26/04/2013 Improving productivities in fermentation processes. Heleen De Wever Köln, April 2013

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1 26/04/2013 Improving productivities in fermentation processes Heleen De Wever Köln, April 2013

2 Bio based production chemicals Aspect Substrate Microorganisms Operation mode Sterilization equipment Product titre Product recovery Product separation Current practice Single Pure culture Batch Yes High Separate/downstream Low amount of impurities 26/04/2013 2

3 Case: Bioplastics from waste streams» Renewable resource:» Organic waste stream» Offgases» Target compound:» Fully biobased biodegradable group of bioplastics selected» Polyhydroxyalkanoates (PHA) general» Polyhydroxybutyrate (PHB)» Biocatalyst: pure bacterial culture» Concept: fed batch process 26/04/2013 3

4 Case: Bioplastics from waste streams» Production process CO 2 Organic C N source CO 2 H 2 Air/O 2 Air/O 2 Phase 1: Biomass production Phase 2: PHA production 26/04/2013 4

5 Bio based production chemicals Aspect Current practice Future Substrate Single 2nd generation feedstocks Organic waste Microorganisms Pure culture Undefined mixed culture Operation mode Batch Continuous Sterilization equipment Yes No Product titre High Low Product recovery Separate/downstream Integrated Product separation Low amount of impurities Dilute product stream High amount of impurities Different technologies Our approach: high conversion efficiencies and product concentrations through process intensification 26/04/2013 5

6 From batch to continuous processes High titer and productivity by using several stirred tanks in series Advantages» Increase throughput» Reduce cleanup time» Reduce required footprint» Often only feasible alternative for high volume, low value products Challenges» Advanced process control» Maintain sterility» On line quality measurements 26/04/2013 6

7 to high cell density fermentation» Membrane bioreactors (MBRs): cell retention by membranes» Advantage: increased throughput and productivity» Challenge: membrane fouling control 26/04/2013 7

8 Case: Organic acids from waste» Renewable resource:» Organic waste stream consisting of» Non edible residues of plants» Fecal material» Toilet paper» Target compound:» Volatile Fatty Acids (VFA, acetate propionate butyrate)» Part of closed loop system for Advanced Life Support in space» Biocatalyst: undefined mixed bacterial culture» Concept: continuous fermentation at increased cell density (MBR) 26/04/2013 8

9 Towards integrated biorefinery concepts» Two stage bioconversion processes based on organic acids from waste (Source: Li and Yu, 2011) 26/04/2013 9

10 to inclusion of product removal techniques» In situ product recovery or removal (ISPR)» Advantages:» Integration of fermentation with first step of downstream process» Higher productivity by removal of product inhibition» Concentrated feedstocks can be fermented» Challenges:» Match mode of operation of bioreactor/separation units» Optimize integrated set up for maximum productivity gain Source: Woodley et al. (2008) 26/04/

11 Case: Biobutanol from sugars» Acetone Butanol Ethanol (ABE) fermentation one of the largest biotechnological processes ever developed» Process challenges» Product inhibition, low product concentrations and low productivity» Cost of substrates» Renewable resource: sugars» Target compound: butanol» Biocatalyst: pure bacterial culture» Concept: continuous fermentation with in situ butanol removal 26/04/

12 Case: Biobutanol from sugars» In situ butanol removal by organophilic pervaporation» Proof of concept: continuous conversion in two stage fermentation using commercial composite membrane with PDMS top layer Pervaporation module Acidogenic fermentation Solventogenic fermentation Fermentor temperature: 35 C Permeate pressure: ~19.9 mbar 26/04/

13 Case: Biobutanol from sugars» Our own optimization studies in long term continuous experiments Result Gain Increased productivity from Decreased fermentor cost 0.35 to 1.15 g.l 1.h 1 Increased flux from Decreased capital costs for 375 to 620 g.m 2.h 1 pervaporation Increased permeate concentration from Decreased energy consumption in 120 to >200 g.l 1 distillation section» Next step: switch to high cell density fermentation (MBR concept) 26/04/

14 Conclusions» Bioconversions on organic waste streams present challenges in terms of product separation and purification» Combination of bioconversion and separation technology results in improved productivities» Current efforts are mainly at laboratory scale» Need for upscaling, demonstration of robustness 26/04/

15 VITO experience» Feedstocks:» Synthetic media and organic waste streams» Synthetic gas mixtures and waste gases» Target compounds:» Intracellular: bioplastics» Extracellular: organic acids, alcohols, biosurfactants,» Biocatalysts:» Pure bacterial cultures and mixed cultures» Enzymes» Concepts: H 2 CO 2» Batch, fed batch and continuous operation» Single and multistage fermentations, stand alone or integrated with separation technology 26/04/

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