METHOD AND SYSTEM FOR PRODUCING METABOLITES USING HYDROGEN-RICH, C1-CONTAINING SUBSTRATES - Patent application

Abstract

To provide a process for producing one or more fermentation products in a multi-stage process including an inoculation reactor and at least one bioreactor.SOLUTION: An inoculation reactor is fed with a C1-containing gaseous substrate containing a reduced amount of hydrogen. The hydrogen is reduced to increase the proportion of CO in the C1-containing gaseous substrate being provided to the inoculation reactor. The inoculation reactor ferments the CO-rich C1-containing gaseous substrate and produces an inoculum, which is fed to at least one bioreactor. The bioreactor receives the C1-containing gaseous substrate, which may or may not contain reduced amounts of hydrogen, to produce one or more fermentation products. By providing a CO-rich C1-containing gaseous substrate to the inoculation reactor, both the inoculation reactor and the subsequent bioreactor(s), are able to have increased stability and product selectivity.SELECTED DRAWING: None

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. Provisional Patent Application No. 62 / 556,099, filed September 8, 2017. No. 6,313,635, filed on Oct. 23, 2006, the contents of which are incorporated herein by reference.

[0002] FIELD OF THEINVENTION The present invention relates to a multi-stage gas fermentation process comprising an inoculum reactor and at least one bioreactor. The present invention relates to a method for producing one or more fermentation products via a process comprising: The present study describes a method in which an O-rich C1-containing gaseous substrate is fed into a seed reactor to generate inoculum. do. [Background technology]

[0003] Carbon dioxide (CO2) accounts for approximately 76% of the world's greenhouse gas emissions caused by human activities. methane (16%), nitrous oxide (6%), and fluorinated gases (2%) make up the remainder. (United States Environmental Protection Agency) Greenhouse gas emissions, especially CO2 reduction in greenhouse gas emissions will help to halt the progression of global warming and associated changes in climate and weather. It is important.

[0004] Industrial waste gases or synthetic gases are extracted using catalytic processes such as the Fischer-Tropsch process. Carbon dioxide (CO2), carbon monoxide (CO), and / or hydrogen (H2), such as It has long been recognized that gases containing volatile organic compounds can be converted into a variety of fuels and chemicals. Recently, gas fermentation has emerged as an alternative platform for the biological fixation of such gases. In particular, C1-fixing microorganisms have emerged as a key component of the biofuel metabolism, using CO2, CO, and / or H2. It can convert the gases it contains into products such as ethanol and 2,3-butanediol. As shown.

[0005] Such gases include, for example, gases from carbohydrate fermentation, gases from cement production, Paper manufacturing, steel manufacturing, petroleum refining and related processes, petrochemical manufacturing, coke making, anaerobic or Aerobic digestion, syngas (biomass, liquid waste streams, solid waste streams, municipal streams, natural gas, coal and derived from sources including, but not limited to, fossil fuels, including petroleum, natural gas, extraction of petroleum; manufacture and / or refining of aluminum, copper and / or ferroalloys metallurgical processes for the production of natural gas, geological reservoirs, and catalytic processes (steam methane reforming, Steam naphtha reforming, Petroleum coke gasification, Catalyst regeneration-fluid catalytic cracking, Catalyst regeneration-naphtha reforming and steam sources including, but not limited to, dry methane reforming. It may be derived from industrial processes.

[0006] In certain industrial processes, the composition of the gas may not be ideal for fermentation. If the composition is not ideal, cell growth, product selectivity, and stability may not be optimal. be.

[0007] Therefore, it is important to improve cell growth, product selectivity, and stability in downstream fermentation processes. There remains a need for inventions that optimize the composition of gases from industrial processes in order to facilitate be. Summary of the Invention

[0008] The present invention provides a method for producing one or more fermentation products, comprising: is fed to an inoculation reactor containing a liquid nutrient medium containing a culture of one or more C1 fixing microorganisms. where the CO-rich C1-containing gaseous substrate is fermented to produce an inoculum; At least a portion of the is passed to a bioreactor system, the bioreactor system comprising: At least one bioreactor containing a culture of one or more C1-fixing microorganisms in a liquid nutrient medium. A reactor is defined, and a H2-rich C1-containing gaseous substrate is delivered to the bioreactor system. In the process, a H2-rich C1-containing gaseous substrate is fermented to produce at least one fermentation product. Complete.

[0009] In certain embodiments, the CO-rich C1-containing gaseous substrate fed to the inoculum reactor comprises H2 in a H2:CO molar ratio of less than 1:1.

[0010] In a particular example, the CO-rich C1-containing gaseous substrate fed to the seed reactor contains H2 at a H2:CO molar ratio of less than 0.5:1.

[0011] Preferably, the CO-rich C1-containing gaseous substrate fed to the inoculum reactor is 0.02:1 H2 in a H2:CO molar ratio of 1:1. In certain embodiments, the H2:CO molar ratio is , 0.05:1~1:1, or 0.15:1~1:1, or 0.25:1~1:1, or 0.35:1~1:1, or 0.45:1~1:1, or 0.55:1~1: 1, or 0.65:1~1:1, or 0.75:1~1:1, or 0.85:1~ 1:1, or 0.95:1 to 1:1.

[0012] In certain embodiments, the H2-rich C1-containing gaseous radical is fed to the bioreactor system. The material contains H2 in a H2:CO molar ratio of at least 1.1:1.

