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US20030180900A1 - Methods for producing ethanol from carbon substrates - Google Patents

Methods for producing ethanol from carbon substrates Download PDF

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Publication number
US20030180900A1
US20030180900A1 US10/360,010 US36001003A US2003180900A1 US 20030180900 A1 US20030180900 A1 US 20030180900A1 US 36001003 A US36001003 A US 36001003A US 2003180900 A1 US2003180900 A1 US 2003180900A1
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substrate
enzyme
converting enzyme
product
starch
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Oreste Lantero
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Danisco US Inc
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Assigned to GENENCOR INTERNATIONAL, INC. reassignment GENENCOR INTERNATIONAL, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LANTERO, ORESTE
Publication of US20030180900A1 publication Critical patent/US20030180900A1/en
Priority to US10/856,214 priority patent/US20050100996A1/en
Assigned to GENENCOR INTERNATIONAL, INC. reassignment GENENCOR INTERNATIONAL, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SHETTY, JAYARAMA K.
Assigned to GENENCOR INTERNATIONAL, INC. reassignment GENENCOR INTERNATIONAL, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SHETTY, JAYARAMA K.
Priority to US11/243,382 priority patent/US8293508B2/en
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    • CCHEMISTRY; METALLURGY
    • C12BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12PFERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00Preparation of oxygen-containing organic compounds
    • C12P7/02Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06Ethanol, i.e. non-beverage
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    • C12BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12PFERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00Preparation of oxygen-containing organic compounds
    • C12P7/02Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06Ethanol, i.e. non-beverage
    • C12P7/08Ethanol, i.e. non-beverage produced as by-product or from waste or cellulosic material substrate
    • C12P7/10Ethanol, i.e. non-beverage produced as by-product or from waste or cellulosic material substrate substrate containing cellulosic material
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    • C12PFERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00Preparation of oxygen-containing organic compounds
    • C12P7/02Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/18Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic polyhydric
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    • C12BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12PFERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00Preparation of oxygen-containing organic compounds
    • C12P7/02Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/18Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic polyhydric
    • C12P7/20Glycerol
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    • C12PFERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00Preparation of oxygen-containing organic compounds
    • C12P7/40Preparation of oxygen-containing organic compounds containing a carboxyl group including Peroxycarboxylic acids
    • C12P7/44Polycarboxylic acids
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    • C12BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12PFERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00Preparation of oxygen-containing organic compounds
    • C12P7/40Preparation of oxygen-containing organic compounds containing a carboxyl group including Peroxycarboxylic acids
    • C12P7/56Lactic acid
    • CCHEMISTRY; METALLURGY
    • C12BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12PFERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00Preparation of oxygen-containing organic compounds
    • C12P7/40Preparation of oxygen-containing organic compounds containing a carboxyl group including Peroxycarboxylic acids
    • C12P7/58Aldonic, ketoaldonic or saccharic acids
    • CCHEMISTRY; METALLURGY
    • C12BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12PFERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00Preparation of oxygen-containing organic compounds
    • C12P7/40Preparation of oxygen-containing organic compounds containing a carboxyl group including Peroxycarboxylic acids
    • C12P7/58Aldonic, ketoaldonic or saccharic acids
    • C12P7/602-Ketogulonic acid
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00Technologies for the production of fuel of non-fossil origin
    • Y02E50/10Biofuels, e.g. bio-diesel

Definitions

  • At least one substrate-converting enzyme converts at least 50% of the substrate to the intermediate within 72 hours, while in other embodiments, at least one substrate-converting enzyme converts at least 90% of the substrate to the intermediate within 72 hours, and in some preferred embodiments, at least one substrate-converting enzyme converts at least 95% of the substrate to the intermediate within 72 hours.
  • at least one substrate-converting enzyme and at least one intermediate-converting enzyme are obtained from a microorganism selected from the group consisting of Rhizopus and Aspergillus.
  • the substrate-converting and/or intermediate-converting enzyme(s) are provided as a cell-free extract.
  • the contacting steps take place in a reaction vessel, including but not limited to vats, bottles, flasks, bags, bioreactors, and any other receptacle suitable for conducting the methods of the present invention.
  • FIG. 1 provides a graph showing the ethanol results for the experiments described in Example 1.
  • FIG. 2 Panels A, B and C provide graphs showing the ethanol results from uncooked ground corn fermentation using M1 (Panel A), CU (Panel B), and M1 with DISTILLASE® (Panel C).
