Model-based investigation of the pH-dependent chromatographic separation of itaconic acid from aqueous solution using strongly hydrophobic adsorbents.

In this study, we propose a model for the simulation of the pH-dependent separation of dicarboxylic acids from aqueous solutions using strongly hydrophobic adsorbents. Building upon results of our previous study, where we experimentally investigated the pH-dependent adsorption behavior of the individual acid species of itaconic acid (IA) on a strongly hydrophobic adsorbent using in-line Raman spectroscopy, we utilize a transport-dispersive model as the basis for our simulation model. Instead of considering IA as a single component in our model, we simulated each acid species of IA individually. For this purpose, we expanded the transport-dispersive model with reaction terms in all aqueous phases. The reaction terms include all dissociation reactions of all involved components for each time step and spatial discretization. This model enables the time and spatial dependent simulation of the pH value in the chromatographic column and thus the time and spatial dependent knowledge of each acid species concentration. The consideration of activity coefficients due to high local ionic strength is achieved using the Truesdell-Jones (TdJ) model. The simulation model is successfully validated using experimental data from our previous study and used in a simulation study that demonstrates the potential of the model approach for analyzing associated separation tasks.

Balancing pH and yield: exploring itaconic acid production in Ustilago cynodontis from an economic perspective.

BACKGROUND: Itaconic acid is a promising bio-based building block for the synthesis of polymers, plastics, fibers and other materials. In recent years, Ustilago cynodontis has emerged as an additional itaconate producing non-conventional yeast, mainly due to its high acid tolerance, which significantly reduces saline waste coproduction during fermentation and downstream processing. As a result, this could likely improve the economic viability of the itaconic acid production process with Ustilaginaceae. RESULTS: In this study, we characterized a previously engineered itaconate hyper-producing Ustilago cynodontis strain in controlled fed-batch fermentations to determine the minimal and optimal pH for itaconate production. Under optimal fermentation conditions, the hyper-producing strain can achieve the theoretical maximal itaconate yield during the production phase in a fermentation at pH 3.6, but at the expense of considerable base addition. Base consumption is strongly reduced at the pH of 2.8, but at cost of production yield, titer, and rate. A techno-economic analysis based on the entire process demonstrated that savings due to an additional decrease in pH control reagents and saline waste costs cannot compensate the yield loss observed at the highly acidic pH value 2.8. CONCLUSIONS: Overall, this work provides novel data regarding the balancing of yield, titer, and rate in the context of pH, thereby contributing to a better understanding of the itaconic acid production process with Ustilago cynodontis, especially from an economic perspective.

Interdisciplinary development of an overall process concept from glucose to 4,5-dimethyl-1,3-dioxolane via 2,3-butanediol.

To reduce carbon dioxide emissions, carbon-neutral fuels have recently gained renewed attention. Here we show the development and evaluation of process routes for the production of such a fuel, the cyclic acetal 4,5-dimethyl-1,3-dioxolane, from glucose via 2,3-butanediol. The selected process routes are based on the sequential use of microbes, enzymes and chemo-catalysts in order to exploit the full potential of the different catalyst systems through a tailor-made combination. The catalysts (microbes, enzymes, chemo-catalysts) and the reaction medium selected for each conversion step are key factors in the development of the respective production methods. The production of the intermediate 2,3-butanediol by combined microbial and enzyme catalysis is compared to the conventional microbial route from glucose in terms of specific energy demand and overall yield, with the conventional route remaining more efficient. In order to be competitive with current 2,3-butanediol production, the key performance indicator, enzyme stability to high aldehyde concentrations, needs to be increased. The target value for the enzyme stability is an acetaldehyde concentration of 600 mM, which is higher than the current maximum concentration (200 mM) by a factor of three.

In situ adsorption of itaconic acid from fermentations of Ustilago cynodontis improves bioprocess efficiency.