[0013] Preferably, the H2-rich C1-containing gaseous substrate fed to the bioreactor system is .H2 in a H2:CO molar ratio of 1:1 to 6:1. In certain embodiments, H2:CO The molar ratio is 1.5:1 to 6:1, or 2:1 to 6:1, or 2.5:1 to 6:1, or or 3:1~6:1, or 3.5:1~6:1, or 4:1~6:1, or 4.5 :1~6:1, or 5:1~6:1.

[0014] In at least one embodiment, either the inoculum reactor or the bioreactor system Either or both C1-fixing microorganisms are carboxydotrophs.

[0015] In embodiments in which the C1 fixing microorganism is carboxydotrophic, the carboxydotrophic bacterium , Moorella, Clostridium, Luminella Ruminococcus, Acetobacterium rium, Eubacterium, Butyrivacterium tyribacterium, Oxobacter, Methanosarcina Methanosarcina, and Desulfotomaculum omaculum).

[0016] Preferably, the carboxydotrophic bacterium is Clostridium autoethanogenum (Cl ostridium autoethanogenum).

[0017] In at least one embodiment, the bioreactor system includes one or more secondary bioreactors. The bioreactor includes one or more primary bioreactors coupled to the actor.

[0018] Preferably, the method comprises passing at least a portion of the C1-containing gaseous substrate to a seed reactor. and delivering at least a portion of the C1-containing gaseous substrate to a bioreactor. In the inoculum reactor, the C1-containing gaseous substrate is fermented to produce inoculum, and a small amount of the inoculum is At least a portion of the C1 The contained gaseous substrate is fermented to produce at least one fermentation product and delivered to an inoculum reactor. The C1-containing gaseous substrate is passed through at least one H2 removal process before being sent to the inoculation reactor. The mixture is subjected to a process.

[0019] In certain embodiments, the C1-containing gaseous substrate delivered to the inoculum reactor comprises H2 in a H2:CO molar ratio of less than 1:1.

[0020] In a particular example, the C1-containing gaseous substrate delivered to the inoculum reactor comprises H2 at a H2:CO molar ratio of less than 0.8:1.

[0021] In a particular example, the C1-containing gaseous substrate delivered to the inoculum reactor comprises H2 at a H2:CO molar ratio of less than 0.5:1.

[0022] Preferably, the C1-containing gaseous substrate fed to the inoculation reactor is in a ratio of 0.02:1 to 1:1. In a particular embodiment, the H2:CO molar ratio is 0.05 :1~1:1, or 0.15:1~1:1, or 0.25:1~1:1, or 0. 35:1~1:1, or 0.45:1~1:1, or 0.55:1~1:1, or 0.65:1~1:1, or 0.75:1~1:1, or 0.85:1~1:1, or or 0.95:1 to 1:1.

[0023] In certain embodiments, the H2 removal process comprises at least one pressure swing adsorption process. Includes s.

[0024] In certain embodiments, the H2 removal process comprises at least one membrane separation module. .

[0025] Preferably, at least a portion of the C1-containing gaseous substrate is derived from an industrial source. .

[0026] In certain examples, at least a portion of the C1-containing gaseous substrate is subjected to carbohydrate fermentation, gas fermentation, Cement manufacturing, Pulp and paper manufacturing, Steel manufacturing, Petroleum refining and related processes, Petrochemical manufacturing, Coke Gas production, anaerobic or aerobic digestion, synthetic gas, natural gas extraction, petroleum extraction, aluminum metallurgical processes for the manufacture and / or refining of iron, copper, and / or ferroalloys; At least one industrial supply selected from the group consisting of industrial reservoirs, industrial impoundments, and catalytic processes. It may be derived from a source.

[0027] Preferably, the method is carried out using ethanol, acetate, butanol, butyrate, 2,3- Butanediol, 1,3-butanediol, lactate, butene, butadiene, methyl ether Chirketone, ethylene, acetone, isopropanol, lipids, 3-hydroxypropionate esters, isoprene, fatty acids, 2-butanol, 1,2-propanediol, 1-propano The group consisting of alcohol, monoethylene glycol, isobutene, and C6 to C14 alcohols The fermentation product is selected from the group consisting of:

[0028] In at least one embodiment, the one or more fermentation products are selected from the group consisting of diesel fuel, jet fuel, and the like. Fuel, gasoline, propylene, nylon 6-6, rubber, and / or plastics is further converted to at least one component.

[0029] In certain embodiments, the at least one fermentation product is a microbial biomass. In one embodiment, the microbial biomass is further processed to produce at least one component of an animal feed. It can be generated. [Brief description of the drawings]

[0030] [Figure 1] 1 is a schematic flow chart showing the integration of the hydrogen removal process, the inoculum reactor, and the bioreactor system. [Diagram 2] 1 is a schematic flow chart illustrating the integration of a hydrogen removal process, an inoculum reactor, and a bioreactor system according to one embodiment of the present invention, where the hydrogen removal process is upstream of both the inoculum reactor and the bioreactor system. [Diagram 3] 1 is a schematic flow chart further illustrating two water gas shift processes and a pressure swing adsorption process upstream of a bioreactor system, where one water gas shift process is bypassed, according to an embodiment of the present invention. [Figure 4] 1 is a schematic flow chart further illustrating two water gas shift processes upstream of the bioreactor system and a pressure swing adsorption process according to an embodiment of the present invention. [Diagram 5] 1 is a schematic flow chart further illustrating an additional hydrogen removal process upstream of the inoculation reactor in accordance with an embodiment of the present invention. [Figure 6] 6a and 6b are graphs showing metabolite production and gas uptake in the first bioreactor according to Example 1. [Figure 7] 7a and 7b are graphs showing metabolite production and gas uptake in the second bioreactor according to Example 1. [Figure 8]8a and 8b are graphs showing metabolite production and gas uptake in the first bioreactor according to Example 2. [Figure 9] 9a and 9b are graphs showing metabolite production and gas uptake in the second bioreactor according to Example 2. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] The inventors have demonstrated that by optimizing the composition of the gas stream fed to the inoculation reactor, Cell growth, product selectivity, and Specifically, the inventors determined that the inoculum reactor was subjected to Optimal cell growth, product selectivity, and cell cycle regeneration are observed when the feed gas stream contains reduced amounts of hydrogen. and stability.

