04 Fakultät Energie-, Verfahrens- und Biotechnik
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Item Open Access Factors affecting the synthesis of cellobiose lipids by Sporisorium scitamineum(2020) Oraby, Amira; Werner, Nicole; Sungur, Zehra; Zibek, SusanneCellobiose lipids (CL) are extracellular glycolipids that are produced by many microorganisms from the family Ustilaginaceae. The sugarcane smut fungus Sporisorium scitamineum has been long known as a producer of the glycolipids mannosylerythritol lipids (MEL) and was recently described to additionally secrete CL as a byproduct. In fact, we identified 11 homologous genes in S. scitamineum by in silico analysis sharing a high similarity to the CL biosynthesis gene cluster of Ustilago maydis. We here report the first systematic cultivation of S. scitamineum targeting the synthesis of CL with high product titers and its transfer to the bioreactor. In an initial screening we examined different fermentation media compositions, consisting of a mineral salts solution with vitamins and/or trace elements, three carbon sources (glucose, fructose, sucrose), three pH values (2.5, 4.0, 6.7) and three levels of C/N values (42.2, 83.8, 167.2 molC molN -1) with urea as nitrogen source. A pH of 2.5 proved to result in the highest product titers. An increase of urea concentration from 0.6 to 1.2 g L-1 had a positive effect on biomass formation, however the glycolipid formation was favored at a C/N ratio of 83.8 molC molN -1, using 0.6 g L-1 urea. Amongst the examined carbon sources, sucrose resulted in an increase in the secretion of cellobiose lipids, compared to glucose. Comparing different media compositions, vitamins were identified as not necessary for CL synthesis. We obtained a concentration of cellobiose lipids of 8.3 1.0 g L-1 in shaking flasks. This increased to 17.6 g L-1 in the 1 L bioreactor with additional feeding of carbon source, with a final purity of 85-93%. As a side product, erythritol and mannosylerythritol lipids (MEL) were also synthesized. Via HPTLC coupled MALDI-TOF MS we were able to analyze the secreted CL structures. S. scitamineum produces a mixture of acylated low molecular weight D-glucolipids, linked to a 2,15,16-trihydroxy-hexadecanoic acid via their &-hydroxyl group (CL-B). The produced cellobiose lipids precipitate as needle like crystals at an acidic pH value of 2.5.Item Open Access Optimization and kinetic modeling of a fed-batch fermentation for mannosylerythritol lipids (MEL) production with moesziomyces aphidis(2022) Beck, Alexander; Vogt, Franziska; Hägele, Lorena; Rupp, Steffen; Zibek, SusanneMannosylerythritol lipids are glycolipid biosurfactants with many interesting properties. Despite the general interest in those molecules and the need for a robust process, studies on their production in bioreactors are still scarce. In the current study, the fermentative production of MEL in a bioreactor with Moesziomyces aphidis was performed using a defined mineral salt medium. Several kinetic process parameters like substrate consumption rates and product formation rates were evaluated and subsequently enhanced by increasing the biomass concentration through an exponential fed-batch strategy. The fed-batch approaches resulted in two to three fold increased dry biomass concentrations of 10.9-15.5 g/L at the end of the growth phase, compared with 4.2 g/L in the batch process. Consequently, MEL formation rates were increased from 0.1 g/Lh up to around 0.4 g/Lh during the MEL production phase. Thus, a maximum concentration of up to 50.5 g/L MEL was obtained when oil was added in excess, but high concentrations of residual fatty acids were also present in the broth. By adjusting the oil feeding to biomass-specific hydrolysis and MEL production rates, a slightly lower MEL concentration of 34.3 g/L was obtained after 170 h, but at the same time a very pure crude lipid extract with more than 90% MEL and a much lower concentration of remaining fatty acids. With rapeseed oil as substrate, the ideal oil-to-biomass ratio for full substrate conversion was found to be around 10 goil/gbiomass. In addition, off-gas analysis and pH trends could be used to assess biomass growth and MEL production. Finally, kinetic models were developed and compared to the experimental data, allowing for a detailed prediction of the process behavior in future experiments.Item Open Access Growth behavior of selected Ustilaginaceae fungi used for mannosylerythritol lipid (MEL) biosurfactant production - evaluation of a defined culture medium(2020) Beck, Alexander; Zibek, SusanneFungi of the Ustilaginaceae family are a promising source for many biotechnologically relevant products. Among these, mannosylerythritol lipid (MEL) biosurfactants have drawn a special interested over the last decades due to their manifold application possibilities. Nevertheless, there is still a knowledge gap regarding process engineering of MEL production. As an example, no reports on the use of a chemically defined culture medium have been published yet, although such a defined medium might be beneficial for scaling-up the production process toward industrial scale. Our aim therefore was to find a mineral medium that allows fast biomass growth and does not negatively affect the successive MEL production from plant oils. The results showed comparable growth performance between the newly evaluated mineral medium and the established yeast extract medium for all seven investigated Ustilaginaceae species. Final biomass concentrations and specific growth rates of 0.16-0.25 h-1 were similar for the two media. Oxygen demand was generally higher in the mineral medium than in the yeast extract medium. It was shown that high concentrations of vitamins and trace elements were necessary to support the growth. Increasing starting concentrations of the media by a factor of 10 resulted in proportionally increasing final biomass concentrations and up to 2.3-times higher maximum growth rates for all species. However, it could also lead to oxygen limitation and stagnant growth rates when too high medium