A life cycle assessment of early-stage enzyme manufacturing simulations from sustainable feedstocks.

Enzyme-catalyzed reactions have relatively small environmental footprints. However, enzyme manufacturing significantly impacts the environment through dependence on traditional feedstocks. With the objective of determining the environmental impacts of enzyme production, the sustainability potential of six cradle-to-gate enzyme manufacturing systems focusing on glucose, sea lettuce, acetate, straw, and phototrophic growth, was thoroughly evaluated. Human and ecosystem toxicity categories dominated the overall impacts. Sea lettuce, straw, or phototrophic growth reduces fermentation-based emissions by 51.0, 63.7, and 79.7%, respectively. Substituting glucose-rich media demonstrated great potential to reduce marine eutrophication, land use, and ozone depletion. Replacing organic nitrogen sources with inorganic ones could further lower these impacts. Location-specific differences in electricity result in a 14% and a 27% reduction in the carbon footprint for operation in Denmark compared to the US and China. Low-impact feedstocks can be competitive if they manage to achieve substrate utilization rates and productivity levels of conventional enzyme production processes.

Can biotechnology lead the way toward a sustainable pharmaceutical industry?

The impact-intensive and rapidly growing pharmaceutical industry must ensure its sustainability. This study reveals that environmental sustainability assessments have been conducted for only around 0.2% of pharmaceuticals, environmental impacts have significant variations among the assessed products, and different impact categories have not been consistently studied. Highly varied impacts require assessing more products to understand the industry's sustainability status. Reporting all impact categories will be crucial, especially when comparing production technologies. Biological production of (semi)synthetic pharmaceuticals could reduce their environmental costs, though the high impacts of biologically produced monoclonal antibodies should also be optimized. Considering the sustainability potential of biopharmaceuticals from economic, environmental, and social perspectives, collaboratively guiding their immense market growth would lead to the industry's sustainability transition.

Chemoenzymatic indican for light-driven denim dyeing.

Blue denim, a billion-dollar industry, is currently dyed with indigo in an unsustainable process requiring harsh reducing and alkaline chemicals. Forming indigo directly in the yarn through indican (indoxyl-ß-glucoside) is a promising alternative route with mild conditions. Indican eliminates the requirement for reducing agent while still ending as indigo, the only known molecule yielding the unique hue of blue denim. However, a bulk source of indican is missing. Here, we employ enzyme and process engineering guided by techno-economic analyses to develop an economically viable drop-in indican synthesis technology. Rational engineering of PtUGT1, a glycosyltransferase from the indigo plant, alleviated the severe substrate inactivation observed with the wildtype enzyme at the titers needed for bulk production. We further describe a mild, light-driven dyeing process. Finally, we conduct techno-economic, social sustainability, and comparative life-cycle assessments. These indicate that the presented technologies have the potential to significantly reduce environmental impacts from blue denim dyeing with only a modest cost increase.

Automating relative and absolute environmental sustainability assessments of bio-based products.

Awareness of long-term environmental challenges has motivated society toward a more sustainable future. Biotechnology is expected to contribute to the transition towards sustainability. Automation can play an important role in this transition, enabling faster decision-making at early stages. Therefore, an automated relative and absolute environmental sustainability assessment is presented to boost innovation in biotechnology. The automated calculation methodology uses computer-aided tools (dedicated software and Python codes) for the fast quantification of the environmental sustainability performance of bio-based products including scenario and uncertainty analysis. Two case studies (i) succinic acid (SA) and (ii) poly-lactic acid (PLA) are evaluated to test the capabilities of the automated assessment. The results show a carbon footprint and land use of 5.46 kg CO2 eq and 1.26 m2a crop eq for SA and 3.82 kg CO2 eq and 0.74 m2a crop eq for PLA. Transgression of planetary boundaries was found in both SA and PLA production.

Beet red food colourant can be produced more sustainably with engineered Yarrowia lipolytica.