  • FIG. 5 shows the glucose profile after 72 hour of fermentation as described in Example 4.
  • carbon substrate refers to a material containing at least one carbon atom which can be enzymatically converted into an intermediate for subsequent conversion into the desired carbon end-product.
  • exemplary carbon substrates include, but are not limited to biomass, starches, dextrins and sugars.
  • intermediate refers to a compound that contains at least one carbon atom into which the carbon substrates are enzymatically converted.
  • exemplary intermediates include, but are not limited to pentoses, (e.g., xylose, arabinose, lyxose, ribose, ribulose, xylulose); hexoses (e.g., glucose, allose, altrose, mannose, gulose, idose, galactose, talose, psicose, fructose, sorbose, and tagatose); and organic acids thereof.
  • pentoses e.g., xylose, arabinose, lyxose, ribose, ribulose, xylulose
  • hexoses e.g., glucose, allose, altrose, mannose, gulose, idose, galactose, talose, psicose, fructos
  • glucose oxidase unit is defined as the amount of enzyme required to oxidize one micromole of D-glucose per minute under assay conditions of 25° C. and pH 7.0, to gluconic acid.
  • one AG unit is the amount of enzyme which splits one micromole of maltose per minute at 25° C. and pH 4.3.
  • AGU is the amount of enzyme which splits one micromole of maltose per minute at 25° C. and pH 4.3.
  • a commercially available liquid form of glucoamylase OPTIDEX® L-400; Genencor International
  • AMG NOVO 150 a commercially available liquid form of glucoamylase
  • microorganism refers to any organism with cells that are typically considered to be microscopic, including such organisms as bacteria, fungi (yeasts and molds), rickettsia, and protozoa. It is not intended that the present invention be limited to any particular microorganism(s) or species of microorganism(s), as various microorganisms and microbial enzymes are suitable for use in the present invention. It is also not intended that the present invention be limited to wild-type microorganisms, as microorganisms and microbial enzymes produced using recombinant DNA technologies also find use in the present invention.
  • microbial enzyme refers to any enzyme that is produced by a microorganism.
  • a “microbial intermediate-converting enzyme” is an enzyme that converts an intermediate to an end-product
  • a “microbial substrate-converting enzyme” is an enzyme that converts a substrate to an intermediate or directly converts a substrate to an end-product (i.e., there is not intermediate compound).
  • ethanol producer and “ethanol producing organism” refer to any organism or cell that is capable of producing ethanol from a hexose or a pentose.
  • ethanol producing cells contain an alcohol dehydrogenase and pyruvate decarboxylase.
  • antimicrobial refers to any compound that kills or inhibits the growth of microorganisms.
  • the term “linked culture” refers to a fermentation system that employs at least two cell cultures, in which the cultures are added sequentially.
  • a primary culture or a set of primary cultures is grown under optimal fermentation conditions for the production of a desired intermediate (i.e., the intermediate is released into the culture media to produce a “conditioned medium”).
  • the conditioned medium is then exposed to the secondary culture(s).
  • the secondary cultures then convert the intermediate in the conditioned media to the desired end-product.
  • the primary cultures are typically glycerol producers and the secondary cultures are 1,3-propanediol producers.
  • the term “enhanced” refers to improved production of proteins of interest.
  • the present invention provides enhanced (i.e., improved) production and secretion of a protein of interest.
  • the “enhanced” production is improved as compared to the normal levels of production by the host (e.g., wild-type cells).
  • the host e.g., wild-type cells.
  • the present invention provides dramatic improvements in the process for directly converting a commonly available carbon substrate (e.g., biomass and/or starch) into an intermediate, preferably, an intermediate that is readily convertible into a multitude of desired end-products, including alcohols such as ethanol.
  • the present invention provides means for dramatically improving the processes for directly converting granular starch into glucose, an intermediate readily convertible into an ethanol.
  • Exemplary methods of providing such excessive intermediate conversion include providing an excess of intermediate converting enzyme, increasing the enzyme activity of the intermediate converting enzyme, and/or decreasing the activity of the substrate converting enzyme to convert the intermediate to end-product as quickly as it is converted from the substrate. As the actual rate of conversion is contemplated to vary with the specific end product produced, some variation in the amount and experimentation in determining the amount are contemplated. However guidelines for making these determinations are provided herein.
