Polyhydroxyalkanoate production methods and materials and microorganisms used in same

Abstract

Embodiments of the invention relate generally to methods to generate microorganisms and / or microorganism cultures that exhibit the ability to produce polyhydroxyalkanoates (PHA) from carbon sources at high efficiencies. In several embodiments, preferential expression of, or preferential growth of microorganisms utilizing certain metabolic pathways, enables the high efficiency PHA production from carbon-containing gases or materials. Several embodiments relate to the microorganism cultures, and / or microorganisms isolated therefrom.

Description

RELATED CASES[0001]This application is a continuation-in-part of co-pending U.S. application Ser. No. 16 / 577,373, filed Sep. 20, 2019, which is a continuation of co-pending U.S. application Ser. No. 15 / 643,905, filed Jul. 7, 2017 (now issued as U.S. Pat. No. 10,450,592), which is a continuation of U.S. application Ser. No. 14 / 740,056, filed Jun. 15, 2015 (now issued as U.S. Pat. No. 9,725,744), which is a continuation of U.S. application Ser. No. 13 / 802,622, filed Mar. 13, 2013 (now issued as U.S. Pat. No. 9,085,784), which claims the benefit of U.S. Provisional Application No. 61 / 617,534, filed on Mar. 29, 2012 the entire disclosure of each of which is incorporated in its entirety by reference herein.BACKGROUNDField of the Invention[0002]Embodiments of the invention relate to an improved process for the production, processing, and functional modification of polyhydroxyalkanoates (PHAs), and specifically to processes for the production, processing, and functional modification of PHA...

AI Technical Summary

Benefits of technology

The patent text discusses a method for producing polyhydroxyalkanoate (PHA) using gas bubbles instead of traditional carbon crops or plant-based sources of carbon. The use of carbon-containing off-gases from industry offers economic and environmental advantages. The method also involves manipulating the culture conditions to select for less pigmented microorganisms, which reduces PHA production costs. The resulting PHA product, however, may still contain certain compounding agents that improve its quality and performance. Overall, this patent provides a technical solution to reduce carbon input costs while maintaining high-quality PHA production.

Problems solved by technology

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.

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.

Unfortunately, the fermentation or biotechnological conversion of carbon-containing gases into PHAs 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.

These technical challenges and stoichiometric limitations include, but are not limited to low mass transfer rates, low microorganism growth rates, extended polymerization times, low cell densities, high oxygen demand, low PHA cellular inclusion concentrations, low polymer production per unit of biocatalyst production, low biocatalyst yield per unit gas input, poor polymer functionality, and / or high downstream functionalization costs.

As a result, the ratio of energy-to-PHA required to carry out upstream carbon mass transfer, oxygen mass transfer, and culture mixing, as well as downstream PHA processing and / or 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.

Many such compounding agents, however, adversely affect the quality and / or performance (or other characteristic) of the final PHA product.

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