[0032] definition Unless otherwise stated, the following terms used throughout this specification are defined as follows: can be.

[0033] "C1" refers to a one-carbon molecule, e.g., CO, CO2, CH4, or CH3OH. "C1 oxygenates" are one-carbon molecules that also contain at least one oxygen atom, e.g., CO, CO 2, or CH3OH. A "C1 carbon source" refers to a partial or complete source of carbon for the microorganism of the present invention. A one-carbon molecule that serves as the sole carbon source. For example, C1 carbon sources are CO, CO2, It may contain one or more of CH4, CH3OH, or CH2O2. The carbon source includes one or both of CO and CO. "C1 fixing microorganisms" are those that A microorganism that has the ability to produce one or more products from one carbon source. The microorganisms in question are C1-fixing microorganisms.

[0034] "C1-containing gaseous substrate" includes any gas from an industrial process that contains C1. In various examples, the C1-containing gaseous substrate may be CO, H2, CO2, or a combination thereof. The gaseous substrate typically contains a significant proportion of CO, preferably at least about 5 volumes. % to about 100% by volume of CO. The gaseous substrate may contain a significant proportion of hydrogen. For example, in certain embodiments, the substrate is about 2:1, or 1:1, or 1:2 H In one embodiment, the substrate may contain up to about 30% by volume H2, 20% by volume CO. % H2 by volume or less, about 15% H2 by volume or less, or about 10% H2 by volume or less. Also, for example, about 1% by volume to about 80% by volume of CO2, or 1% by volume to about 30% by volume of CO 2を In one embodiment, the substrate may contain some CO2, such as about 20 volumes. In certain embodiments, the substrate contains about 15% or less by volume of CO2, Contains about 10% or less by volume of CO2, about 5% or less by volume of CO2, or is essentially free of CO2 In addition, C1-containing gaseous substrates do not include oxygen (O2), nitrogen (N2), and / or may contain one or more of methane (CH4).

[0035] The substrate is typically gaseous, although the substrate may also be provided in alternative forms. For example, the substrate may be a liquid saturated with CO2-containing gas using a microbubble dispersion generator. As a further example, the substrate may be adsorbed onto a solid support.

[0036] The term "co-substrate" does not necessarily refer to the primary energy and material supply for product synthesis. is not a source of ATP but can be utilized for product synthesis when added to another substrate, such as the primary substrate Refers to a substance.

[0037] Substrates and / or C1 carbon sources may be derived from vehicle exhaust or biomass gasification. , obtained as a by-product of an industrial process, or waste gas from some other source. In certain embodiments, the industrial process may include producing gas from carbohydrate fermentation. Emissions, gas fermentation, gas emissions from cement manufacturing, pulp and paper, steel, petroleum refining and related Processes, petrochemical manufacturing, coke making, anaerobic or aerobic digestion, syngas (biomass This includes but is not limited to: natural gas, liquid waste streams, solid waste streams, municipal streams, and fossil fuel sources including coal and petroleum. (derived from sources such as, but not limited to, natural gas extraction, petroleum extraction, aluminum metallurgical processes for the manufacture and / or refining of copper and / or ferroalloys; geological Reservoirs, and catalytic processes (steam methane reforming, steam naphtha reforming, petroleum coke gas catalytic cracking, catalytic regeneration-fluid catalytic cracking, catalytic regeneration-naphtha reforming, and dry methane reforming. These examples are selected from the group consisting of: In an embodiment, the substrate and / or C1 carbon source can be selected from a wide variety of sources, including those that are soluble in water, using any convenient method. It may also be captured from industrial processes before being emitted into the air.

[0038] "Gas flow" refers to, for example, from one module to another, from one module to a buffer, to the ioreactor, from one module to the inoculation reactor, from one process to another and / or any flow of substrate that may be sent from a module to a carbon capture means. vinegar.

[0039] As used herein, the term "carbon capture" refers to the release of CO and / or CO and sequestration of carbon compounds, including CO2 and / or CO, from streams containing Converting CO2 and / or CO into products; or Converting CO2 and / or CO into a substance suitable for long-term storage; or Trapping the CO2 and / or CO in a material suitable for long-term storage, or It refers to any combination of these processes.

[0040] As used herein, a "reactant" is an entity that participates in a change during a chemical reaction and In certain embodiments, the reactants include CO and / or H 2, but are not limited to these.

[0041] "Hydrogen removal process" refers to a process for removing and / or separating hydrogen from a C1-containing gaseous substrate. In certain embodiments, pressure swing adsorption processes and / or Alternatively, a membrane separation process is used as the hydrogen removal process.

