one or more
biodegradable solvent may be contacted with the culture, and both
the PHA-reduced biomass and the solvent may be utilized by the
culture as a source of carbon. Non-limiting examples of such
solvents include carbon dioxide, acetone, ethanol, methanol, and
methylene chloride, among others.
[0215] In several embodiments a mixture of solvent and PHA
comprises multiple phases, e.g. an aqueous phase and an organic
phase. In some embodiments, solvent-based extraction comprises a
more uniform mixture of solvent and PHA. In some embodiments,
depending on the solvent the phases are separated prior to recovery
of the PHA. In some embodiments, a non-PHA polymer is also used,
alone or in conjunction with other processes, for separation,
flocculation, or other processing. In some embodiments,
centrifugation is employed to further distinguish and separate the
phases of the mixture (e.g., separation of the solvent-PHA phase
from the water-biomass phase). In some embodiments, heat is also
employed to maintain the solubility of the PHA in a given
solvent.
[0216] It shall be appreciated that the solubility of PHA varies
with the solvent used, and therefore the temperature (if adjusted)
and the separation techniques are tailored to match the
characteristics of a given solvent. Thus, in some embodiments
employing centrifugation, for example, a low speed centrifugation
is used to separate the solvent-PHA phase from the water-biomass
phase. In other embodiments, depending on the solvent, higher speed
centrifugation is used. In some embodiments, centrifugation is
employed in stages, e.g., low speed centrifugation followed by high
speed centrifugation. Any of a variety of centrifuges can be
employed, depending on the solvent used, for example, basket
centrifuges, swinging bucket centrifuges, fixed rotor centrifuges,
disc-back centrifuges, supercentrifuges, or ultracentrifuges.
[0217] In some embodiments, adjustable discharge ports suitable for
a particular centrifuge are used in order to control the rate and
degree of separation of solvent-PHA phase from the water-biomass
phase. In some embodiments, the concentration of water in the
water-biomass phase is adjusted to allow for suitable flow of the
mixture through the centrifuge (or within a centrifuge tube). For
example, in some embodiments, flow is suitable for separating the
phases when the concentration of biomass (relative to water) is
between about 1 and 100 g/L. In some embodiments, the concentration
is between about 10 to about 20 g/L, about 20 to about 30 g/L,
about 30 to about 40 g/L, about 40 to about 50 g/L, about 50 to
about 60 g/L, about 60 to about 70 g/L, about 70 to about 80 g/L,
about 80 to about 90 g/L, about 90 to about 100 g/L, about 100 to
about 200 g/L, about 200 to about 400 g/L, about 400 to about 600
g/L, and overlapping ranges thereof.
[0218] In still additional embodiments, increases in temperature
not only facilitate the extraction of the PHA, they also facilitate
the isolation of the PHA from the solvent (e.g. increased
temperature increases solvent evaporation).
[0219] In some embodiments, an extraction process is carried out to
remove PHA from a microorganism in such a manner that the
microorganism is deactivated. In some embodiments, the deactivation
is permanent, while in some embodiments the deactivation is
temporary. Without being bound by theory, it is believed that PHA
extraction techniques which do not permanently disable
microorganisms enable the PHA-reduced biomass generated thereby to
contribute to the metabolism of carbon sources after a PHA
extraction process, including through intracellular and
extracellular metabolism. In one embodiment, methods useful for the
temporary disablement of microorganisms include solvent extraction,
including solvent extraction carried out below about 100.degree.
C., and particularly at intracellular temperatures below about
100.degree. C., including extraction temperatures of about
10.degree. C. to about 30.degree. C., about 30.degree. C. to about
50.degree. C., about 50.degree. C. to about 60.degree. C., about
60.degree. C. to about 70.degree. C., about 70.degree. C. to about
80.degree. C., about 80.degree. C. to about 90.degree. C., about
90.degree. C. to about 100.degree. C., and overlapping ranges
thereof.
[0220] In several embodiments, the PHA concentration of
PHA-containing biomass is reduced as a result of the PHA extraction
process. In several embodiments, the PHA concentration of
PHA-containing biomass is reduced by at least about 0.01% (by dry
cell weight). In some embodiments, the PHA concentration is reduced
by about 10% to about 50%, about 50% to about 70%, about 70% to
about 75%, about 75% to about 80%, about 80% to about 85%, about
85%, to about 90%, about 90% to about 95%, about 95% to about
99.9%, and overlapping ranges thereof.
[0221] While a variety of methods are known to enable the
extraction PHA from biomass, most methods can be categorized into
one of two classes: a) solvent-based extraction, or b) NPCM
(non-polymer cellular material) dissolution-based extraction. NPCM
dissolution-based extraction methods utilize chemicals (such as
hypochlorite, or bleach), enzymes (such as protease), heat
(especially to reach temperatures above 100.degree. C.), pH (acids
and bases), and/or mechanical means (such as homogenization) to
break down, oxidize, and/or emulsify non-PHA cellular material. In
some cases, extraction methods from both categories can be
combined, such as the simultaneous utilization of hypochlorite and
methylene chloride.
[0222] NPCM dissolution-based extraction methods require continuous
and non-recoverable chemical inputs, such as hypochlorite,
peroxides, enzymes, and pH adjustors, and also generate significant
waste disposal issues. Thus, while these methods are effective, the
use of solvent-based extraction methods is generally preferred in
the industry due to the capacity of solvents to be distilled and
recovered for continuous re-utilization in a closed loop cycle.
Unfortunately, despite its benefits, some solvent-based extraction
methods are energy intensive processes that play a major role in
the high cost of PHA production, often accounting for more than 50%
of total production costs. Accordingly, there exists a significant
need for a novel method to significant increase the energy
efficiency of solvent-based extraction.
[0223] In several embodiments, a process for the extraction of
polyhydroxyalkanoates from biomass using a solvent-based extraction
method is provided, wherein the energy required to carry out the
process is reduced relative to prior solvent-based extraction
methods. Specifically, in one embodiment a high efficiency PHA
extraction process is provided comprising providing a
PHA-containing biomass comprising PHA and water, mixing the biomass
with a solvent at a temperature sufficient to dissolve at least a
portion of the PHA into the solvent and at a pressure sufficient to
enable substantially all or part of the solvent to remain in liquid
phase, thereby producing a PHA-lean biomass phase and a PHA-rich
solvent phase comprising solvent, water, and PHA, separating the
PHA-rich solvent phase from the PHA-lean biomass phase at a
temperature and pressure sufficient to enable substantially all or
part of the solvent to remain in the liquid phase and prevent
substantially all or part of the PHA within the PHA-rich solvent
phase from precipitating, reducing the pressure or increasing the
temperature of the PHA-rich solvent phase to cause the solvent to
vaporize and the PHA to precipitate or become a solid while
maintaining the temperature and/or the pressure of the PHA-rich
solvent phase to prevent all or part of the temperature-dependent
precipitation of the PHA into water, and collecting the solid PHA
material, including optionally separating the precipitated PHA from
the solvent and/or the water.
[0224] In the past, PHA precipitation has been induced in PHA-rich
solvent by a) adding a non-PHA solvent to the solvent phase to
reduce the solubility of PHA in the solvent phase and/or b)
reducing the temperature of the solvent phase to reduce the
solubility of PHA in the solvent. In particular, some methods 1)
dissolve PHA in a solvent by increasing the temperature of the
solvent and 2) precipitate PHA by reducing the temperature (and,
thus, solubility) of the solvent. Other methods require adding
water to a solution of PHA-rich solvent comprising dissolved PHA,
wherein the addition of water to the solution reduces the
solubility of the PHA in the solvent and causes the PHA to
precipitate into the solvent and/or water. (For example, U.S. Pat.
No. 4,562,245; U.S. Pat. No. 4,968,611; U.S. Pat. No. 5,894,062;
U.S. Pat. No. 4,101,533, all herein incorporated by reference.) In
each of these cases, energy efficiency is compromised;
specifically, by adding water or a non-PHA solvent to reduce the
PHA solubility of a solvent, additional energy is required for
downstream water/non-solvent removal, heating, and/or distillation.