  • Indirect measurement of the levels of intermediate or end-products produced can be assessed by the measurement of oxygen uptake or carbon dioxide production, using methods known in the art (e.g., by determining the oxygen uptake rate and/or the carbon evolution rate).
  • a particularly useful carbon substrate is corn starch.
  • granular starch is used in a slurry having a percentage of starch between about 20% and about 35%.
  • the starch is in a concentration between about 10% and about 35%.
  • the range for percent starch is between 30% and 32%.
  • other carbon substrate sources find use in the present invention include, but are not limited to biomass, polysaccharides, and other carbon based materials capable of being converted enzymatically to an intermediate.
  • the conditions for converting sugars to ethanol are known in the art.
  • the temperature is between about 25° C. and 35° C. (e.g., between 25° and 35°, and more particularly at 30° C).
  • Useful pH ranges for the conversion medium are provided between about 4.0 and 6.0, between 4.5 and 6.0, and between pH 5.5 and 5.8.
  • the alpha-amylase used in some methods of the present invention is generally an enzyme which effects random cleavage of alpha-(1-4) glucosidic linkages in starch.
  • the alpha-amylase is chosen from among the microbial enzymes having an E. C. number E. C. 3.2.1.1 and in particular E. C. 3.2.1.1-3.
  • the alpha-amylase is a thermostable bacterial alpha-amylase.
  • the alpha-amylase is obtained or derived from Bacillus species.
  • the quantity of alpha-amylase used in the methods of the present invention will depend on the enzymatic activity of the alpha-amylase and the rate of conversion of the generated glucose by the end-product converter. Generally an amount between 0.001 and 2.0 ml of a solution of the alpha-amylase is added to 1000 gm of raw materials, although in some embodiments, it is added in an amount between 0.005 and 1.5 ml of such a solution. In some preferred embodiments, it is added in an amount between 0.1 and 1.0 ml of such a solution. In further embodiments, other quantities are utilized.
  • SPEZYME® FRED For example, generally an amount between 0.01 and 1.0 kg of SPEZYME® FRED (Genencor) is added to one metric ton of starch.
  • the enzyme is added in an amount between 0.4 to 0.6 kg, while in other embodiments, it is added in an amount between 0.5 and 0.6 kg of SPEZYME® FRED/metric ton of starch.
  • Rhizopus glucoamylase has a stronger degradation activity than Aspergillus niger glucoamylase preparations which also contain ⁇ -amylase (See, Yamamoto et al., Denpun Kagaku, 37:129-136 [1990]).
  • One commercial preparation that finds use in the present invention is the glucoamylase preparation derived from the Koji culture of a strain of Rhizopus niveus available from Shin Nippo Chemical Co., Ltd.
  • Another commercial preparation that finds use in the present invention is the commercial starch hydrolyzing composition M1 is available from Biocon India (Bangalore, India).
  • pullulanases also find use in the methods of the present invention. These enzymes hydrolyze alpha.-1,6-glucosidic bonds. Thus, during the saccharification of the liquefied starch, pullulanases remove successive glucose units from the non-reducing ends of the starch. This enzyme is capable of hydrolyzing both the linear and branched glucosidic linkages of starch, amylose and amylopectin.
  • Additional enzymes that find use in the present invention include starch hydrolyzing (RSH) enzymes, including Humicola RSH glucoamylase enzyme preparation (See, U.S. Pat. No. 4,618,579).
  • This Humicola RSH enzyme preparation exhibits maximum activity within the pH range of 5.0 to 7.0 and particularly in the range of 5.5 to 6.0.
  • this enzyme preparation exhibits maximum activity in the temperature range of 50° C. to 60° C.
  • the enzymatic solubilization of starch is preferably carried out within these pH and temperature ranges.
  • Humicola RSH enzyme preparations obtained from the fungal organism strain Humicola grisea var. thermoidea find use in the methods of the present invention.
  • these Humicola RSH enzymes are selected from the group consisting of ATCC (American Type Culture Collection) 16453, NRRL (USDA Northern Regional Research Laboratory) 15219, NRRL 15220, NRRL 15221, NRRL 15222, NRRL 15223, NRRL 15224, and NRRL 15225, as well as genetically altered strains derived from these enzymes.