[0042] The terms "bioreactor" and "bioreactor system" refer to continuous stirred tank reactors (C Continuous Stirred Tank Reactor (CSTR), fixed Immobilized Cell Reactor (ICR), Trickle Bed Reactor (TBR), Bubble Column (Bubble Column), Gas Lift Fermenter ter), static mixer, circulation loop reactor, Hollow Fiber Membrane Bioreactor The reactor may be a membrane reactor, such as a high-pressure membrane reactor (HFM BR), or other vessel or device suitable for gas-liquid contact. A fermentation apparatus consisting of one or more tanks and / or columns, or a piping arrangement, including other equipment. The bioreactor preferably comprises CO or CO2 or H2 or any of these. The bioreactor is adapted to receive a gaseous substrate comprising a mixture of The reactor may comprise multiple reactors (stages), either in series or in series. The bioreactor is configured to receive the inoculum from the start-up reactor. The reactor is configured as a production reactor in which the majority of the fermentation product is produced.

[0043] The terms "inoculation reactor", "inoculation device", "seed reactor" and the like are used to describe the process by which cell growth is established. and a fermentation apparatus for promoting the inoculum. The inoculum reactor is preferably CO or CO and adapted to receive a gaseous substrate comprising H2 or H2 or a mixture thereof. Preferably, the inoculum reactor is the reactor in which cell growth is first initiated. In an embodiment, the inoculum reactor is where already grown cells are revived. In this embodiment, the inoculation device initiates cell growth of one or more microorganisms to generate an inoculum and then wherein the inoculum is configured to promote the production of one or more fermentation products in each bioreactor. In certain instances, the inoculation device may be transferred to a subsequent bioreactor system. It has a small volume when compared to two or more bioreactors.

[0044] "Nutrient media" or "Nutrient medium" "Microbial growth medium" is used to describe a bacterial growth medium. In general, the term "Nutrients" refers to a medium containing nutrients and other components suitable for the growth of cultured microorganisms. The term includes any substance that can be utilized in the metabolic pathway of a microorganism. Contains potassium, B vitamins, trace metals, and amino acids.

[0045] The term "fermentation broth" or "broth" refers to a nutrient medium and culture or one or more The term microorganism is intended to encompass mixtures of components that contain microorganisms of the same type. It should be noted that the terms are used interchangeably throughout this specification.

[0046] The term "inoculum" includes the fermentation broth that is initially grown in the inoculum reactor. and then transferring one or more of the cultures to inoculate one or more subsequent bioreactors. Preferably, the inoculum is fed to one or more subsequent bioreactors. The fermentation products are utilized by the yeast to produce one or more fermentation products.

[0047] The term "desired composition" refers to the desired concentrations and concentrations of components in a substance, such as a gas stream. More specifically, a gas is a gas that is made up of a specific component (e.g., C O, H 2、 and / or CO2) and / or specific proportions of specific ingredients and / or do not contain certain ingredients (e.g., components harmful to microorganisms). and / or does not contain certain ingredients in certain proportions, has a "desired composition" In determining whether a gas stream has a desired composition, it is considered that two or more components In one or more embodiments, the "desired composition" of the C1-containing gaseous substrate may be It is defined in terms of the H2:CO molar ratio. In various embodiments, The desired composition of the C1-containing gaseous substrate is determined by the C1-containing gaseous substrate fed to the bioreactor system. The desired composition of the substrate is different.

[0048] The terms "enhance efficiency" and "enhance efficiency" are used in reference to fermentation processes. In the case of fermentation, the growth rate of the microorganisms catalyzing the fermentation, the growth and / or is the product production rate, the volume of desired product produced per volume of substrate consumed, The rate or level of production of the product, as well as the amount of the product produced compared to other by-products of fermentation These include, but are not limited to, increasing the relative proportion of one or more of the desired products. I can't.

[0049] As used herein, unless the context requires otherwise, "fermentation," "fermentation process," " " or "fermentation reaction" refers to both the growth phase of a gaseous substrate and the product biosynthesis phase. It is intended to be inclusive.

[0050] A "microorganism" is a microscopic organism, in particular a bacterium, an archaea, a virus, or a fungus. The microorganism is typically a bacterium. As used herein, reference to a "microorganism" includes It should be construed as encompassing "bacteria."

[0051] A "parental microorganism" is a microorganism used to generate a microorganism of the invention. can be derived from naturally occurring microorganisms (e.g., wild-type microorganisms) or from previously modified microorganisms (e.g., The microorganism of the present invention may be a parent microorganism (e.g., a mutant or recombinant microorganism). To express or overexpress one or more enzymes that were not previously expressed or overexpressed Similarly, the microorganisms of the invention may be modified to contain one or more genes that the parent microorganism did not contain. The microorganisms of the invention may also be modified to contain one or more of the 1 expressed in the parent microorganism. The recombinant vector may be modified to express no or lesser amounts of one or more enzymes. In an embodiment, the parent microorganism is Clostridium autoethanogenum. ium autoethanogenum, Clostridium jungdahlii (Clo stridium ljungdahlii, or Clostridium ragsdalei ( In a preferred embodiment, the parent microorganism is Clostridium ragsdalei. The item was registered on June 7, 2010 at Inhoffenstraβ 7B, D-38124 B. German Sammlun located in Raunschweig, Germany g von Mikroorganismen und Zellkulturen G Deposited on June 7, 2010 at the 2010 National Diet Library (DSMZ) under the terms of the Budapest Treaty and accepted Clostridium autoethanogenum (Clos tridium autoethanogenum LZ1561. , International Patent Application No. PCT / NZ201, published as WO2012 / 015317 This is described in issue 1 / 000144.