By reducing the temperature of the solvent to reduce the solubility
of the solvent and induce PHA precipitation, heat energy is
redundantly expended, as the solvent must be re-heated for
distillation and recovery. Therefore, in several embodiments,
rather than adding a non-solvent to a PHA-solvent or reducing the
temperature of the PHA-solvent to effect PHA precipitation,
pressure and/or an increase in temperature is used to induce the
precipitation or solidification of the PHA without redundantly
reducing the temperature of solvent. Thus, in such embodiments,
there is a significant reduction in the energy required to heat
and/or distill non-solvent and/or solvent in downstream PHA
processing.
[0225] In one embodiment, the extraction process is substantially
carried out at intracellular temperatures less than about
100.degree. C. In other embodiments, temperatures for extraction
range from about 10.degree. C. to about 30.degree. C., from about
30.degree. C. to about 50.degree. C., from about 50.degree. C. to
about 70.degree. C., from about 70.degree. C. to about 90.degree.
C., from about 90.degree. C. to about 120.degree. C., from about
100.degree. C. to about 140.degree. C., from about 20.degree. C. to
about 150.degree. C., or from about 120.degree. C. to about
180.degree. C., or higher. In one embodiment, cells are reused for
polymerization following the extraction process as viable cells. In
one embodiment, PHA-containing biomass is treated to one or more
chemical treatment steps to control, modify, or increase the
concentration or functional characteristics (e.g., molecular
weight, monomer composition, melt flow profile, purity, non-PHA
residuals concentration, protein concentration, DNA concentration,
antibody concentration, antioxidant concentration) of PHA in a
PHA-containing material or biomass. In one embodiment, temperature
is used to control, modify, reduce, or optimize the molecular
weight, polydispersity, melt flow, and other characteristics of
PHA. In one embodiment, temperature and/or time is used to control
the molecular weight of PHA between the range of 5,000,000 and
10,000 daltons. In one embodiment, a slurry comprising
PHA-containing biomass and a culture media is subject to one or
more water removal steps or water addition steps to increase the
concentration of PHA in a PHA-containing biomass. In one
embodiment, the water removal step is a dewatering step or
combination of dewatering steps, such as centrifugation,
filtration, spray drying, flash drying, and/or chemical dewatering
(e.g., with acetone, ethanol, or methanol), wherein at least a
portion of the water concentration relative to the concentration of
PHA-containing biomass in the slurry is reduced. In one embodiment,
a temperature and/or pressure control step is carried out under
atmospheric (0 psi), sub-atmospheric (-100-0 psi), or
above-atmospheric pressure (e.g., 0-30,000 psi) and at temperature
conditions wherein the PHA-containing biomass, or the liquid in
and/or around the PHA-containing biomass, is maintained, for at
least a period of time, at a temperature ranging from about -30 to
about 10 degrees Celsius, about 10 degrees Celsius to about 100
degrees Celsius, about 10 degrees Celsius to about 150 degrees
Celsius, about 20 degrees Celsius to about 250 degrees Celsius,
and/or about 100 to about 200 degrees Celsius. In one embodiment,
the PHA-containing biomass is subject to a dewatering step before
or after the temperature and/or pressure control step, wherein the
dewatering step is centrifugation, filtration, and/or spray drying,
to produce a fully or partially de-watered PHA-containing biomass
or PHA-containing biomass slurry, wherein the water concentration
of the dried slurry is less than about 99%, less than about 95%,
less than about 80%, less than about 60%, less than about 40%, less
than about 30%, less than about 20%, less than about 10%, less than
about 5%, less than about 3%, less than about 2%, or less than
about 1% water. In one embodiment, the PHA-containing biomass is
subject to a temperature control step, wherein the liquid chemicals
within and/or around the biomass, e.g., water, methylene chloride,
carbon dioxide, and/or ammonia, is controlled and maintained at a
temperature of at least -30, at least -10, at least -5, at least
-4, at least -3, at least -2, at least -1, at least 0, at least 10,
at least 20, at least 30, at least 40, at least 50, at least 60, at
least 70, at least 80, at least 90, at least 100, at least 110, at
least 120, at least 130, at least 140, at least 150, at least 160,
at least 170, at least 180, at least 190, at least 200, at least
210, at least 220, at least 230, at least 240, at least 250, at
least 260, at least 270, at least 280, at least 290, at least 300
degrees Celsius (or overlapping ranges of those temperatures),
wherein the solubility, dispersitivity, or homogeneity of non-PHA
material increases in the liquid in and/or around the biomass. In
one embodiment, the PHA-biomass is not dried prior to such
temperature control step. In one embodiment, the PHA-containing
biomass is dried or de-watered prior to such temperature control
step. In one embodiment, the PHA-containing biomass is filtered or
centrifuged following the temperature control step. In one
embodiment, the PHA-containing cell slurry is not dewatered, for
example, by centrifugation or other drying mechanism, prior to the
temperature control step. In one embodiment, a mechanism to impart
shear onto or into the PHA-containing biomass is coupled with a
temperature control step; such shear may be imparted in the form of
one or more shear induction mechanisms, e.g., centrifugal pump,
agitator, blender, high shear mixer, vortex mixer, etc. In one
embodiment, the PHA-containing biomass is dewatered in one step and
the treated PHA-containing biomass is further dewatered in one or
more additional steps. In one embodiment, the PHA-containing
biomass is dewatered, water and/or other chemicals are added and
temperature and/or pressure is controlled, and the treated
PHA-containing biomass is further dewatered and/or purified. In one
embodiment, the water and/or chemicals within, around, and/or added
to the PHA-containing biomass is temperature and/or pressure
controlled, and the treated PHA-containing biomass is further
purified in one or more purification steps. In one embodiment, the
temperature control step process time is approximately 1 second,
approximately 5 seconds, approximately 10 seconds, approximately 25
seconds, approximately 60 seconds, approximately 2 minutes,
approximately 5 minutes, approximately 20 minutes, approximately 45
minutes, approximately 1 hour, approximately 2 hours, approximately
5 hours, approximately 6 hours, approximately 7 hours,
approximately 12 hours, approximately 15 hours, approximately 24
hours, approximately 36 hours, approximately 48 hours, or
overlapping ranges of those times. In one embodiment, inorganic
materials may be used to effect PHA modification, purification, or
extraction, including carbon dioxide and dinitrogen. In one
embodiment, the PHA-containing slurry or biomass is treated with
carbon dioxide under elevated temperatures and pressures, including
supercritical ranges, to induce PHA extraction or functional
modification of PHA. In one embodiment, organic solvents, including
methylene chloride, acetone, chloroform, dichloroethane, ethanol,
and/or methanol are used in conjunction with any of the above
steps. In one embodiment, solvents or extraction materials may be
used or recycled for biomass production, biogas production, and/or
PHA synthesis.
[0226] In one embodiment, chemicals are added to a PHA-containing
biomass to cause the crystallization of PHA. In one embodiment,
methylene chloride, carbon dioxide, acetone, water, dichloroethane,
or methanol may be added to a PHA-containing biomass in order to
induce the crystallization of PHA in the PHA-containing biomass. In
some embodiments, this step may be useful for the downstream
processing of PHA, wherein crystallized PHA is less prone than
amorphous to degradation, including molecular weight loss, when
contacted with extraction chemicals, including solvents, enzymes,
acids, bases, and bleach. In one embodiment, silicon, silica,
derivatives thereof, and/or chemicals containing silicon may be
added to the PHA-containing biomass in order to impact the
metabolic status of the culture, and thereby control the functional
characteristics of the PHA produced by the culture, including
molecular weight, monomer composition, co-polymer structure, melt
index, and polydispersity.