concentrations were used, which was observed for Ustilago siamensis and Moesziomyces aphidis. Successive MEL production from rapeseed oil was effectively shown for 4 out of 7 organisms when the mineral medium was used for cell growth, and it was even enhanced for two organisms, M. aphidis and Pseudozyma hubeiensis pro tem., as compared to the established yeast extract medium. Conversion of rapeseed oil into MEL was generally improved when higher biomass concentrations were achieved during the initial growth phase, indicating a positive relationship between biomass concentration and MEL production. Overall, this is the first report on the use of a chemically defined mineral medium for the cell growth of Ustilaginaceae fungi and successive MEL production from rapeseed oil, as an alternative to the commonly employed yeast extract medium.Item Open Access Mannosylerythritollipide : mikrobielle Biotenside aus dem Bioreaktor(2020) Beck, Alexander; Zibek, SusanneMannosylerythritol lipids (MEL) are microbial biosurfactants belonging to the class of glycolipids. They can be produced biotechnologically by smut fungi and have the potential to replace current chemical surfactant products, for example in household detergents or cosmetics. In this article, we highlight our latest research on the various producer organisms as well as the genetics and regulation of MEL biosynthesis, aiming for the development of an industrial production process in the future.Item Open Access Transmembrane chemical absorption process for recovering ammonia as an organic fertilizer using citric acid as the trapping solution(2024) Reyes Alva, Ricardo; Mohr, Marius; Zibek, SusanneMembrane contactors are among the available technologies that allow a reduction in the amount of ammoniacal nitrogen released into the environment through a process called transmembrane chemical absorption (TMCA). This process can be operated with different substances acting as trapping solutions; however, strong inorganic acids have been studied the most. The purpose of this study was to demonstrate, at laboratory scale, the performance of citric acid as a capturing solution in TMCA processes for recovering ammonia as an organic fertilizer from anaerobic digestor reject water using membrane contactors in a liquid-liquid configuration and to compare it with the most studied solution, sulfuric acid. The experiments were carried out at 22 °C and 40 °C and with a feed water pH of 10 and 10.5. When the system was operated at pH 10, the rates of recovered ammonia from the feed solution obtained with citric acid were 10.7-16.5 percentage points (pp) lower compared to sulfuric acid, and at pH 10.5, the difference decreased to 5-10 pp. Under all tested conditions, the water vapor transport in the system was lower when using citric acid as the trapping solution, and at pH 10 and 40 °C, it was 5.7 times lower. When estimating the operational costs for scaling up the system, citric acid appears to be a better option than sulfuric acid as a trapping solution, but in both cases, the process was not profitable under the studied conditions.Item Open Access Current state of chitin purification and chitosan production from insects(2020) Hahn, Thomas; Tafi, Elena; Paul, Aman; Salvia, Rosanna; Falabella, Patrizia; Zibek, SusanneChitin, and especially its deacetylated variant chitosan, has many applications, e.g. as carrier material for pharmaceutical drugs or as a flocculant in wastewater treatment. Despite its versatility and accessibility, chitin, the second most abundant polysaccharide on Earth, has so far been commercially extracted only from crustaceans and to a minor extent from fungi. Insects are a viable alternative source of chitin, but they have not been exploited in the past due to limited availability. Today however, for the sustainable production of animal feed, insect farming is being developed substantially. The availability of large quantities of insect biomass and chitin‐rich side products such as exuviae and exoskeletons has been increasing. This review provides an overview of recently published studies of chitin extraction from insects, its subsequent conversion into chitosan and the primary analytical methods used to characterize insect‐based chitin and chitosan. We have discovered a large number of research articles published over the past 20 years, confirming the increased attention being received by chitin and chitosan production from insects. Despite numerous publications, we identified several knowledge gaps, such as a lack of data concerning chitin purification degree and chitosan yield. Furthermore, analytical methods used to obtain physicochemical characteristics, structural information and chemical composition meet basic qualitative requirements but do not satisfy the need for a more quantitative evaluation. Despite the current shortcomings that need to be overcome, this review presents encouraging data on the use of insects as an alternative source of chitin and chitosan in the future.Item Open Access Techno-economic analysis as a driver for optimisation of cellobiose lipid fermentation and purification(2022) Oraby, Amira; Rupp, Steffen; Zibek, SusanneCellobiose lipids (CL) are glycolipids synthesized by Ustilaginaceae species with potential application as detergents or in cosmetics. This study identified process optimisation potential for CL fermentation based on process modelling and techno-economic analysis. Using a stoichiometric equation based on laboratory data, we calculated the maximum possible CL yield YP/S of 0.45 gCL·gglucose -1 at the biomass yield of 0.10 gBiomass·gglucose -1 with an Ustilago maydis strain. Due to substrate inhibition that may occur at high glucose concentrations, a fed-batch process to increase biomass and CL concentrations was considered in our model. Simulation of different process scenarios showed that the choice of aeration units with high oxygen transfer rates and adaptation of power input to oxygen uptake can significantly decrease electricity consumption. We further assessed scenarios with different fermentation media