[0052] The term "derived from" refers to a nucleic acid, protein, or organism that is different (e.g., derived from a parent). or wild-type) nucleic acids, proteins, or microorganisms modified or adapted to create new nucleic acids Such modifications or adaptations are representative of Typically, this includes an insertion, deletion, mutation, or substitution of a nucleic acid or gene. The organism is derived from a parental microorganism. In one embodiment, the parental microorganism of the present invention is Clostridium Clostridium autoethanogenum, Clostridium ljungdahlii, or Clostridium ragsdalei In a preferred embodiment, the microorganism of the invention is derived from DSMZ accession number DSM2. Clostridium autoethanogenum, deposited under the 3693 um autoethanogenum) LZ1561.

[0053] "Wood-Ljungdahl" is Ragsdale, Biochim Biophys Acta, 1784:1873-1898, 2008 This refers to the Wood-Ljungdahl pathway of carbon fixation. "Dahl microbes" refers to microbes that contain the Wood-Ljungdahl pathway, as expected. Generally, the microorganisms of the present invention contain a naturally occurring Wood-Ljungdahl pathway. In the text, the Wood-Ljungdahl pathway is dahl pathway, or CO, CO2, and / or H2 can be acetylated Some degree of genetic modification (e.g., excess The Wood-Ljungdahl pathway is a pathway that has a specific function (e.g., expression, heterologous expression, gene deletion, etc.) Good too.

[0054] "Anaerobic bacteria" are microorganisms that do not require oxygen to grow. If the element is present above a certain threshold, it may respond negatively or die. However, some anaerobic bacteria can survive at low concentrations of oxygen (e.g., 0.000001 to 5 vol % oxygen). Typically, the microorganism of the present invention is an anaerobic bacterium.

[0055] "Acetogens" are used to conserve energy and to convert acetyl-CoA such as acetate into and acetyl-CoA-derived products, as their primary mechanism. It is an obligate anaerobic bacterium that uses the -Ljungdahl pathway (Ragsdale, Biology, Biophys Acta, 1784:1873-1898, 2008). Specifically, acetogens can be synthesized by the Wood-Ljungdahl pathway, which consists of: (1) the conversion of CO2 to Mechanism for reductive synthesis of acetyl-CoA, (2) terminal electron-accepting, energy-saving process (3) as a mechanism for fixation (assimilation) of CO2 in the synthesis of cellular carbon (D rake,Acetogenic Prokaryotes,In:The Proka Ryotes,3 rd edition, p.354, New York, NY, 200 6) All naturally occurring acetogens are C1-fixing, anaerobic, autotrophic, and non-metabolite. Typically, the microorganisms of the present invention are acetogenic.

[0056] An "ethanologen" is a microorganism that produces or is capable of producing ethanol. Typically, the microorganisms of the present invention are ethanologens.

[0057] An "autotroph" is a microorganism that can grow in the absence of organic carbon. In contrast, autotrophs use inorganic carbon sources such as CO and / or CO2. Typically The microorganisms of the present invention are autotrophs.

[0058] "Carboxydotrophs" use CO as their sole source of carbon and energy Typically, the microorganism of the present invention is a carboxydotroph. It is.

[0059] The microorganisms of the present invention can be cultured with a gas stream to produce one or more products. For example, the microorganism of the present invention can produce ethanol (WO2007 / 117157), acetate (W O2007 / 117157), butanol (WO2008 / 115080 and WO20 12 / 053905), butyrate (WO2008 / 115080), 2,3-butanediol ol (WO2009 / 151342 and WO2016 / 094334), lactate (WO2011 / 112103), butene (WO2012 / 024522), butadiene (WO2012 / 024522), methyl ethyl ketone (2-butanone) (WO2012 / 024522 and WO2013 / 185123, ethylene (WO2012 / 026 833), acetone (WO2012 / 115527), isopropanol (WO2012 / 115527), lipids (WO2013 / 036147), 3-hydroxypropionate terpenes containing isoprene (WO20 13 / 180584), fatty acids (WO2013 / 191567), 2-butanol (WO 2013 / 185123), 1,2-propanediol (WO2014 / 036152) , 1-propanol (WO2014 / 0369152), chorismate-derived products (WO 2016 / 191625), 3-hydroxybutyrate (WO2017 / 066498) , and 1,3-butanediol (WO2017 / 0066498). In addition to one or more target products, the present invention The microorganisms also produce ethanol, acetate, and / or 2,3-butanediol. In certain embodiments, the microbial biomass itself may be considered a product. These products can be further converted to produce diesel, jet fuel, and / or gasoline. In addition, the microbial biomass may be further processed to produce at least one of the components. By using this method, single cell proteins (SCPs) can be produced.

[0060] "Single-cell proteins" (SCPs) are protein-rich human and / or animal feed It refers to microbial biomass that can be used as a feed, often in place of traditional feed such as soybean or fishmeal. To produce single cell proteins or other products, The method may include additional separation, processing, or treatment steps. For example, the method may include Sterilizing the biomass, centrifuging the microbial biomass, and / or In certain embodiments, the microbial biomass may include drying the microbial biomass. It is dried using spray drying or paddle drying. When a diet high in nucleic acid is consumed, The method is based on the prior art and may result in accumulation of nucleic acid degradation products and / or gastrointestinal disorders. It may also include reducing the nucleic acid content of the microbial biomass using any method known in the art. The single-cell protein may be suitable for feeding to animals, such as livestock and pets. Animal feed is food for one or more beef or dairy cattle, swine, sheep, goats, horses, mules, donkeys, deer, burros, falcons / bison, llamas, alpacas, reindeers, camels, bantengs, gayal, yaks, Chickens, turkeys, ducks, geese, quail, guinea fowl, pigeons, fish, shrimp, shellfish The composition of the animal feed may be suitable for feeding different animals, cats, dogs, and rodents. The method can be tailored to the nutritional requirements of the animal being cultured. It may include mixing or combining with the above excipients.