[0227] The removal of non-PHA materials from PHA often accounts for
a significant fraction of PHA production costs. As a specific
example, pigments often cause unwanted discoloration of PHA, and
must be removed through costly processes, such as ozonation,
peroxide washing, acetone washing, ethanol washing, solvent
refluxing, hypochlorite digestion, enzymatic degradation,
surfactant dissolution, or other methods disclosed in the art. In
several embodiments, a non-sterile process is used to select for
microorganisms exhibiting minimal pigmentation. Applicant has
surprisingly discovered that, by manipulating the concentration of
dissolved oxygen in a microorganism system, a culture may be
selected wherein white, tan, off-white, light brown, and/or light
yellow pigments are exhibited rather than purple, red, pink, dark
brown, orange, or other heavy pigments. Specifically, in some
embodiments, an excess of dissolved oxygen is introduced into a
growth media over successive periods, resulting in selective growth
of strains of methanotrophic microorganisms which produce white,
tan, off-white, light brown, and light yellow pigments, rather than
those producing pink, red, purple, dark yellow, dark brown, and/or
other heavy pigments. As a result, such embodiments, reduce the
need for costly downstream pigmentation removal.
[0228] As used herein, the term "PHA-reduced biomass" or
"substantially PHA-reduced biomass" shall be given its ordinary
meaning and shall be used to describe a biomass material wherein
the concentration of PHA relative to non-PHA material has been
reduced in a PHA-containing biomass through the utilization of a
PHA extraction process. In some embodiments, PHA-reduced biomass is
further treated in a variety of ways. In some embodiments, the
further treatment includes, but is not limited to, one or more of
dewatering, chemical treatment, sonication, additional PHA
extraction, homogenization, heat treatment, pH treatment,
hypochlorite treatment, microwave treatment, microbiological
treatment, including both aerobic and anaerobic digestion, solvent
treatment, water washing, solvent washing, and/or drying, including
simple or fractional distillation, spray drying, freeze drying,
rotary drying, and/or oven drying.
[0229] In one embodiment, PHA-reduced biomass is substantially
dried, wherein the resulting dried material comprises less than
about 99% liquids, including water, solvents, salts, and/or
growth-culture media. In some embodiments, the drying processes
disclosed herein yield a dried material containing between about
95% and about 75% liquids, between about 75% and about 50% liquids,
between about 50% and about 25% liquids, between about 25% and
about 15% liquids. between about 15% and about 10% liquids, between
about 10% and about 1% liquids, and overlapping ranges thereof. In
some embodiments, drying is complete (e.g., between about 1% and
0.1% liquids, or less). In another embodiment of the invention, a
liquid phase comprising PHA-reduced biomass is subjected to
filtration, centrifugation, density differentiation, or other
method to increase the solids content of the PHA-reduced
biomass.
[0230] Traditionally, the separation of biomass from liquid growth
media is difficult and impractical due to the plugging and fouling
characteristics of biomass. In several embodiments, a method
enabling the efficient filtration of microorganisms is provided. In
some embodiments, a liquid chemical is added to the growth media
comprising microorganisms, wherein the liquid chemical is ethanol,
acetone, methanol, methylene chloride, ketones, alcohols, and/or
chlorinated solvents, or a combination thereof. In some
embodiments, microorganisms are then efficiently separated from
liquid growth media using standard filtration equipment, such as a
Buchner filter, filter press, or similar apparatus. In one
embodiment, approximately 2 parts acetone are mixed with one part
water, including both intracellular and extracellular water, to
effect the efficient filtration of microorganisms comprising the
water.
[0231] As used herein, the terms "isolated PHA" and "substantially
isolated PHA" shall be given their ordinary meaning and shall refer
to PHA that has been removed from a biomass material as a result of
an extraction process, or a biomass material wherein the
concentration of PHA relative to non-PHA material has been
increased by an extraction process. In several embodiments,
isolated PHA is further treated in one or more of a variety of
ways, including, but not limited to, purification, filtration,
washing, oxidation, odor removal, pigment removal, lipid removal,
non-PHA material removal, and/or drying, including centrifugation,
filtration, spray drying, freeze drying, simple or fractional
distillation, or density differentiation. Methods for the
purification of PHA include the use of peroxides, water,
hypochlorite, solvents, ketones, alcohols, and various other agents
to separate and remove non-PHA material from PHA material. In some
embodiments, PHA is removed from a microorganism culture by solvent
extraction to produce isolated PHA in a PHA-rich solvent phase and
PHA-reduced biomass in a PHA-lean liquid phase. In some
embodiments, the solvent phase is separated from the liquid phase
by filtration or centrifugation. In some embodiments, both
centrifugation and filtration are used in combination (e.g.,
sequentially). In some embodiments, centrifugation is optionally
followed by filtration. In other embodiments, filtration is
optionally followed by centrifugation. Filtration, in some
embodiments is performed under vacuum pressure, via gravity feed,
under positive pressure, or in specialized filtration centrifuges.
In some embodiments, the filter pore size is adjusted based on the
species composition of the microorganism culture. In some
embodiments, pore sizes of up to 200 .mu.m are used. In some
embodiments, smaller pore sizes are used, for example 15 to 20
.mu.m, 10 to 15 .mu.m, 5 to 10 .mu.m, 1 to 5 .mu.m, 0.001 to 1
.mu.m, and overlapping ranges thereof.
[0232] In addition to the steps outlined above, additional steps
may be taken to remove solvent from the extracted PHA, including
evaporation, solvent casting, steam stripping, heat treatment, and
vacuum treatment, each of which may be preferential,
cost-effective, time-effective, or advantageous depending on the
volatility and type of solvent used. In other embodiments, active
processes can be used to reduce the solvent content of the
solvent-PHA mixture. For example, in certain embodiments,
alterations in temperature of certain solvents change the
solubility of the PHA in the solvent, which effectively removes
solvent from the PHA (e.g., the solvent is now separable from a
precipitated PHA). In some embodiments, filtration, solvent
temperatures, or vacuum treatment can be increased to reduce a
portion of the solvent. In some embodiments, solvent to PHA ratios
post extraction, filtration, evaporation, solvent casting, steam
stripping, heat treatment, and/or vacuum treatment range from about
0.1:1 to about 1,000:1, including about 0.2:1, about 0.3:1, about
4.0:1, about 5.0:1, about 10.0:1, about 20.0:1, about 60:1, about
70:1, about 80:1, about 90:1, about 100:1, about 200:1, about
500:1, and about 900:1.
[0233] As a result of the processes disclosed above, in some
embodiments, the solvent is substantially removed from the isolated
PHA in the PHA-rich solvent phase and the liquid is substantially
removed from the PHA-reduced biomass in the PHA-lean liquid phase.
In some embodiments, the isolated PHA is dried in a heated vessel
to produce substantially pure isolated PHA (e.g., at least 80% PHA
by dry weight, preferably at least 98% PHA by weight, more
preferably at least 99% PHA by weight).
[0234] Numerous varieties of heated or drying vessels may be used
to dry the isolated PHA, including ovens, centrifugal dryers, air
dryers, spray dryers, and freeze dryers, among others. In some
embodiments, heat is applied to a drying vessel to speed the
process and/or to remove (e.g., evaporate traces of solvent from
the PHA). It shall be appreciated that the moisture content of the
isolated PHA will depend, in some embodiments, on the solvent used,
and the corresponding separation technique used (as described
above). For example, a volatile solvent in combination with
ultracentrifugation would result in a less moist extracted PHA,
while a less active separation technique (e.g., gravity phase
separation) would yield a more moist extracted PHA. In some
embodiments, internal dryer temperatures range from 20.degree. C.
to 40.degree. C. to about 200.degree. C. In some embodiments,
internal temperatures range from about 50.degree. C. to about
90.degree. C., about 90.degree. C. to about 180.degree. C., about
65.degree. C. to about 175.degree. C. and overlapping ranges
thereof. In some embodiments, outlet temperatures are substantially
lower than inlet on internal temperatures. In some embodiments,
outlet temperatures range from 30.degree. C. to 90.degree. C. In
some embodiments, outlet temperatures are between about 35.degree.