  • the enzyme obtained from the Koji strain of Rhizopus niveus available from Shin Nihon Chemical Co., Ltd., Ahjyo, Japan, under the tradename “CU CONC” is used.
  • Another useful enzyme preparation is a commercial digestive from Rhizopus available from Amano Pharmaceutical under the tradename “GLUCZYME” (See, Takahashi et al., J. Biochem., 98:663-671 [1985]).
  • the carbon source is enzymatically converted to the intermediate, it is converted into the desired end-product by the appropriate methodology.
  • Conversion is accomplished via any suitable method (e.g., enzymatic or chemical).
  • conversion is accomplished by bioconversion of the intermediate by contacting the intermediate with a microorganism.
  • the respective substrate-converting enzyme and the intermediate-converting enzyme are placed in direct contact with the substrate and/or intermediate.
  • the enzyme(s) are provided as isolated, purified or concentrated preparations.
  • microorganisms that are genetically modified to express enzymes not normally produced by the wild-type organism are utilized.
  • the organisms are modified to overexpress enzymes that are normally produced by the wild-type organism.
  • glucoamylase is used so effectively that economically feasible dosage levels of glucoamylase are suitable for use in the methods of the present invention (i.e., glucoamylase dosage of 0.05-10.0 GAU/g of starch; and preferably 0.2-2.0 GAU/g starch).
  • starch hydrolyzing enzymes will find use in the present invention as part of a enzyme mixture which includes starch hydrolyzing enzymes, alpha amylases and glucoamylases.
  • RSHs e.g., the enzyme obtained from Rhizopus
  • non-cooking temperatures e.g., 25 to 35° C.
  • these enzymes find particular use in the methods of the present invention.
  • the desired end-product can be any product that may be produced by the enzymatic conversion of the substrate to the end-product.
  • the substrate is first converted to at least one intermediate and then converted from the intermediate to an end-product.
  • hexoses can be bioconverted into numerous products, such as ascorbic acid intermediates, ethanol, 1,3-propanediol, and gluconic acid.
  • Ascorbic acid intermediates include but are not limited to 2,5-diketogluconate, 2 KLG (2-keto-L-gluconate), and 5-KDG (5-keto-D-gluconate).
  • Gluconate can be converted from glucose by contacting glucose with glucose dehydrogenase (GDH).
  • ethanologenic microorganisms include ethanologenic bacteria expressing alcohol dehydrogenase and pyruvate decarboxylase, such as can be obtained with or from Zymomonas mobilis (See e.g., U.S. Pat. Nos. 5,028,539, 5,000,000, 5,424,202, 5,487,989, 5,482,846, 5,554,520, 5,514,583, and copending applications having U.S. Ser. No. 08/363,868 filed on Dec. 27, 1994, U.S. Ser. No. 08/475,925 filed on Jun. 7, 1995, and U.S. Ser. No. 08/218,914 filed on Mar. 28, 1994, the teachings of all of which are hereby incorporated by reference, in their entirety).
  • the ethanologenic microorganism expresses xylose reductase and xylitol dehydrogenase, enzymes that convert xylose to xylulose.
  • xylose isomerase is used to convert xylose to xylulose.
  • the ethanologenic microorganism also expresses xylulokinase, an enzyme that catalyzes the conversion of xylulose to xylulose-5-phosphate. Additional enzymes involved in the completion of the pathway include transaldolase and transketolase. These enzymes can be obtained or derived from Escherichia coli, Klebsielia oxytoca and Erwinia species (See e.g., U.S. Pat. No. No. 5,514,583).
  • supplements are added to the nutrient medium (i.e., the culture medium), including, but not limited to vitamins, macronutrients, and micronutrients.
  • Vitamins include, but are not limited to choline chloride, nicotinic acid, thiamine HCl, cyanocobalamin, p-aminobenzoic acid, biotin, calcium pantothenate, folic acid, pyridoxine.HCl, and riboflavin.
  • Vitamins include, but are not limited to (NH 4 ) 2 SO 4 , K 2 HPO 4 , NaCl, and MgSO 4 . 7H 2 O.
  • Micronutrients include, but are not limited to FeCl 3 6H 2 O, ZnCl 2 .4H 2 O, CoCl 2 .6H 2 O, molybdic acid (tech), CuCl 3 .2H 2 O, CaCl 2 .2H 2 O, and H 3 BO 3 .