BACKGROUND: Reducing the costs of biorefinery processes is a crucial step in replacing petrochemical products by sustainable, biotechnological alternatives. Substrate costs and downstream processing present large potential for improvement of cost efficiency. The implementation of in situ adsorption as an energy-efficient product recovery method can reduce costs in both areas. While selective product separation is possible at ambient conditions, yield-limiting effects, as for example product inhibition, can be reduced in an integrated process. RESULTS: An in situ adsorption process was integrated into the production of itaconic acid with Ustilago cynodontis IAmax, as an example of a promising biorefinery process. A suitable feed strategy was developed to enable efficient production and selective recovery of itaconic acid by maintaining optimal glucose concentrations. Online monitoring via Raman spectroscopy was implemented to enable a first process control and understand the interactions of metabolites with the adsorbent. In the final, integrated bioprocess, yield, titre, and space-time yield of the fermentation process were increased to values of 0.41 gIA/gGlucose, 126.5 gIA/L and 0.52 gIA/L/h. This corresponds to an increase of up to 30% in comparison to the first extended batch experiment without in situ product removal. Itaconic acid was recovered with a purity of at least 95% and high concentrations above 300 g/L in the eluate. CONCLUSION: Integration of product separation via adsorption into the bioprocess was successfully conducted and improved the efficiency of itaconic acid production. Raman spectroscopy was proven to be a reliable tool for online monitoring of various metabolites and facilitated design and validation of the complex separation and feed process. The general process concept can be transferred to the production of various similar bioproducts, expanding the tool kit for design of innovative biorefinery processes.

Holistic Approach to Process Design and Scale-Up for Itaconic Acid Production from Crude Substrates.

Bio-based bulk chemicals such as carboxylic acids continue to struggle to compete with their fossil counterparts on an economic basis. One possibility to improve the economic feasibility is the use of crude substrates in biorefineries. However, impurities in these substrates pose challenges in fermentation and purification, requiring interdisciplinary research. This work demonstrates a holistic approach to biorefinery process development, using itaconic acid production on thick juice based on sugar beets with Ustilago sp. as an example. A conceptual process design with data from artificially prepared solutions and literature data from fermentation on glucose guides the simultaneous development of the upstream and downstream processes up to a 100 L scale. Techno-economic analysis reveals substrate consumption as the main constituent of production costs and therefore, the product yield is the driver of process economics. Aligning pH-adjusting agents in the fermentation and the downstream process is a central lever for product recovery. Experiments show that fermentation can be transferred from glucose to thick juice by changing the feeding profile. In downstream processing, an additional decolorization step is necessary to remove impurities accompanying the crude substrate. Moreover, we observe an increased use of pH-adjusting agents compared to process simulations.

Influence of mixed salts on retention behavior of model proteins in cation exchange chromatography.

Mobile phase composition is an important factor for a further improvement of ion exchange chromatography steps of proteins. In this work, the effects of mixed salts on the retention factors of the two model proteins lysozyme (LYZ) and bovine serum albumin (BSA) in cation exchange chromatography (CEC) were investigated and compared to effects previously observed in hydrophobic interaction chromatography (HIC). The model equation describing the effects in HIC was adjusted for linear gradient elution experiments in CEC. The investigated salts were sodium chloride, sodium sulfate, ammonium chloride and ammonium sulfate. By varying binary salt mixtures as well as using pure salts, model parameters were determined. The normalized root mean square error (NRMSE) of the predicted retention factors for the calibration runs was 4.1% for BSA and 3.1% for LYZ. Additional validation experiments proved the ability of the model to describe and predict retention behavior of the proteins for further salt compositions. Hereby, the NRMSE values for BSA and LYZ were 2.0% and 1.5%, respectively. While the retention factors of LYZ changed linearly with the salt composition, non-linearities in the impact of the anion composition were found for BSA. This was contributed to an overlay of a synergetic salt effect on a protein-specific effect by sulfate on BSA with non-specific effects of the ions for CEC. However, the impact of the synergetic effects on protein separation is lower for CEC than for HIC, as mixed salts do not increase the separation of these proteins. The best salt composition for separating BSA and LYZ is pure ammonium sulfate. Thus, synergetic salt effects can also occur in CEC, but they have a lower impact than in HIC.