C. to 40.degree. C., about 40.degree. C. to about 45.degree. C.,
about 45.degree. C. to about 50.degree. C., about 50.degree. C. to
about 55.degree. C., about 55.degree. C. to about 90.degree. C.,
and overlapping ranges thereof. It shall also be appreciated that
the internal and outlet temperatures may be adjusted throughout the
drying process (e.g., the temperature difference may initially be
large, but decrease over time, or vice versa).
[0235] From the above discussion, it shall be appreciated that the
type of dryer used, and the temperatures used (if other than
atmospheric temperatures) are easily tailored to correspond to the
techniques used in the extraction process. In some embodiments,
particular dryer components are beneficial in the isolation of PHA.
For example, depending on the moisture content of the extracted PHA
(e.g., the amount of residual solvent) particular components of an
evaporative-type dryer, such as an oven dryer, rotary dryer, spin
flash dryer, spray dryer (equipped with various types of nozzle
types, including rotary atomizor, single flow atomizer, mist
atomizer, pressure atomizer, dual-flow atomizer) convection heat
dryer, tray dryer, scrape-flash dryer, or other dryer type are
used. By way of additional example, if a freeze dryer (e.g., a
lyophilizer) is used, in some embodiments a manifold dryer is used,
optionally in conjunction with a heat source. Also by way of
example, a tray lyophilizer can be used, in some embodiments, with
the isolated and dried PHA being stored and sealed in containers
(e.g., vials) before re-exposure to the atmosphere. In certain
embodiments, such an approach is used when long-term storage of the
PHA is desired.
[0236] It shall also be appreciated that certain varieties of
heated/drying apparatuses have adjustable flow rates that can be
tailored to the moisture content of the isolated PHA. For example,
an isolated PHA having a high moisture content would be fed into a
dryer at a slower input rate to allow a higher degree of drying per
unit of PHA inputted into the dryer. Conversely, a low moisture
content isolated PHA would likely require less time to dry, and
therefore could be input at a faster rate. In some embodiments,
input rates of isolated PHA range from several hundred liters of
isolated PHA-solvent mixture per minute down to several milliliters
per minute. For example, input rates can range from about 10 mL/min
to about 6 L/min, including about 10 ml/min to about 50 ml/min,
about 50 mL/min to about 100 ml/min, about 100 ml/min to about 500
ml/min, about 500 ml/min to about 1 L/min, about 1 L/min to about 2
L/min, about 2 L/min to about 4 L/min, about 4 L/min to about 6
L/min, and about 100 L/min to about 500 L/min.
[0237] A range of PHA functional characteristics can be attained by
mixing one PHA molecule, such as PHB, with various PHA polymers,
including PHB, at various molecular weights. Therefore, in several
embodiments, a first isolated PHA is heated to reduce the molecular
weight of the first isolated PHA, and then subsequently mixed with
a second PHA wherein the molecular weight of the second PHA is
higher than the molecular weight of the first PHA. With such
embodiments, Applicant has surprisingly discovered methods to
functionalize one or more PHAs, including PHB. In additional
embodiments of the invention, the molecular weight of a first PHA
is reduced from about 800,000 to about 5,000,000 Daltons to about
30,000 to about 800,000 Daltons and mixed with a second PHA with a
molecular weight of about 800,000 to about 5,000,000 Daltons to
modify the functionalities of the input PHAs. In yet another
embodiment, a first PHA is mixed with a second PHA wherein the
molecular weight of the first PHA is at least 0.1% less than the
molecular weight of the second PHA. In some embodiments, the
difference in molecular weight between the first and second PHA is
about 0.1% to about 1%, about 1% to about 10%, about 10% to about
20%, about 20% to about 30%, about 30% to about 40%, about 40% to
about 50%, about 50% to about 60%, about 60% to about 70%, and
overlapping ranges thereof. In still additional embodiments, PHAs
having greater differences in molecular weight are used. In yet
another embodiment, the molecular weight of a first PHB is reduced
to less than about 100,000-500,000 Daltons and mixed with a second
PHA with a molecular weight greater than about 100,000-500,000
Daltons to modify the functionality of the input PHB. It shall be
appreciated that input PHA and PHB weight may vary from the ranges
disclosed above, but based on the differences in the molecular
weights, the alteration in functionality of the input PHB is still
achieved.
[0238] In one embodiment, the invention comprises a PHA comprising
carbon derived from PHA-reduced biomass, wherein the PHA-reduced
biomass comprises carbon derived from one or more carbon-containing
gas and/or one or more source of source of carbon. In one
embodiment, PHA is co-mingled and/or melted with biomass,
including, as examples, methanotrophic, autotrophic, heterotrophic
biomass, and/or PHA-reduced biomass, to improve the functional
characteristics of the PHA. In one embodiment, PHA is co-mixed
and/or melted with biomass, including, as examples, methanotrophic,
autotrophic, heterotrophic biomass, and/or PHA-reduced biomass, to
improve the functional characteristics of PHA. In one embodiment,
the percentage of non-PHA microorganism biomass included in a PHA,
PHA compound, or PHA mixture is about 0.00001% to about 0.001%,
about 0.001% to about 0.01%, about 0.01% to about 0.1%, to about
0.1% to about 0.5%, about 0.5% to about 1%, about 1%, to about 2%,
about 2% to about 3%, about 3% to about 5%, about 5% to about 7%,
about 7% to about 10%, about 10% to about 15%, about 15% to about
20%, about 20% to about 30%, about 30% to about 40%, about 40% to
about 50%, about 50% to about 60%, about 60% to about 70%, about
70% to about 80%, about 80% to about 90%, about 90% to about 98%,
about 98% to about 99.99%, and overlapping ranges thereof. In some
embodiments, the inclusion of microorganism biomass to a PHA
improves the functional characteristics of a PHA by acting as one
or more of the following: nucleating agent, plasticizer,
compatibilizer, melt flow modifier, mold release agent, filler,
strength modifier, elasticity modifier, or density modifier. In
some embodiments, microscopic size of microorganism biomass,
including nucleic acids and proteins, is particularly and
surprisingly effective as a functionalization agent for PHA. In
some embodiments, microorganism biomass acts as a surprisingly
effective compatibilizer for PHA and non-PHA polymers, such as
polypropylene and polyethylene. In one embodiment, microorganism
biomass is mixed with a PHA to modify the nucleation,
plasticization, compatibilization, melt flow, density, strength,
elongation, elasticity, mold strength, mold release, and/or bulk
density characteristics of a PHA, which may be melted, extruded,