  • preferred carbon substrates include monosaccharides, disaccharides, oligosaccharides, polysaccharides, and one-carbon substrates.
  • the carbon substrates are selected from the group consisting of glucose, fructose, sucrose and single carbon substrates such as methanol and carbon dioxide.
  • the substrate is glucose.
  • the present process uses a batch method of fermentation.
  • a classical batch fermentation is a closed system, wherein the composition of the media is set at the beginning of the fermentation and is not subject to artificial alterations during the fermentation. Thus, at the beginning of the fermentation the medium is inoculated with the desired organism(s). In this method, fermentation is permitted to occur without the addition of any components to the system.
  • a batch fermentation qualifies as a “batch” with respect to the addition of the carbon source and attempts are often made at controlling factors such as pH and oxygen concentration. The metabolite and biomass compositions of the batch system change constantly up to the time the fermentation is stopped.
  • the present invention is practiced using batch processes, while in other embodiments, fed-batch or continuous processes, as well as any other suitable m0de of fermentation are used. Additionally, in some embodiments, cells are immobilized on a substrate as whole-cell catalysts and are subjected to fermentation conditions for the appropriate end-product production.
  • the end-product is identified directly by submitting the media to high pressure liquid chromatography (HPLC) analysis.
  • HPLC high pressure liquid chromatography
  • One method of the present invention involves analysis of fermentation media on an analytical ion exchange column using a mobile phase of 0.01 N sulfuric acid in an isocratic fashion.
  • means for bioconversion and fermentation of a granular starch slurry having 10-35% starch by weight are provided.
  • fermentation of a 10-35% starch slurry with E. coli results in the production of residual starch when fermentation has proceeded to the intended organic acid or 1,3-propane diol content levels.
  • this reaction is dependent on the microorganism and bioprocessing conditions used and, therefore, recycling of the enzymes on the starch particles occurs when the residual starch is again fermented.
  • the fermentation is halted before complete disappearance of the granular starch, for fermentation anew.
  • recycling of starch is a facile way to recover enzymes for reuse.
  • means for fermentation of a granular starch slurry of 25-25% by weight are provided. Fermenting a 25-35% starch slurry with common baker's yeast will invariably result in residual starch when fermentation has proceeded to the intended alcohol content levels (e.g., 7-10%), dependent on the microorganism used and the recycling of the enzymes on the starch particles occurs when the residual starch is again fermented.
  • the present invention be limited to this range, as other weight percentages will find use in the present invention, depending upon the substrate and/or enzyme system utilized in the methods.
  • a granular starch slurry of 10-35% by weight is preferred.
  • a particularly useful microorganism is one that is resistant to the alcohol produced by the process.
  • bioconversion and fermentation of a corn-stover slurry having 10-35% cellulosics by weight is provided.
  • fermenting a 10-35% cellulosic slurry with E. coli results in residual cellulosic when fermentation has proceeded to the intended organic acid or 1,3-propane diol content levels. This reaction is dependent upon the microorganism and bioprocessing conditions used. As above, recycling of the enzymes on the cellulosics occurs when the residual corn-stover is again fermented.
  • the granular starch or corn stover and microorganisms are removed together (e.g., by centrifugation or filtration). This mixture of removed granular starch or corn stover and microorganisms is mixed with fresh granular starch or corn stover and additional aliquot(s) of enzyme(s) as needed, to produce a fermentation charge for another fermentation run.
  • the present invention saves considerable thermal energy.
  • the starting substrate e.g., starch
  • the substrate is not thermally sterilized.
  • the starting substrate e.g., granular starch
  • the starting substrate adds contaminating microorganisms to the fermentation medium.
  • the method involves seeding the fermentation medium with the great number of the ethanol producing microorganism that are likely to accompany the recycled granular starch. Through their great numbers, the recycled microorganisms overwhelm any contaminating microorganisms, thereby dominating the fermentation, as is, of course, desired.
  • the practice of the present invention controls the fermentation rate by releasing metabolizable sugars to the microorganisms (e.g., yeast) at a controlled rate and maintaining the concentration of the intermediate (e.g., glucose) at a level that does not trigger enzyme inhibition or catabolite repression.
  • the microorganisms e.g., yeast
  • the concentration of the intermediate e.g., glucose
  • This approach is very different from what was done prior to the development of the present invention. Indeed, the prior art suggests treating solid starch with enzymes prior to fermentation and/or including enzymes in the fermentation medium to conserve energy and/or to improve fermentation efficiency.