Synthetic food colourants are widely used in the food industry, but consumer concerns about safety and sustainability are driving a need for natural food-colour alternatives. Betanin, which is extracted from red beetroots, is a commonly used natural red food colour. However, the betanin content of beetroot is very low (~0.2% wet weight), which means that the extraction of betanin is incredibly wasteful in terms of land use, processing costs and vegetable waste. Here we developed a sustainability-driven biotechnological process for producing red beet betalains, namely, betanin and its isomer isobetanin, by engineering the oleaginous yeast Yarrowia lipolytica. Metabolic engineering and fermentation optimization enabled production of 1,271 ± 141 mg l-1 betanin and 55 ± 7 mg l-1 isobetanin in 51 h using glucose as carbon source in controlled fed-batch fermentations. According to a life cycle assessment, at industrial scale (550 t yr-1), our fermentation process would require significantly less land, energy and resources compared with the traditional extraction of betanin from beetroot crops. Finally, we apply techno-economic assessment to show that betanin production by fermentation could be economically feasible in the existing market conditions.

Advances and opportunities in integrating economic and environmental performance of renewable products.

There is a growing global need to transition from a fossil-based to a bio-based economy to produce fuels, chemicals, food, and materials. In the specific context of industrial biotechnology, a successful transition toward a sustainable development requires not only steering investment toward a bioeconomy, but also responsibly introducing bio-based products with lower footprints and competitive market prices. A comprehensive sustainability assessment framework applied along various research stages to guide bio-based product development is urgently needed but currently missing. To support holistic approaches to strengthen the global bioeconomy, the present study discusses methodologies and provides perspectives on the successful integration of economic and environmental performance aspects to guide product innovation in biotechnology. Efforts on quantifying the economic and environmental performance of bio-based products are analyzed to highlight recent trends, challenges, and opportunities. We critically analyze methods to integrate Techno-Economic Assessment (TEA) and Life Cycle Assessment (LCA) as example tools that can be used to broaden the scope of assessing biotechnology systems performance. We highlight the lack of social assessment aspects in existing frameworks. Data need for jointly applying TEA and LCA of succinic acid as example commodity chemical are assessed at various Technology readiness levels (TRLs) to illustrate the relevance of the level of integration and show the benefits of the use of combined assessments. The analysis confirms that the implementation of integrated TEA and LCA at lower TRLs will provide more freedom to improve bio-based product's sustainability performance. Consequently, optimizing the system across TRLs will guide sustainability-driven innovation in new biotechnologies transforming renewable feedstock into valuable bio-based products.

Sustainable Design Approach for Modeling Bioprocesses from Laboratory toward Commercialization: Optimizing Chitosan Production.

Enhancing the biochemical supply chain towards sustainable development requires more efforts to boost technology innovation at early design phases and avoid delays in industrial biotechnology growth. Such a transformation requires a comprehensive step-wise procedure to guide bioprocess development from laboratory protocols to commercialization. This study introduces a process design framework to guide research and development (R&D) through this journey, bearing in mind the particular challenges of bioprocess modeling. The method combines sustainability assessment and process optimization based on process efficiency indicators, technical indicators, Life Cycle Assessment (LCA), and process optimization via Water Regeneration Networks (WRN). Since many bioprocesses remain at low Technology Readiness Levels (TRLs), the process simulation module was examined in detail to account for uncertainties, providing strategies for successful guidance. The sustainability assessment was performed using the geometric mean-based sustainability footprint metric. A case study based on Chitosan production from shrimp exoskeletons was evaluated to demonstrate the method's applicability and its advantages in product optimization. An optimized scenario was generated through a WRN to improve water management, then compared with the case study. The results confirm the existence of a possible configuration with better sustainability performance for the optimized case with a sustainability footprint of 0.33, compared with the performance of the base case (1.00).

Combining Environmental and Economic Performance for Bioprocess Optimization.