film blown, die cast, pressed, injection molded, or otherwise
processed. In one embodiment, PHA is partially or not removed from
PHA-containing microorganism biomass prior to melt processing,
e.g., extrusion, injection molding, etc. In one embodiment, non-PHA
biomass parts or materials are caused to remain with PHA derived
from a PHA-containing biomass in order to modify or control the
functional characteristics of a PHA material. In one embodiment,
PHA is present in PHA-containing biomass at a concentration ranging
from 1-99.99999%, 1-99.99%, 1-99%, 5-99%, 10-99%, 20-99%, 30-99%,
50-99%, 70-99%, 80-99%, 90-99%, 95-99%, or 98-99%, and overlapping
ranges thereof. In one embodiment, PHA, biomass, and one or more
non-PHA material, polymer, or thermoplastic are mixed, melted, or
processed together. In one embodiment, the non-PHA polymer consists
of one or more of the following: polypropylene, polyethylene,
polystyrene, polycarbonate, Acrylonitrile butadiene styrene,
Polyethylene terephthalate, Polyvinyl chloride, Fluoropolymers,
Liquid Crystal Polymers, Acrylic, Polyamide/imide, Polyarylate,
Acetal, Polyetherimide, Polyetherketone, Nylon, Polyphenylene
Sulfide, Polysulfone, Cellulosics, Polyester, Polyurethane,
Polyphenylene oxide, Polyphenylene Ether, Styrene Acrylonitrile,
Styrene Maleic Anhydride, Thermoplastic Elastomer, Ultra High
Molecular Weight Polyethylene, Epoxy, Melamine Molding Compound,
Phenolic, Unsaturated Polyester, Polyurethane Isocyanates, Urea
Molding Compound, Vinyl Ester, Polyetheretherketone,
Polyoxymethylene plastic, Polyphenylene sulfide, Polyetherketone,
Polysulphone, Polybutylene terephthalate, Polyacrylic acid,
Cross-linked polyethylene, Polyimide, Ethylene vinyl acetate,
Styrene maleic anhydride, Styrene-acrylonitrile, Poly(methyl
methacrylate), Polytetrafluoroethylene, Polybutylene, Polylactic
acid, Polyvinylidene chloride Polyvinyl chloride, Polyvinyl
acetate, Polyvinyl acetate co-Polyvinylpyrrolidone,
Polyvinylpyrrolidone, Polyvinyl alcohol, Cellulose, Lignin,
Cellulose Acetate Butryate, Polypropylene, Polypropylene Carbonate,
Propylene Carbonate, Polyethylene, ethyl alcohol, ethylene glycol,
ethylene carbonate, glycerol, polyethylene glycol, pentaerythritol,
polyadipate, dioctyl adipate, triacetyl glycerol, triacetyl
glycerol-co-polyadipate, tributyrin, triacetin, chitosan,
polyglycidyl methacrylate, polyglycidyl metahcrylate, oxypropylated
glycerine, polyethylene oxide, lauric acid, trilaurin, citrate
esters, triethyl citrate, tributyl citrate, acetyl tri-n-hexyl
citrate, saccharin, boron nitride, thymine, melamine, ammonium
chloride, talc, lanthanum oxide, terbium oxide, cyclodextrin,
organophosphorus compounds, sorbitol, sorbitol acetal, sodium
benzoate, clay, calcium carbonate, sodium chloride, titanium
dioxide, metal phosphate, glycerol monostearate, glycerol
tristearate, 1,2-hydroxystearate, cellulose acetate propionate,
polyepichlorohydrin, polyvinylphenol, polymethyl methacrylate,
polyvinylidene fluoride, polymethyl acrylate,
polyepichlorohydrin-co-ethylene oxide, polyvinyl idene
chloride-co-acrylonitrile, polycyclohexyl methacrylate, cellulose
acetate butryate, cellulose, starch, cellulose acetate
butyrate-g-polyethyelene glycol, polyvinylidene chloride
co-acrylonitrile, polyvinyl acetate, polyethylene glycol
b-poly(e-caprolactone), R-PHB-OH, S-PHB-OH, polyphenol
poly(4,4'-dihydroxydiphenyl ester, 4-tert-butylphenol,
polyglutamate, acrylonitrile-butadiene-styrene, polystyrene,
styrene acrylonitrile, polyethylene 2,6-napthalate, polypropylene
oxide, polyethylene terepthalate, polybutylacrylate,
poly-y-benzyl-1-glutamate, starch-b-PPG-urethane, ethylene
propylene rubber-g-sodium acrylate EPR-g-SA, polypropylene
carbonate, polypropylene carbonate-co-polyvinyl acetate, natural
starch, starch adipate, starch-b-polyester-urethane,
starch-b-PEG-urethane, PHBV, polycaprolactone, PLLA,
polyoxymethylene, polyvinyl acetate-co-vinyl alcohol,
ethylene-propylene rubber, ethylene-vinyl-acetate copolymer,
synthetic poly3-hydroxybutyrate,
poly-3-hydroxybutyrate-co-poly-3-hydroxyvalerate,
poly-3-hydroxypropionate, polybutylene succinate-co-butylene
adipate, polybutylene succinate-co-caprolactone, phenol
poly(4,4'-dihydroxydiphenyl ester, and/or other similar materials.
In one embodiment, PHA, methanotrophic, autotrophic, and/or
heterotrophic microorganism biomass, and a non-PHA polymer are
mixed and melted together. In one embodiment, the concentration of
non-PHA microorganism biomass in such a mixture ranges from 0.0001%
to 90%, 0.1% to 30%, 0.1% to 10%, or 0.5% to 8%, and overlapping
ranges thereof. In one embodiment, the functional characteristics
of a polyhydroxyalkanoate (PHA) material are augmented, controlled,
or optimized, comprising the steps of: (a) providing a PHA and a
microorganism biomass, (b) combining the PHA and the biomass in a
mixture to form a compound, (c) heating the compound to between 40
degrees Celsius and 250 degrees Celsius. In one embodiment, the
biomass is present in said mixture at a concentration of about 0.1
to about 20%. In one embodiment, the biomass is present in said
mixture at a concentration of about 0.1 to about 80%. In one
embodiment, the biomass is present in said mixture at a
concentration of about 0.1 to about 8%. In one embodiment, the
biomass is methanotrophic biomass. In one embodiment, the biomass
is autotrophic biomass. In one embodiment, the biomass is
heterotrophic biomass. In one embodiment, the biomass is present in
said mixture at a concentration of about 0.1 to about 20%. In one
embodiment, the functional characteristics of a
polyhydroxyalkanoate (PHA) material are optimized, controlled, or
augmented, comprising the steps of: (a) providing a PHA, a
microorganism biomass, and a non-PHA polymer, (b) combining the
PHA, the non-PHA polymer, and the biomass in a mixture to form a
compound, and (c) heating the compound to between 40 degrees
Celsius and 250 degrees Celsius. In one embodiment, the biomass is
present in said mixture at a concentration of between about 0.1 to
about 20%. In one embodiment, the biomass is present in said
mixture at a concentration of between about 0.1 to about 80%. In
one embodiment, the biomass is present in said mixture at a
concentration of between about 0.1 to about 8%. In one embodiment,
the biomass is methanotrophic biomass. In one embodiment, the
biomass is autotrophic biomass. In one embodiment, the biomass is
heterotrophic biomass. In one embodiment, the biomass is present in
said mixture at a concentration of between about 0.1 to about 20%.
In one embodiment, the biomass is present in said mixture at a
concentration of between about 0.1 to about 20%. In one embodiment,
the biomass is present in said mixture at a concentration of
between about 0.1 to about 80%. In one embodiment, the biomass is
present in said mixture at a concentration of between about 0.1 to
about 8%. In one embodiment, the biomass is methanotrophic biomass.