Respiration-based investigation of adsorbent-bioprocess compatibility.

BACKGROUND: The efficiency of downstream processes plays a crucial role in the transition from conventional petrochemical processes to sustainable biotechnological production routes. One promising candidate for product separation from fermentations with low energy demand and high selectivity is the adsorption of the target product on hydrophobic adsorbents. However, only limited knowledge exists about the interaction of these adsorbents and the bioprocess. The bioprocess could possibly be harmed by the release of inhibitory components from the adsorbent surface. Another possibility is co-adsorption of essential nutrients, especially in an in situ application, making these nutrients unavailable to the applied microorganism. RESULTS: A test protocol investigating adsorbent-bioprocess compatibility was designed and applied on a variety of adsorbents. Inhibitor release and nutrient adsorption was studied in an isolated manner. Respiratory data recorded by a RAMOS device was used to assess the influence of the adsorbents on the cultivation in three different microbial systems for up to six different adsorbents per system. While no inhibitor release was detected in our investigations, adsorption of different essential nutrients was observed. CONCLUSION: The application of adsorption for product recovery from the bioprocess was proven to be generally possible, but nutrient adsorption has to be assessed for each application individually. To account for nutrient adsorption, adsorptive product separation should only be applied after sufficient microbial growth. Moreover, concentrations of co-adsorbed nutrients need to be increased to compensate nutrient loss. The presented protocol enables an investigation of adsorbent-bioprocess compatibility with high-throughput and limited effort.

Evaluation of a Prototype for Electrochemical pH-Shift Crystallization of Succinic Acid.

Downstream processing of biotechnologically produced carboxylic acids, such as succinic acid, poses environmental and economic challenges. Conventional downstream processes cause large amounts of waste salts, which have to be purified or disposed of. Therefore, lean and waste-free downstream processes are necessary for the biotechnological production of succinic acid. Electrochemical downstream processes gain especially significant attention due to low chemical consumption and waste reduction. This work presents the pH-dependent solid-liquid equilibrium of succinic acid, a prototype for electrochemical pH-shift crystallization processes, and its characterization. Based on the supersaturation, energy consumption, and electrochemical protonation efficiency the proposed electrochemical pH-shift crystallization is evaluated. This evaluation highlights the potential of the proposed electrochemical crystallization processes as waste-free and economically attractive processes for bio-based succinic acid production.

Comparison of the impact of anion and cation selection onto cation exchange chromatography of model proteins.

For a further improvement of ion exchange chromatography for protein purification, the optimization of mobile phase composition is an important factor. The effects of salt type selection on cation exchange chromatography (CEC) have been investigated in this work. Hereby, the significance of co-ion and displacing ion selection were compared. Therefore, the suitability of a constant cationic or anionic strength for multivalent salts for the determination of salt impact were evaluated. The retention and separation behavior of the three model proteins bovine serum albumin, lysozyme and α-chymotrypsin were investigated with varying salts in the elution buffer. For this, five different cations and five different anions were used. Hereby, the effects of anion and cation selection were analyzed independently. It was shown that a constant cationic strength is a suitable setup for the determination of salt effects on protein retention in CEC, as the resulting retention factors did not show a clear trend regarding ion valence. It was observed that for the used process conditions the anion selection could change the separation factor by up to 30% and the cation selection by up to 16%. These changes were attributed to protein specific salt effects of citrate on bovine serum albumin and magnesium on α-chymotrypsin. It was demonstrated that at constant cationic strength the co-ion selection can be of the same or even of higher importance for protein separation as the selection of the displacing ion in CEC.

Investigation of the elution behavior of dissociating itaconic acid on a hydrophobic polymeric adsorbent using in-line Raman spectroscopy.