[0061] "Excipient" means any substance used to enhance or modify the form, characteristics, or nutritional content of animal feed. In particular, excipients may refer to any substance that can be added to microbial biomass. For example, excipients may be carbohydrates, Fats, fiber, fats, proteins, vitamins, minerals, water, flavors, sweeteners, antioxidants, yeast The composition may include one or more of the following: antioxidants, preservatives, probiotics, or antibiotics. In some embodiments, the excipient is hay, straw, silage, grain, oil or fat, or Excipients may be any of the plant materials described in Chiba, Section 18: Die t Formulation and Common Feed Ingredient s, Animal Nutrition Handbook, 3rd edition, sections 575-633. The feed component may be any feed component identified in US Pat. No. 6,2014.

[0062] A "natural product" is a product produced by a non-genetically modified microorganism. For example, ethanol, acetate, and 2,3-butanediol are known to inhibit Clostridium perfringens. Clostridium autoethanogenum , Clostridium ljungdahlii ), and Clostridium ragsdalei i) natural products. "Non-natural products" are those produced by genetically modified microorganisms. The genetically modified microorganism is derived from a non-genetically modified microorganism. It is a product not produced by

[0063] "Selectivity" refers to the ratio of production of a target product to the production of all fermentation products produced by a microorganism. The microorganisms of the present invention produce products with a particular selectivity or with a minimum selectivity. In one embodiment, the target product can be engineered to be produced by the microorganism of the invention. At least about 5%, 10%, 15%, 20%, or 30% by weight of all fermentation products produced %, 30%, 50%, 75% or 90% by weight. The target product is a product in which the microorganism of the present invention has a selectivity of at least 10% by weight for the target product. At least 10% of all fermentation products produced by the microorganisms of the present invention have In another embodiment, the target product is a product of the present invention. The microorganisms of the present invention are produced with a selectivity of at least 30% by weight. In one embodiment, the target product comprises at least 30% by weight of all fermentation products. The microorganisms of the invention are cultured to have a selectivity for the target product of at least 90% by weight. It accounts for at least 90% by weight of all fermentation products produced by the organism.

[0064] The target product can be, for example, fractionated, evaporated, pervaporated, gas stripped, phase separated, and, for example, Any method or combination of methods known in the art, including extractive fermentation, including liquid-liquid extraction. In certain embodiments, the present invention can be separated or purified from the fermentation broth using a combination of The preparation was carried out by continuously removing a portion of the broth from the bioreactor and separating the microbial cells from the broth. by separating the product from the broth (conveniently by filtration) and recovering one or more target products from the broth. Thus, the alcohol and / or acetone are recovered from the fermentation broth. The acid may be recovered by distillation. The acid may be recovered, for example, by adsorption on activated carbon. The extracted microbial cells are preferably returned to the bioreactor. The cell-free permeate remaining after the addition of additional nutrients is also preferably returned to the bioreactor. Vitamins (such as vitamin B) are added to the cell-free permeate to replenish the medium and then the bioreactor is The data may be returned to the kuta.

[0065] The culture / fermentation should desirably be carried out under conditions suitable for the production of the target product. Typically, the culture / fermentation is carried out under anaerobic conditions. The reaction conditions considered are pressure ( or partial pressure), temperature, gas flow rate, liquid flow rate, medium pH, medium redox potential, stirring speed (continuous If a continuous stirred tank reactor is used, ensure that the inoculum level and gas in the liquid phase are not limiting. maximum gas substrate concentration to achieve optimal reaction and maximum product concentration to avoid product inhibition. Specifically, the rate of substrate introduction is determined by the rate at which the product is consumed by the culture under gas-limited conditions. To obtain the desired gas concentration, the concentration of the gas in the liquid phase may be controlled to ensure that it is not limiting. .

[0066] Operating the bioreactor at elevated pressure allows for gas mass transfer from the gas phase to the liquid phase. Therefore, in general, culture / fermentation is carried out at pressures higher than atmospheric pressure. It is also preferred to carry out the process such that a given gas conversion rate is in part a function of substrate retention time. and the retention time indicates the required volume of the bioreactor, the use of a pressurized system Significantly reduce the required bioreactor volume and, therefore, the capital costs of the culture / fermenter This further reduces the liquid volume in the bioreactor by The retention time, defined as the pressure the bioreactor is raised above atmospheric pressure, is This means that the optimum reaction conditions can be reduced when the reaction is maintained at a constant temperature. Partly dependent on the organism, but generally fermentation is carried out at pressures greater than atmospheric pressure. It is also preferred that a given gas conversion rate is in part a function of substrate retention time, and Achieving the desired retention time also dictates the required volume of the bioreactor, so the pressurized system The use of the system reduces the required bioreactor volume and, therefore, the capital costs of the fermenter. This can significantly reduce costs.

[0067] explanation Control the composition of the C1-containing gaseous substrate fed to the inoculum and / or bioreactor The objective is to perform cell growth, product selection, and purification in both the inoculum reactor and the subsequent bioreactor. It has been found to be particularly useful in promoting the activity and stability of the C1-containing The substrate is compositionally controlled before being fed to the inoculum reactor and then fed to one or more downstream reactors. Preferably, the inoculum reactor comprises one or more inoculum in a liquid nutrient medium. The microorganisms are cultured with the above C1-fixing microorganisms, and are fed a gaseous substrate containing C1 of controlled composition to grow the microorganisms through fermentation. to generate the inoculum.