In one embodiment, the biomass is autotrophic biomass. In one
embodiment, the biomass is heterotrophic biomass. In one
embodiment, the non-PHA polymer is one or more of the following:
polypropylene, polyethylene, polystyrene, polycarbonate,
Acrylonitrile butadiene styrene, Polyethylene terephthalate,
Polyvinyl chloride, Fluoropolymers, Liquid Crystal Polymers,
Acrylic, Polyamide/imide, Polyarylate, Acetal, Polyetherimide,
Polyetherketone, Nylon, Polyphenylene Sulfide, Polysulfone,
Cellulosics, Polyester, Polyurethane, Polyphenylene oxide,
Polyphenylene Ether, Styrene Acrylonitrile, Styrene Maleic
Anhydride, Thermoplastic Elastomer, Ultra High Molecular Weight
Polyethylene, Epoxy, Melamine Molding Compound, Phenolic,
Unsaturated Polyester, Polyurethane Isocyanates, Urea Molding
Compound, Vinyl Ester, Polyetheretherketone, Polyoxymethylene
plastic, Polyphenylene sulfide, Polyetherketone, Polysulphone,
Polybutylene terephthalate, Polyacrylic acid, Cross-linked
polyethylene, Polyimide, Ethylene vinyl acetate, Styrene maleic
anhydride, Styrene-acrylonitrile, Poly(methyl methacrylate),
Polytetrafluoroethylene, Polybutylene, Polylactic acid, and/or
Polyvinylidene chloride, Polyvinyl chloride, Polyvinyl acetate,
Polyvinyl acetate co-Polyvinylpyrrolidone, Polyvinylpyrrolidone,
Polyvinyl alcohol, Cellulose, Lignin, Cellulose Acetate Butryate,
Polypropylene, Polypropylene Carbonate, Propylene Carbonate,
Polyethylene, ethyl alcohol, ethylene glycol, ethylene carbonate,
glycerol, polyethylene glycol, pentaerythritol, polyadipate,
dioctyl adipate, triacetyl glycerol, triacetyl
glycerol-co-polyadipate, tributyrin, triacetin, chitosan,
polyglycidyl methacrylate, polyglycidyl metahcrylate, oxypropylated
glycerine, polyethylene oxide, lauric acid, trilaurin, citrate
esters, triethyl citrate, tributyl citrate, acetyl tri-n-hexyl
citrate, saccharin, boron nitride, thymine, melamine, ammonium
chloride, talc, lanthanum oxide, terbium oxide, cyclodextrin,
organophosphorus compounds, sorbitol, sorbitol acetal, sodium
benzoate, clay, calcium carbonate, sodium chloride, titanium
dioxide, metal phosphate, glycerol monostearate, glycerol
tristearate, 1,2-hydroxystearate, cellulose acetate propionate,
polyepichlorohydrin, polyvinylphenol, polymethyl methacrylate,
polyvinylidene fluoride, polymethyl acrylate,
polyepichlorohydrin-co-ethylene oxide, polyvinyl idene
chloride-co-acrylonitrile, polycyclohexyl methacrylate, cellulose
acetate butryate, cellulose, starch, cellulose acetate
butyrate-g-polyethyelene glycol, polyvinylidene chloride
co-acrylonitrile, polyvinyl acetate, polyethylene glycol
b-poly(e-caprolactone), R-PHB-OH, S-PHB-OH, polyphenol
poly(4,4'-dihydroxydiphenyl ester, 4-tert-butylphenol,
polyglutamate, acrylonitrile-butadiene-styrene, polystyrene,
styrene acrylonitrile, polyethylene 2,6-napthalate, polypropylene
oxide, polyethylene terepthalate, polybutylacrylate,
poly-y-benzyl-1-glutamate, starch-b-PPG-urethane, ethylene
propylene rubber-g-sodium acrylate EPR-g-SA, polypropylene
carbonate, polypropylene carbonate-co-polyvinyl acetate, natural
starch, starch adipate, starch-b-polyester-urethane,
starch-b-PEG-urethane, PHBV, polycaprolactone, PLLA,
polyoxymethylene, polyvinyl acetate-co-vinyl alcohol,
ethylene-propylene rubber, ethylene-vinyl-acetate copolymer,
synthetic poly3-hydroxybutyrate,
poly-3-hydroxybutyrate-co-poly-3-hydroxyvalerate,
poly-3-hydroxypropionate, polybutylene succinate-co-butylene
adipate, polybutylene succinate-co-caprolactone, and/or phenol
poly(4,4'-dihydroxydiphenyl ester.
Purifying the Isolated PHA
[0239] In some embodiments, isolated PHA is purified to produce a
PHA material that is substantially pure PHA. In some embodiments,
the isolated PHA is purified to at least 20% pure PHA by dry
weight. In some embodiments, the isolated PHA is purified to at
least 55% pure PHA by dry weight, while in some embodiments, the
isolated PHA is purified to at least 90% pure PHA by dry weight. In
additional embodiments, purity of the isolated PHA is between about
90 and 99.9%, including about 91, about 92, about 93, about 94,
about 95, about 96, about 97, about 98, and about 99% pure.
[0240] In several embodiments, isolated PHA may be recovered by any
one, or a combination, of the methods described above, including,
but not limited to: washing, filtration, centrifugation,
dewatering, purification, oxidation, non-PHA material removal,
solvent removal, and/or drying. In some embodiments, isolated PHA
is recovered according to the manner in which it has been removed
from the culture. For example, in embodiments in which
solvent-based extraction is employed, a recovery method may be
employed to remove the isolated PHA from the solvent and/or other
non-PHA material. In one embodiment, solvent may be used to extract
the PHA, wherein the solvent is then substantially removed from the
isolated PHA by carrying out PHA precipitation and filtration,
excess solvent distillation and/or removal, and/or drying,
resulting in the recovery of dry, isolated PHA. In embodiments
employing enzyme, surfactant, protonic, hydroxide, and
hypochlorite-based extraction techniques wherein the dissolution of
non-PHA material is induced, isolated PHA may be filtered, washed,
separated, centrifuged, and/or dried, resulting in the recovery of
dry, isolated, purified PHA. The resultant PHA, in some
embodiments, is further used in downstream processing, including
thermoforming.
Returning PHA-Reduced Biomass to the PHA-Producing Culture to
Convert PHA-Reduced Biomass into PHA
[0241] In several embodiments of the invention, the PHA-reduced
biomass is returned to the culture to cause the biomass-utilizing
microorganisms within the culture to convert the carbon within the
PHA-reduced biomass into PHA. By using PHA-reduced biomass as a
source of carbon for the production of microorganisms in a
microorganism fermentation system, a series of biochemical
enzymatic pathways are generated in situ by the microorganism
culture to carry out the metabolic utilization of PHA-reduced
biomass for growth, reproduction, and PHA synthesis.
[0242] Without being limited by theory, it is believed that
gas-utilizing microorganisms and biomass-utilizing microorganisms
are able to co-exist as a single microorganism consortium because
they utilize sources of carbon that require distinctly different
bioenzymatic assimilation pathways. For instance, while methane
metabolism requires the methane monooxygenase enzyme to catalyze
the conversion of methane into methanol for cellular assimilation,
and methane monooxygenase is competitively inhibited by a wide
range of compounds, it is not inherently deactivated by high
concentrations of cellular biomass, including PHA-reduced biomass.
Similarly, the chlorophyll-based metabolic assimilation systems
required for the conversion of carbon dioxide into biomass and PHA
are not inherently deactivated or competitively inhibited by high
concentrations of cellular biomass, including PHA-reduced biomass.
Likewise, the enzymatic architecture enabling the metabolic
utilization, breakdown, and/or assimilation of PHA-reduced biomass
is not inherently deactivated or competitively inhibited by high
concentrations of methane and/or carbon dioxide, particularly as
the process requires neither methane monooxygenase nor chlorophyll.
Without being limited by theory, Applicant believes that the
relatively noncompetitive, and in some cases commensal or
mutualistic relationships between microorganisms consuming a
carbon-containing gas and a PHA-reduced biomass, make it possible
to create a microorganism culture comprising biomass-utilizing
microorganisms and gas-utilizing microorganisms, wherein both
carbon-containing gases and PHA-reduced biomass may be metabolized
as simultaneously assimilable sources of carbon.
[0243] In the case of autotrophic, methanotrophic, and/or
biomass-utilizing microorganisms, Applicant has found that a
mutualistic, positive-feedback loop relationship can be created in
a single (or optionally multiple) reaction vessel. In such
embodiments, the oxygen created by autotrophic metabolism is
utilized by methanotrophic and/or biomass-utilizing microorganisms
for metabolic functions, the carbon dioxide created by
methanotrophic and/or biomass-utilizing microorganism metabolism is
utilized for autotrophic metabolism, the methane and/or carbon
dioxide created by anaerobic methanogenic microorganisms is
utilized by methanotrophic microorganisms, and the biomass created
by methanotrophic, autotrophic, and/or heterotrophic microorganisms
is used to provide a source of carbon to methanogenic and/or other
heterotrophic microorganisms. Due to the microscopic-level
induction of oxygen and/or carbon dioxide created therein, mass
transfer efficiencies in several embodiments are significantly
improved over traditional gas induction means, such as gas
sparging, mechanical mixing, static mixing, or other means known in
the art. To applicant's knowledge, prior to the disclosure herein,
the use of autotrophic microorganisms cultured in association with
heterotrophic microorganisms has never been suggested as a means to
improve mass transfer efficiencies, supply oxygen, and/or augment
microorganism growth rates in a positive feedback loop system.