  • these teachings do not alter the character of the fermentation so as to avoid the adverse effects of catabolite repression and/or enzymatic inhibition.
  • the microbes are removed from the residual starch or biomass particles prior to recycling of the residual starch or biomass.
  • practice of the present invention does not necessarily require thermal treatment of the starting substrate (e.g., starch).
  • the starting substrate is heat-sterilized, while in other embodiments, it is not. Therefore, in some embodiments, the fermentation/bioconversion is conducted in the presence of a relatively large proportion of microorganisms, in order to overcome the effects of any contamination.
  • antimicrobials are added to the fermentation medium to suppress growth of contaminating microorganisms.
  • cold sterilization techniques, UV radiation, 65° C. pasteurization are used to sterilize the starting (e.g., substrate) materials.
  • biomass poses no problem regarding sterilization of fermentation vats or bioreactors.
  • starch as the starting material does not only address the above shortcomings of currently used methods, but has three additional significant benefits in terms of the raw material cost of corn starch vs. D-glucose, reduction of substrate and/or product based inhibition of enzymes employed in the bioconversion, and a concomitant significant reduction in the requirement of high enzyme dosages.
  • OD optical density
  • OD 280 optical density at 280 nm
  • OD 600 optical density at 600 nm
  • PAGE polyacrylamide gel electrophoresis
  • PBS phosphate buffered saline [150 mM NaCl, 10 mM sodium phosphate buffer, pH 7.2]
  • Cerestar Cerestar, a Cargill, inc., company, Minneapolis, Minn.
  • SDS sodium dodecyl sulfate
  • Tris tris(hydroxymethyl)aminomethane
  • w/v weight to volume
  • v/v volume to volume
  • ATCC American Type Culture Collection, Rockville, Md.
  • Difco Difco Laboratories, Detroit, Mich.
  • GIBCO BRL Gibco BRL (Life Technologies, Inc., Gaithersburg, Md.); Genencor (Genencor International, Inc., Palo Alto, Calif.); Shin Nihon (
  • FIG. 1 provides a graph showing the ethanol content of the various tests.
  • Example 2 the same procedure was used for this experiment as in Example 1, except that 35.9% ground corn slurry was used (instead of corn mash), and prior to starting the fermentation the slurry was placed in a 65° C. water for one hour as a pasteurization step. No observed gelatinization of the slurry was observed.
  • the enzymes tested were Sumizyme CU (Example 1), a Rhizopus glucoamylase preparation (M1) from Biocon assayed at 178 GAU/gm and 277 RHU/gm, and DISTILLASE® L-400 (Dist.) at 361 GAU/gm and 196 RHU/gm. Table 2 provides the conditions used for this study, and also summarizes the results.
  • the ethanol results from the fermentations with M1 and CU are plotted in FIGS. 2A and 2B.
  • the rate and yield of ethanol is less than the 0.5 and 0.75 levels indicating the 0.2 level is enzyme limiting.
  • the 0.5 and 0.75 levels of M1 seem to give very similar results indicating that enzyme is no longer limiting.
  • the results from CU similarly shows that the 0.2 enzyme level is somewhat limiting the fermentation, but is faster than 0.2 GAU/gm for M1 results. This indicates that the RHU activity is a better parameter that indicates the hydrolysis of uncooked starch.
  • CU has about twice the RHU activity per GAU as does M1, and CU is seen to hydrolyze the uncooked starch faster at similar GAU levels. At the 0.5 and 0.75 GAU/gm dosage excess glucose is observed particularly at the higher enzyme level. Actually it appears that starch hydrolyzing rate is faster than the fermentation rate. These results also show that at around 15% ethanol, the ethanol seems to become toxic to the yeast since the fermentations appeared to stop.

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US20060084156A1 (en) 2006-04-20
CN100564534C (zh) 2009-12-02
US8293508B2 (en) 2012-10-23
WO2003066826A3 (fr) 2005-03-03
US20050100996A1 (en) 2005-05-12
JP2005523689A (ja) 2005-08-11
CN1639346A (zh) 2005-07-13
CA2475416A1 (fr) 2003-08-14
AU2003217338A1 (en) 2003-09-02
EP1525300A2 (fr) 2005-04-27
EP1525300A4 (fr) 2006-03-15

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