The use of adsorption for the purification of dicarboxylic acids is rather limited and currently predominantly confined to ion-exchange chromatography. A promising, but less regarded alternative is the use of hydrophobic adsorbents. Regarding hydrophobic absorbents, the literature focuses on screenings of adsorbents for purification of (di)carboxylic acids with regard to adsorption equilibria. The investigation of dynamic phenomena in the column received only minor attention. In this contribution, this knowledge gap is addressed. First, the adsorption behavior of itaconic acid species on the hydrophobic, highly-crosslinked polymeric adsorbent Chromalite™ PCG1200C is investigated. For this purpose, adsorption isotherms are determined via frontal analysis at pH values of 2, 3, 4.5, 6.5, and 8 to evaluate the dependency of the adsorption capacity on the dissociation state. Capacities above 150 g Lads-1 at liquid phase concentrations of 70 g L-1 are observed at a pH of 2. A strong decrease of capacity with increasing pH value, i.e., with increasing fraction of dissociated negatively charged acid species, is observed. Second, pulse experiments at aforementioned pH values are performed. Thereby, in-line Raman spectra are recorded at the column outlet, which allows the direct differentiation of the acid species state of dissociation. The spectral information is evaluated for quantitative concentration profiles of itaconic acid species using Indirect Hard Modeling with mixture hard models that are calibrated subject to ideal as well as non-ideal thermodynamics. In-line measurement errors of ≤ 3.5 g L-1 are achieved for the itaconic acid species. In dependency of the pH of the feed solution, a separation of the individual acid species within the pulse experiments is observed. It is conjectured that the process is dominated by a superposition of species-dependent adsorption characteristics and dissociation reactions.

Model-Based Simultaneous Solvent Screening and Column Design Based on a Holistic Consideration of Extraction and Solvent Recovery.

A methodology for a model-based simultaneous solvent screening and dimensioning of extraction columns is presented. Therefore, a rate-based extraction model is combined with a distillation model for solvent recovery and product purification to consider the whole extraction process. The optimal operating point and the required column dimensions are determined for each solvent candidate specifically to minimize total costs, which are used as a basis for solvent ranking. The methodology is applied to the extraction of levulinic acid from an aqueous feed with a special focus on the influence of mutual solubility between the solvent candidates and water. It is shown that using mixture properties for both phases in accordance with the mutual solubility significantly impacts the calculation of fluid dynamics, mass transfer, and thereby on the required extraction column height. Furthermore, additional costs due to solvents solubilized in the aqueous raffinate strongly affect the economic evaluation of the solvents.

Yeast-based production and in situ purification of acetaldehyde.

Acetaldehyde is a platform chemical with a production volume of more than 1 Mt/a, but is chiefly synthesized from petrochemical feedstocks. We propose the fermentative conversion of glucose towards acetaldehyde via genetically modified S. cerevisiae. This allows for ethanol-free bioactaldehyde production. Exploiting the high volatility of the product, in situ gas stripping in an aerated reactor is inevitable and crucial due to the respiratory toxicity effects of the acetaldehyde overproduction. We devise a lab-scale setup for the recovery of the product from the off-gas. Water was chosen as a suitable solvent and the Henry coefficient of acetaldehyde in water was validated experimentally. Based on an experimentally verified capture efficiency of 75%, an acetaldehyde production rate of over 100 mg/g/h was reached in 200 mL lab-scale fermentations.

MIXed plastics biodegradation and UPcycling using microbial communities: EU Horizon 2020 project MIX-UP started January 2020.

This article introduces the EU Horizon 2020 research project MIX-UP, "Mixed plastics biodegradation and upcycling using microbial communities". The project focuses on changing the traditional linear value chain of plastics to a sustainable, biodegradable based one. Plastic mixtures contain five of the top six fossil-based recalcitrant plastics [polyethylene (PE), polyurethane (PUR), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS)], along with upcoming bioplastics polyhydroxyalkanoate (PHA) and polylactate (PLA) will be used as feedstock for microbial transformations. Consecutive controlled enzymatic and microbial degradation of mechanically pre-treated plastics wastes combined with subsequent microbial conversion to polymers and value-added chemicals by mixed cultures. Known plastic-degrading enzymes will be optimised by integrated protein engineering to achieve high specific binding capacities, stability, and catalytic efficacy towards a broad spectrum of plastic polymers under high salt and temperature conditions. Another focus lies in the search and isolation of novel enzymes active on recalcitrant polymers. MIX-UP will formulate enzyme cocktails tailored to specific waste streams and strives to enhance enzyme production significantly. In vivo and in vitro application of these cocktails enable stable, self-sustaining microbiomes to convert the released plastic monomers selectively into value-added products, key building blocks, and biomass. Any remaining material recalcitrant to the enzymatic activities will be recirculated into the process by physicochemical treatment. The Chinese-European MIX-UP consortium is multidisciplinary and industry-participating to address the market need for novel sustainable routes to valorise plastic waste streams. The project's new workflow realises a circular (bio)plastic economy and adds value to present poorly recycled plastic wastes where mechanical and chemical plastic recycling show limits.