[0244] In several further embodiments of the invention, PHA-reduced
biomass is used by heterotrophic microorganisms, including
acidogenic, acetogenic, and methanogenic microorganisms, to produce
methane, which is further utilized by methanotrophic microorganisms
to produce biomass, including PHA. In some embodiments of the
invention, anaerobic microorganisms coexist with aerobic
microorganisms under microaerobic conditions (e.g., mean dissolved
oxygen concentrations approximately 0.00-1.0 ppm, including about
0.001 to about 0.002 ppm, about 0.002 to about 0.03 ppm, about 0.03
to about 0.04 ppm, about 0.04 to about 0.5 ppm, about 0.5 to about
0.6 ppm, about 0.6 to about 0.7 ppm, about 0.7 to about 0.8 ppm,
about 0.8 to about 0.9 ppm, about 0.9 to about 1.0 ppm, and
overlapping ranges thereof.
[0245] In some embodiments of the invention, heterotrophic,
methanotrophic, methanogenic, and/or autotrophic microorganisms are
divided into multiple stages and vessels, in particular, anaerobic
and aerobic stages, in order to carry out the conversion of
PHA-reduced biomass into methane and PHA. In further embodiments of
the invention, PHA-reduced biomass is returned to the culture using
one or more vessels, whereby it is first converted to carbon
dioxide, methane, and/or volatile organic compounds by a
heterotrophic, e.g., methanogenic, microorganism consortium under
anaerobic conditions and then converted to PHA by methanotrophic
microorganisms under aerobic conditions, whereby carbon dioxide is
also metabolized or otherwise used by autotrophic microorganisms,
methanotrophic microorganisms, and heterotrophic
microorganisms.
[0246] In several embodiments, light intensity is utilized to
regulate the growth rate of heterotrophic and/or methanotrophic
microorganisms. In some embodiments, light intensity is manipulated
to regulate the generation of oxygen by autotrophic microorganisms.
In some embodiments, the rate of oxygen generated by autotrophic
microorganisms is subsequently used to control the growth and
metabolism of heterotrophic and methanotrophic microorganisms.
[0247] In several embodiments, carbon dioxide is supplied to
autotrophic microorganisms in the form of carbon dioxide created by
methanotrophic and/or heterotrophic microorganisms. In some
embodiments, each of these varieties of microorganism is cultured
in a single vessel. In some embodiments, methane, sugar, biomass,
and/or another non-carbon dioxide source of carbon is used to grow
autotrophic microorganisms. To applicant's knowledge, autotrophic
microorganisms have never been cultured using methane as a sole
carbon input.
[0248] Some gas-utilizing microorganisms are unable to produce high
concentrations of intracellular PHA. However, according to several
embodiments, certain microorganism consortiums utilizing
PHA-reduced biomass, or derivatives thereof, as a source of carbon
are able to generate high intracellular PHA concentrations and thus
effectively convert low PHA concentration biomass derived from a
carbon-containing gas into a high PHA concentration biomass
material under the conditions disclosed herein. In several
embodiments, the concentration (by weight) of intracellular PHA is
between about 10% to about 30%, about 30% to about 50%, about 50%
to about 70%, about 70% to about 80%, about 80% to about 90%, about
90% or more, and overlapping ranges thereof. Thus, in one
embodiment, the culture is contacted with the PHA-reduced biomass
and then manipulated, according to the processes described herein,
to effect PHA synthesis, wherein the PHA-reduced biomass is
converted into PHA by biomass-utilizing microorganisms. In some
embodiments, PHA synthesis is induced by nutrient limitation,
nutrient excess, nutrient imbalance, or large shifts in nutrient
concentration. In still further embodiments, PHA synthesis is
induced by reducing the availability of nitrogen, oxygen,
phosphorus, or magnesium to the culture. In some embodiments, these
nutrients are simultaneously reduced (to varying or similar
degrees). In some embodiments, the nutrients are reduced
sequentially. In some embodiments, only one of the nutrients is
reduced. For example, in certain embodiments, PHA synthesis is
induced by reducing the availability of oxygen to the culture. In
some embodiments, this is achieved by manipulating the flow rate of
air or oxygen into the growth medium. In some embodiments,
manipulation of the flow rate of other carbon-containing gases,
such as methane and/or carbon dioxide, into the growth medium, or
otherwise manipulating the rate of gas transfer in a system (e.g.,
by adjusting mixing rates or light injection rates) is employed. In
one embodiment, oxygen limitation is induced by reducing the flow
rate of oxygen into the growth medium. In another embodiment,
oxygen limitation is induced by reducing the rate of light
transmission into the medium to reduce the production of oxygen by
autotrophic microorganisms. In some embodiments of the invention,
the concentration of PHA generated in a biomass-utilizing
microorganism culture utilizing PHA-reduced biomass as a source of
carbon is at least 5%, at least 20%, or at least 50% by dry cell
weight; in particularly preferred embodiments of the invention, the
concentration of PHA in a biomass-utilizing microorganism is at
least 80% by dry cell weight.
[0249] In some embodiments, a PHA-reduced biomass recycling system
is utilized wherein substantially all (e.g., at least 50%, at least
60%, at least 70%, at least 80%, at least 90%, or at least 98%) of
the PHA-reduced biomass produced is contacted with the culture
until it is converted into PHA. In some such embodiments, solid
sources of carbon are substantially output from the process or
culture only in the form of isolated PHA.
[0250] In several embodiments, as carbon-containing gases are
continually added to the medium to effect the production of
biomass, the process disclosed above is repeated. Specifically, as
the process continues, a portion of the PHA-containing biomass from
the culture is removed from the medium, PHA is extracted from the
PHA-containing biomass, PHA-reduced biomass is separated from
isolated PHA, isolated PHA is recovered, purified, and dried, and
PHA-reduced biomass is sent back to the culture and converted by
the culture into PHA. In one embodiment, substantially all
PHA-reduced biomass produced is contacted with the culture until it
is converted into isolated PHA, and solid sources of carbon are
substantially output from the process only in the form of isolated
PHA. In other embodiments, carbon is substantially output from the
system only in the form of PHA and methane, carbon dioxide, and/or
volatile organic compounds.
[0251] The following example is provided to further illustrate
certain embodiments within the scope of the invention. The example
is not to be construed as a limitation of any embodiments, since
numerous modifications and variations are possible without
departing from the spirit and scope of the invention.
Example 1
[0252] A fermentation system comprising one or more vessels are
partially filled with one or more liquid growth mediums, wherein
the medium comprises methanotrophic, autotrophic, methanotrophic,
and/or other heterotrophic or biomass-utilizing microorganisms
containing PHA, and, per liter of water, 0.7-1.5 g
KH.sub.2PO.sub.4, 0.7-1.5 g K.sub.2HPO.sub.4, 0.7-1.5 g KNO.sub.3,
0.7-1.5 g NaCl, 0.1-0.3 g MgSO.sub.4, 24-28 mg
CaCl.sub.2*2H.sub.2O, 5.0-5.4 mg EDTA Na.sub.4(H.sub.2O).sub.2,
1.3-1.7 mg FeCl.sub.2*4H.sub.2O, 0.10-0.14 mg CoCl.sub.2*6H.sub.2O,
0.08-1.12 mg MnCl.sub.2*2H.sub.2O, 0.06-0.08 mg ZnCl.sub.2,
0.05-0.07 mg H.sub.3BO.sub.3, 0.023-0.027 mg NiCl.sub.2*6H.sub.2O,
0.023-0.027 mg NaMoO.sub.4*2H.sub.2O, 0.011-0.019 mg
CuCl.sub.2*2H.sub.2O. One or more of the mediums are anaerobic
and/or aerobic, and carbon containing gases, including methane,
carbon dioxide, and volatile organic compounds, as well as
optionally air or oxygen, are fed into all or part of the system to
induce the growth and reproduction of microorganisms through the
utilization of carbon-containing gases, as well as the production
of PHA.