and CL purification methods, suggesting additional process optimisation potential. Here the omission of vitamins from the fermentation medium proved to be a possible mean to enhance process economy, without compromising CL productivity.Item Open Access Foam fractionation methods in aerobic fermentation processes(2022) Oraby, Amira; Weickardt, Isabell; Zibek, SusanneInherently occurring foam formation during aerobic fermentation of surface‐active compounds can be exploited by fractionating the foam. This also serves as the first downstream processing step for product concentration and is used for in situ product recovery. Compared to other foam prevention methods, it does not interfere with fermentation parameters or alter broth composition. Nevertheless, parameters affecting the foaming behavior are complex. Therefore, the specific foam fractionation designs need to be engineered for each fermentation individually. This still hinders a widespread industrial application. However, few available commercial approaches demonstrate the applicability of foam columns on an industrial scale. This systematic literature review highlights relevant design aspects and process demands that need to be considered for an application to fermentations and proposes a classification of foam fractionation designs and methods. It further analyses substance‐specific characteristics associated with foam fractionation. Finally, solutions for current challenges are presented, and future perspectives are discussed.Item Open Access Past, present and future of glycolipids from Ustilaginaceae : a review on cellobiose lipids and mannosylerythritol lipids(2024) Münßinger, Sini; Beck, Alexander; Oraby, Amira; Zibek, SusanneThe glycolipids cellobiose lipids (CL) and mannosylerythritol lipids (MEL) are biosurfactants mainly synthesized by microorganisms of the Ustilaginaceae family. They have a large structural diversity, varying in their sugar moieties and the attached fatty acids, resulting in a prospectively broad range of applications. This literature review provides a detailed overview of known microbial producers of CL and MEL, and their respective metabolic pathways that result in different molecular structures. Further, current advances in the aerobic fermentative synthesis of the glycolipids and their purification methods are illustrated. All influencing factors identified to date with regard to the fermentation are highlighted in detail: For CL synthesis usually hydrophilic carbon sources are used as substrate, whereas hydrophobic carbon sources are usually metabolized to MEL. Nitrogen limitation was described as a major trigger for glycolipid synthesis and an acidic pH range was favored for increased CL production. An overview of applied fermentation parameters in recent publications (e.g., substrate‐concentrations, feeding approaches) demonstrates the future potential of CL and MEL production optimization. Foaming during fermentation is either combated or exploited by foam fractionation as the first purification step. The current purification processes focus on solvent extractions and chromatography in the laboratory scale and a need for development was identified for future scale‐up. Finally, environmental hotspots during CL and MEL production are presented and future optimization potentials are highlighted.Item Open Access Life cycle assessment as a driver for process optimisation of cellobiose lipids fermentation and purification(2024) Oraby, Amira; Briem, Ann-Kathrin; Bippus, Lars; Rupp, Steffen; Zibek, SusannePurpose: Cellobiose lipids (CL) are biosurfactants produced by various Ustilaginaceae species in aerobic fermentations. They show high potential for application as alternatives to conventional oleochemical- or petrochemical surfactants. To ensure their environmentally friendly performance, we aimed to assess CL production from a life cycle perspective at an early developmental stage to identify process steps that have the highest impact on the environment. With this information, optimisation approaches can be derived.
Materials and methods: Following a cradle-to-gate approach, we modelled the CL fermentation and purification process based on experimental data from the lab scale and process simulation data at a 10 m 3 scale. For LCA, the impact categories (IC) abiotic depletion potential (ADP), eutrophication potential, photochemical ozone creation potential, global warming potential, acidification potential, and the primary energy demand were calculated for all process steps. Based on the obtained results, process bottlenecks were identified, and alternative process scenarios varying the related process parameters were simulated. These were used to assess the environmental impact reduction potential (EIRP) of an optimised process and draw recommendations for experimental process optimisation.
Results and discussion: The obtained results showed that the fermentation caused ~ 73% of ADP and more than 85% of all other ICs. The major contributor was the electricity consumption for continuous fermenter aeration. Thus, reducing the fermentation duration from the initial 14 to 5 days would result in a decrease in all investigated ICs of up to ~ 27-52%. An increase in CL concentration results in a decrease in all ICs of a similar magnitude due to the higher yield per batch at comparable energy and material consumption. Although the share of purification process steps to all ICs is overall relatively small, implementing foam fractionation for in situ product recovery showed an additional EIRP of 18-27% in all purification IC shares.
Conclusions: The conducted LCA showed that overall, more EIRP can be achieved by optimising fermentation process parameters compared to purification process steps. This is mainly due to the long fermentation duration and large energy consumption for fermenter aeration. This highlights the importance of using LCA as a driver for process optimisation to identify process steps with high EIRP. While some of the results are specific to CL, other obtained results can be transferred to other fermentations.