Metabolic and process engineering for microbial production of protocatechuate with Corynebacterium glutamicum.

3,4-Dihydroxybenzoate (protocatechuate, PCA) is a phenolic compound naturally found in edible vegetables and medicinal herbs. PCA is of high interest in the chemical industry and has wide potential for pharmaceutical applications. We designed and constructed a novel Corynebacterium glutamicum strain to enable the efficient utilization of d-xylose for microbial production of PCA. Shake flask cultivation of the engineered strain showed a maximum PCA titer of 62.1 ± 12.1 mM (9.6 ± 1.9 g L-1 ) from d-xylose as the primary carbon and energy source. The corresponding yield was 0.33 C-mol PCA per C-mol d-xylose, which corresponds to 38% of the maximum theoretical yield. Under growth-decoupled bioreactor conditions, a comparable PCA titer and a total amount of 16.5 ± 1.1 g PCA could be achieved when d-glucose and d-xylose were combined as orthogonal carbon substrates for biocatalyst provision and product synthesis, respectively. Downstream processing of PCA was realized via electrochemically induced crystallization by taking advantage of the pH-dependent properties of PCA. This resulted in a maximum final purity of 95.4%. The established PCA production process represents a highly sustainable approach, which will serve as a blueprint for the bio-based production of other hydroxybenzoic acids from alternative sugar feedstocks.

Extracorporeal Hyperoxygenation Therapy (EHT) for Carbon Monoxide Poisoning: In-Vitro Proof of Principle.

Carbon monoxide (CO) poisoning is the leading cause of poisoning-related deaths globally. The currently available therapy options are normobaric oxygen (NBO) and hyperbaric oxygen (HBO). While NBO lacks in efficacy, HBO is not available in all areas and countries. We present a novel method, extracorporeal hyperoxygenation therapy (EHT), for the treatment of CO poisoning that eliminates the CO by treating blood extracorporeally at elevated oxygen partial pressure. In this study, we proof the principle of the method in vitro using procine blood: Firstly, we investigated the difference in the CO elimination of a hollow fibre membrane oxygenator and a specifically designed batch oxygenator based on the bubble oxygenator principle at elevated pressures (1, 3 bar). Secondly, the batch oxygenator was redesigned and tested for a broader range of pressures (1, 3, 5, 7 bar) and temperatures (23, 30, 37 °C). So far, the shortest measured carboxyhemoglobin half-life in the blood was 21.32 min. In conclusion, EHT has the potential to provide an easily available and effective method for the treatment of CO poisoning.

Integration of Genetic and Process Engineering for Optimized Rhamnolipid Production Using Pseudomonas putida.