[0253] Next, a portion of the media volume of the fermentation
system is passed through a basket centrifuge to increase the solids
content of the medium to approximately 167 g/L. The
solids-containing centrate phase of the centrifuged solution is
then transferred to a PHA extraction vessel, and the substantially
solids-free filtrate phase of the centrifuged solution is recycled
back to the fermentation system.
[0254] In some embodiments, the solids-containing centrate phase is
optionally chemically pre-treated prior to extraction. In some
embodiments, one or more of acids, bases, chloride, ozone, and
hydrogen peroxide is added. In several embodiments, chemical
pre-treatment increases the efficiency and yield of the subsequent
extraction process. In some embodiments, the chemical pre-treatment
functions to break down the cell well (partially or fully), thereby
liberating a greater portion of the intracellular PHA. In some
embodiments, chemical pre-treatment dissolves and/or removes
impurities that negatively impact the PHA extraction process. In
some embodiments, chemical pre-treatment enhances cell
agglomeration, which increases the percentage of microorganisms
that are extracted (e.g., cells in an agglomerated mass are not
separated or lost in transfer steps). Next, following optional
chemical pre-treatment, solvent is added into the PHA extraction
vessel to create a solvent solution, and the solvent solution is
then mixed for a period of time to cause the PHA in both the
microorganisms to dissolve into the solvent, and thereby create
PHA-rich solvent and PHA-reduced biomass. Over the course of a
defined mixing period (e.g., 0.1-10 hours), the PHA content of the
microorganisms is reduced by about 80% as it is dissolved into the
solvent.
[0255] Next, the solvent solution comprising the PHA-rich solvent
and PHA-reduced biomass is passed through a filter located at the
bottom of the PHA extraction vessel, and the PHA-rich solvent is
thereby separated from the PHA-reduced biomass. Water is then added
to the PHA extraction vessel to create a water-biomass solution,
and the water-biomass solution is then heated to 75.degree. C. to
cause any remaining solvent associated with the PHA-reduced biomass
to exit the PHA extraction vessel as a gaseous vapor. The vapor
discharged from the PHA extraction vessel is then passed through a
heat exchanger and recovered as liquid solvent. Meanwhile, the
PHA-rich solvent is transferred to a PHA purification vessel and
mixed with room temperature water to create a water-solvent
solution. The water-solvent solution is then heated to cause i) the
solvent to exit the PHA extraction vessel as a gaseous vapor and
ii) the isolated PHA to precipitate into the water and/or become a
solid. The solvent vapor created by heating the water-solvent
solution is then passed through a heat exchanger and converted into
liquid solvent.
[0256] The isolated PHA is then substantially dewatered by
filtration in a Nutsche filter, and the Nutsche filter containing
the substantially dewatered isolated PHA is then heated to remove
any additional volatile compounds, including trace water and/or
solvent. Following heat drying in the Nutsche filter, the isolated
PHA is recovered as substantially pure PHA (e.g., greater than
about 90% PHA).
[0257] Concurrently, the water-biomass solution comprising
PHA-reduced biomass and water is transferred from the PHA
extraction vessel back into the fermentation system, where the
PHA-reduced biomass is contacted with one or more of the
microorganism cultures. Next, the medium of the fermentation system
is manipulated to cause the one or more microorganisms within the
system to metabolize the PHA-reduced biomass as a source of carbon
and nutrients.
[0258] Depending on the embodiment, the culture conditions are
adjusted to determine the point at which the inception of the
growth or PHA metabolism phase occurs. As discussed herein,
manipulation of the concentration of one or more growth culture
media nutrients can alter the metabolic pathways favored by certain
microorganisms. Additionally, the use of PHA-reduced
biomass-derived carbon for the production of additional biomass
versus the production of PHA can be tailored based on whether the
intent is to grow the culture (e.g., increase the overall biomass)
or to harvest PHA (e.g., shift the culture from growth phase to
production of PHA). As such, the reduction, increase, or adjustment
of the concentration certain growth nutrients, and the timing of
such adjustment, plays a role in the metabolic state and PHA
production of the culture. Adjustment of growth nutrients can occur
at any point after the PHA-reduced biomass is returned to the
microorganism system. In some embodiments, adjustment is immediate
(e.g., within minutes to a few hours). In some embodiments, a
longer period of time elapses. In some embodiments, adjustment in
one or more growth nutrients occurs after about 2 to 4 hours, after
about 4 to 6 hours, after about 6 to 8 hours, after about 8 to 10
hours, after about 10 to 12 hours, after about 12 to 14 hours,
after about 14 to 18 hours, after about 18 to 24 hours, and
overlapping ranges thereof. In still additional embodiments,
adjustment in one or more growth nutrients occurs after about 2 to
about 5 days, about 5 to about 10 days, about 10 to about 15 days,
about 15 to about 20 days, about 20 to about 30 days, about 30 to
about 50 days, and overlapping ranges thereof. In some embodiments,
longer times elapse prior to adjusting one or more growth nutrients
to induce PHA polymerization.
[0259] After a desired period of time has elapsed, the dissolved
oxygen and/or nitrogen concentration (or concentration of another
nutrient) of one or more parts of the medium is reduced or adjusted
to cause one or more of the microorganisms within the system to
utilize the PHA-reduced biomass in the medium as a source of carbon
for the synthesis of PHA. In some embodiments, the percent
adjustment ranges from about 20% to about 100%, including about 20%
to about 30%, about 30% to about 40%, about 40% to about 50%, about
50% to about 60%, about 60% to about 70%, about 70% to about 80%,
about 80% to about 90%, about 90% to about 100%, and overlapping
ranges thereof. It shall be appreciated that, depending on the
characteristics of a culture in a given embodiment, a specific
percentage reduction, increase, or adjustment in nutrient may not
be necessary, but a reduction, increase, or adjustment is used that
is sufficient to convert certain cells from a relative growth phase
to a relative PHA synthesis phase. After approximately 12-24 hours
of PHA synthesis, substantially all of the PHA-reduced biomass
within the growth medium has been metabolized into
biomass-utilizing microorganism biomass, including PHA. It shall be
appreciated that, in certain embodiments, greater or lesser PHA
synthesis times result in varying percentages of the PHA-reduced
biomass within the growth medium being metabolized into biomass,
including PHA.
[0260] As carbon containing gases are continually added to the
fermentation system to effect the production of biomass, the
process is repeated, wherein solid sources of carbon substantially
exit the system only in the form of PHA. Specifically, as the
process continues, a portion of the PHA-containing biomass from the
fermentation vessel is passed through a dewatering centrifuge to
increase the solids content of the PHA-containing biomass, PHA is
extracted from the removed PHA-containing biomass using a
solvent-based extraction system to create PHA-reduced biomass and
isolated PHA, PHA-reduced biomass is separated from isolated PHA,
isolated PHA is recovered, purified, and dried, and PHA-reduced
biomass is sent back to the fermentation system and converted by
microorganisms into PHA, such that substantially all PHA-reduced
biomass produced is contacted with the culture until it is
converted into isolated PHA, and wherein solid sources of carbon
are substantially output from the process only in the form of
isolated PHA.
[0261] While the above description of several compositions,
systems, and methods contains many specificities, it should be
understood that the embodiments of the present invention described
above are illustrative only and are not intended to limit the scope
of the invention. Numerous and various modifications can be made
without departing from the spirit of the embodiments described
herein. Accordingly, the scope of the invention should not be
solely determined by the embodiments described herein, but also by
the appended claims and their legal equivalents.
* * * * *