Biochemical production faces economic and environmental challenges that need to be overcome to enable a viable and sustainable bioeconomy. We propose an assessment framework that consistently combines environmental and economic indicators to support optimized biochemical production at early development stages. We define internally consistent system boundaries and a comprehensive set of quantitative indicators from life cycle assessment (LCA) and techno-economic assessment (TEA) to combine environmental and economic performance in a single score. Our framework enables the identification of trade-offs across environmental and economic aspects over the entire biochemical life cycle. This approach provides input for the optimization of future biochemicals in terms of overall sustainability, to overcome prevailing obstacles in the development of biochemical production processes.

Computational Methods to Assess the Production Potential of Bio-Based Chemicals.

Elevated costs and long implementation times of bio-based processes for producing chemicals represent a bottleneck for moving to a bio-based economy. A prospective analysis able to elucidate economically and technically feasible product targets at early research phases is mandatory. Computational tools can be implemented to explore the biological and technical spectrum of feasibility, while constraining the operational space for desired chemicals. In this chapter, two different computational tools for assessing potential for bio-based production of chemicals from different perspectives are described in detail. The first tool is GEM-Path: an algorithm to compute all structurally possible pathways from one target molecule to the host metabolome. The second tool is a framework for Modeling Sustainable Industrial Chemicals production (MuSIC), which integrates modeling approaches for cellular metabolism, bioreactor design, upstream/downstream processes, and economic impact assessment. Integrating GEM-Path and MuSIC will play a vital role in supporting early phases of research efforts and guide the policy makers with decisions, as we progress toward planning a sustainable chemical industry.

Thermodynamics and economic feasibility of acetone production from syngas using the thermophilic production host Moorella thermoacetica.

BACKGROUND: Syngas fermentation is a promising option for the production of biocommodities due to its abundance and compatibility with anaerobic fermentation. Using thermophilic production strains in a syngas fermentation process allows recovery of products with low boiling point from the off-gas via condensation. RESULTS: In this study we analyzed the production of acetone from syngas with the hypothetical production host derived from Moorella thermoacetica in a bubble column reactor at 60 °C with respect to thermodynamic and economic feasibility. We determined the cost of syngas production from basic oxygen furnace (BOF) process gas, from natural gas, and from corn stover and identified BOF gas as an economically interesting source for syngas. Taking gas-liquid mass transfer limitations into account, we applied a thermodynamics approach to derive the CO to acetone conversion rate under the process conditions. We estimated variable costs of production of 389 $/t acetone for a representative production scenario from BOF gas with costs for syngas as the main contributor. In comparison, the variable costs of production from natural gas- and corn stover-derived syngas were determined to be higher due to the higher feedstock costs (1724 and 2878 $/t acetone, respectively). CONCLUSION: We applied an approach of combining thermodynamic and economic assessment to analyze a hypothetical bioprocess in which the volatile product acetone is produced from syngas with a thermophilic microorganism. Our model allowed us to identify process metrics and quantify the variable production costs for different scenarios. Economical production of bulk chemicals is challenging, making rigorous thermodynamic/economic modeling critical before undertaking an experimental program and as an ongoing guide during the program. We intend this study to give an incentive to apply the demonstrated approach to other bioproduction processes.

A multi-scale, multi-disciplinary approach for assessing the technological, economic and environmental performance of bio-based chemicals.

In recent years, bio-based chemicals have gained interest as a renewable alternative to petrochemicals. However, there is a significant need to assess the technological, biological, economic and environmental feasibility of bio-based chemicals, particularly during the early research phase. Recently, the Multi-scale framework for Sustainable Industrial Chemicals (MuSIC) was introduced to address this issue by integrating modelling approaches at different scales ranging from cellular to ecological scales. This framework can be further extended by incorporating modelling of the petrochemical value chain and the de novo prediction of metabolic pathways connecting existing host metabolism to desirable chemical products. This multi-scale, multi-disciplinary framework for quantitative assessment of bio-based chemicals will play a vital role in supporting engineering, strategy and policy decisions as we progress towards a sustainable chemical industry.