Rhamnolipids are biosurfactants produced by microorganisms with the potential to replace synthetic compounds with petrochemical origin. To promote industrial use of rhamnolipids, recombinant rhamnolipid production from sugars needs to be intensified. Since this remains challenging, the aim of the presented research is to utilize a multidisciplinary approach to take a step toward developing a sustainable rhamnolipid production process. Here, we developed expression cassettes for stable integration of the rhamnolipid biosynthesis genes into the genome outperformed plasmid-based expression systems. Furthermore, the genetic stability of the production strain was improved by using an inducible promoter. To enhance rhamnolipid synthesis, energy- and/or carbon-consuming traits were removed: mutants negative for the synthesis of the flagellar machinery or the storage polymer PHA showed increased production by 50%. Variation of time of induction resulted in an 18% increase in titers. A scale-up from shake flasks was carried out using a 1-L bioreactor. By recycling of the foam, biomass loss could be minimized and a rhamnolipid titer of up to 1.5 g/L was achieved without using mechanical foam destroyers or antifoaming agents. Subsequent liquid-liquid extraction was optimized by using a suitable minimal medium during fermentation to reduce undesired interphase formation. A technical-scale production process was designed and evaluated by a life-cycle assessment (LCA). Different process chains and their specific environmental impact were examined. It was found that next to biomass supply, the fermentation had the biggest environmental impact. The present work underlines the need for multidisciplinary approaches to address the challenges associated with achieving sustainable production of microbial secondary metabolites. The results are discussed in the context of the challenges of microbial biosurfactant production using hydrophilic substrates on an industrial scale.

Lignin Precipitation and Fractionation from OrganoCat Pulping to Obtain Lignin with Different Sizes and Chemical Composition.

Fractionation of lignocellulose into its three main components, lignin, hemicelluloses, and cellulose, is a common approach in modern biorefinery concepts. Whereas the valorization of hemicelluloses and cellulose sugars has been widely discussed in literature, lignin utilization is still challenging. Due to its high heterogeneity and complexity, as well as impurities from pulping, it is a challenging feedstock. However, being the most abundant source of renewable aromatics, it remains a promising resource. This work describes a fractionation procedure that aims at stepwise precipitating beech wood (Fagus sp.) lignin obtained with OrganoCat technology from a 2-methyltetrahydrofuran solution, using n-hexane and n-pentane as antisolvents. By consecutive antisolvent precipitation and filtration, lignin is fractionated and then characterized to elucidate the structure of the different fractions. This way, more defined and purified lignin fractions can be obtained. Narrowing down the complexity of lignin and separately valorizing the fractions might further increase the economic viability of biorefineries.

Model-based selection of the degree of cross-linking of cation exchanger resins for an optimised separation of monosaccharides.

One of the main steps in designing preparative chromatographic separation units is the selection of a well-performing adsorbent. This is often based on expert knowledge or based on case studies of preselected adsorbents. Therefore, the selection is usually limited in terms of an optimised choice. In this contribution, a model-based optimisation of the selection of an adsorbent on the basis of correlations between structural adsorbent properties with model parameters of a transport dispersive model is proposed. Model parameters of glucose and xylose for five cation exchanger resins with varying degree of cross-linking are experimentally determined in a sequential approach. Void fractions and particle porosities were determined by pulse experiments with different tracers. Single-component isotherms were determined threefold via breakthrough curves with concentrations of up to 250 g l-1 at 60 °C. Mass transfer coefficients were determined by batch experiments. Correlations between the degree of cross-linking of the resins and the Henry coefficients as well as the mass transfer coefficients were derived and applied in an optimisation case study. Based on the derived mathematical formula, the process performance of experimentally not investigated resins were predicted. Further, the selection of a resin for a preparative monosaccharide separation was included into optimisation algorithms.

Tomato's Green Gold: Bioeconomy Potential of Residual Tomato Leaf Biomass as a Novel Source for the Secondary Metabolite Rutin.

At the end of the annual horticultural production cycle of greenhouse-grown crops, large quantities of residual biomass are discarded. Here, we propose a new value chain to utilize horticultural leaf biomass for the extraction of secondary metabolites. To increase the secondary metabolite content of leaves, greenhouse-grown crop plants were exposed to low-cost abiotic stress treatments after the last fruit harvest. As proof of concept, we evaluated the production of the flavonoid rutin in tomato plants subjected to nitrogen deficiency. In an interdisciplinary approach, we observed the steady accumulation of rutin in young plants under nitrogen deficiency, tested the applicability of nitrogen deficiency in a commercial-like greenhouse, developed a high efficiency extraction for rutin, and evaluated the acceptance of the proposed value chain by its key actors economically. On the basis of the positive interdisciplinary evaluation, we identified opportunities and challenges for the successful establishment of horticultural leaf biomass as a novel source for secondary metabolites.