[0068] The inventors have demonstrated that when a hydrogen-rich C1-containing gaseous substrate is used in the fermentation, the fermentation process have found that in many cases long-term product selectivity and stability are lacking. In addition, the inventors conducted a fermentation process under hydrogen-rich conditions to produce a substitute carbon monoxide (CO)-rich When a C1-containing stream containing Not only does this increase the yield, but it also increases the selectivity for ethanol and the yield in downstream bioreactors. It has also been found that this leads to improved stability at

[0069] The present invention utilizes industrial gas streams containing H2 in a H2:CO molar ratio of at least 3:1. The invention is particularly applicable to fermentation processes in which the fermentation ratio is 2:1 or 1.5:1 or Industrial streams containing lower H2 compositions, such as gas streams having a H2:CO molar ratio of 1.1:1 In one embodiment, the present invention provides a method for producing one or more fermentation products. The method includes: (a) disposing at least a portion of a C1-containing gaseous substrate in a seed reactor; (b) passing at least a portion of the C1-containing gaseous substrate to a bioreactor; and (c) fermenting the gaseous substrate containing 1 in an inoculum reactor to produce an inoculum; (d) passing at least a portion of the inoculum to at least one bioreactor; The C1-containing gaseous substrate is fermented in a bioreactor to produce at least one fermentation product. and generating a C1-containing gaseous substrate fed to the seed reactor. Before being sent to the reactor, it is subjected to at least one H2 removal process.

[0070] In certain embodiments, the bioreactor comprises one or more reactors connected to one or more secondary reactors. In certain embodiments, the primary reactor(s) include a bioreactor. The first reactor is operated under conditions that promote metabolite production, and the second reactor(s) is operated under conditions that promote metabolite production. In various embodiments, H2-rich Cl is provided to the primary and secondary reactors. The contained gaseous substrates are from the same industrial source and have substantially the same composition.

[0071] In one embodiment, a C1-containing gaseous substrate rich in CO and a C1-containing gas rich in H2 The substrate is derived from the same industrial source. In various embodiments, the H2-rich C1 At least a portion of the contained gaseous substrate is subjected to a hydrogen removal process prior to being provided to the seed reactor. The hydrogen removal process comprises extracting at least one of hydrogen from the H2-rich C1-containing gaseous substrate. and separating the C1-containing gaseous substrate from the CO-containing gaseous substrate. In an embodiment, the treatment zone comprises a H2 membrane separation module and / or a pressure swing adsorption ( Preferably, the hydrogen removal process includes a membrane separation module.

[0072] In one or more embodiments, the H2-rich C1-containing gaseous substrate is derived from an industrial process. Be induced.

[0073] In an alternative embodiment, the CO-rich C1-containing gaseous substrate is a CO gas bottle. In one embodiment, the CO gas filled in the cylinder is mixed with nitrogen and / or dioxide. In a further embodiment, the CO-rich Cl The CO-containing gaseous substrate is derived from a different source than the H-rich C1-containing gaseous substrate. In one embodiment, the CO-rich C1-containing gaseous substrate is a CO2 electrochemically Derived from a decomposition process.

[0074] Hydrogen Separation In some cases, the amount of gas required may necessitate the use of cylinder gas due to cost. Thus, a gaseous substrate containing H2-rich C1 may be treated to remove H2 from the substrate. It is preferred to remove at least a portion of the hydrogen to produce a CO-rich C1-containing gaseous substrate. The preferred method for treating H2-rich C1-containing gaseous substrates is membrane separation technology. , and pressure swing adsorption techniques.

[0075] The membrane separation module is configured to use a low-cost process to remove at least a portion of the hydrogen from the gaseous substrate. For example, 72% H2 by volume, 14% CO, 7 The reformer synthesis gas with a composition of 7% CO2 by volume and 7% CH4 by volume was When the CO2-rich stream and the low The high pressure CO2 rich stream remains at 25 bar and is heated to 50 bar. % CO, 16% H2, 25% CH4, and 9% CO2 by volume. The low pressure H2-rich stream is reduced to 1 bar and contains 92% H2 by volume, 6% CO by volume. 2, and 1% by volume each of CO and CH4. The high-pressure CO-rich stream is , can be provided to the inoculation device as a CO-rich C1-containing gaseous substrate. provides the added advantage of not requiring further compression and therefore the inoculation reactor This eliminates the capital costs associated with additional compressor units for

[0076] The pressure swing adsorption process removes at least a portion of the hydrogen from a gaseous substrate. A more complex but effective means of achieving this is the pressure swing adsorption process. In this case, the resulting CO-rich stream is at low pressure. However, the CO-rich C1-containing gaseous substrate can be used in the inoculum reactor or any bioreactor. The inoculum may need to be compressed before being provided to the inoculum reactor, thereby increasing the capital costs associated with the inoculum reactor. However, this is the same as the ethanol produced by the pressure swing adsorption process. Given the fact that the hydrogen streams being produced are at high pressure and may be sold as products, at least some can be offset in part.

[0077] CO2 electrolysis An alternative method of providing a CO-rich C1-containing gaseous substrate is through the use of CO2 electrolysis. The CO2 electrolysis process converts the CO2 feedstock into CO and O2. The use of a CO2 electrolysis process to provide a CO-rich stream to the inoculum device reduces the amount of O2 This may be of interest in industrial settings that contain CO2-rich streams in addition to CO2-rich streams. Additionally, the exhaust gas from the CO2-rich inoculum reactor and / or bioreactor system It is further believed that the CO2 may be used as a feedstock to a CO2 electrolysis unit.

[0078] FIG. 1 shows a schematic flow chart of one embodiment of the present invention. The mixture is delivered to the inoculation reactor 130 via piping means 110, where the C1-containing substrate is At least a portion of the inoculum is fermented through piping means 131 to produce an inoculum. a portion of the C1-containing gaseous substrate is delivered to the bioreactor system 140, 150, where is also delivered via piping means 110 to be fermented to produce at least one product 141, The C1-containing gaseous substrate delivered to the inoculation reactor 130 produces 151. Before being sent to 130, the mixture is subjected to at least one hydrogen removal process 120. The process 120 receives a C1-containing gaseous substrate via piping means 110 and supplies a C1-containing gas removing at least a portion of the hydrogen-121 from the gaseous substrate to produce a CO-rich C1-containing gaseous substrate; The resulting CO-rich C1-containing gaseous substrate is delivered to the inoculum reactor 130 via piping means 122. are supplied to.

[0079] Preferably, the C1-containing gaseous substrate fed to the inoculation reactor 130 comprises H2 with a H2:CO molar ratio of less than 1:1. In certain embodiments, the C1-containing gaseous substrate fed to the inoculation reactor 130 comprises H2 with a H2:CO molar ratio of less than 0.8:1. Preferably, the C1-containing gaseous substrate fed to the inoculation reactor 130 comprises H2 with a H2:CO molar ratio of between 0.02:1 and 1:1. In various examples, the hydrogen removal process 120 removes at least a portion of the hydrogen through the use of at least one membrane separation module. In various examples, the hydrogen removal process 120 removes at least a portion of the hydrogen through the use of at least one pressure swing adsorption process. In various embodiments, the hydrogen removal process 120 removes at least a portion of the hydrogen through the use of both a membrane separation module and a pressure swing adsorption process.

[0080] In a particular example, the inoculum reactor 130 and the bioreactor systems 140, 150 are provided with The C1-containing gaseous substrate fed is at least partially derived from an industrial source. Or industrial sources include carbohydrate fermentation, gas fermentation, cement production, pulp and paper, steelmaking, Petroleum refining and related processes, petrochemical manufacturing, coking, anaerobic or aerobic digestion, Syngas, natural gas extraction, petroleum extraction, aluminum, copper, and / or ferroalloy production Metallurgical processes for the production and / or refining of mineral oils, geological reservoirs, and catalytic processes. The compound is selected from the group consisting of:

[0081] Preferably, the fermentation product 1 produced by the bioreactor system 140, 150 41, 151 are ethanol, acetate, butanol, butyrate, 2,3-butanediol ol, 1,3-butanediol, lactate, butene, butadiene, methyl ethyl keto ethylene, acetone, isopropanol, lipids, 3-hydroxypropionate, isopropanol isoprene, fatty acids, 2-butanol, 1,2-propanediol, 1-propanol, molybdenum Selected from the group consisting of polyethylene glycol, isobutene, and C6 to C14 alcohols. In various examples, at least a portion of the products 141, 151 may be diesel fuel, Jet fuel, gasoline, propylene, nylon 6-6, rubber, and / or plastic sacs In various examples, the at least one fermentation product is further converted into at least one component of the The components 141, 151 are microbial biomass. The syrup may be further processed to produce at least one component of an animal feed.

[0082] In various embodiments, the fermentation broth from one bioreactor 140 is passed through piping means 142 and then fed to another bioreactor 150 in the bioreactor system 140, 150. obtain.

[0083] FIG. 2 shows a schematic flow chart of one embodiment of the present invention. The mixture is delivered to the inoculation reactor 230 via piping means 210, where the C1-containing substrate is At least a portion of the inoculum is fermented through the piping means 231 to produce the inoculum. a portion of the C1-containing gaseous substrate is delivered to the bioreactor system 240, 250, is also delivered via piping means 210 to be fermented to produce at least one product 241, 251. The inoculum reactor 230 and the bioreactor system 140, 150 The C1-containing gaseous substrate to be fed is subjected to at least one The hydrogen removal process 220 is carried out via piping means 210. and receiving a C1-containing gaseous substrate and extracting at least a portion of hydrogen 221 from the C1-containing gaseous substrate. to produce a CO-rich C1-containing gaseous substrate, and the CO-rich C1-containing gaseous substrate is , an inoculation reactor 230 via piping means 222, a bioreactor 233 via piping means 223 The systems 140 and 150 are supplied with

[0084] Preferably, the C1-containing gaseous substrate fed to the inoculum reactor 230 and bioreactor system 240, 250 includes H2 with a H2:CO molar ratio of less than 1:1. In certain embodiments, the C1-containing gaseous substrate fed to the inoculum reactor 230 and bioreactor system 240, 250 includes H2 with a H2:CO molar ratio of less than 0.8:1. Preferably, the C1-containing gaseous substrate fed to the inoculum reactor 230 and bioreactor system 240, 250 includes H2 with a H2:CO molar ratio of between 0.02:1 and 1:1. In various examples, the hydrogen removal process 220 removes at least a portion of the hydrogen through the use of at least one membrane separation module. In various examples, the hydrogen removal process 220 removes at least a portion of the hydrogen through the use of at least one pressure swing adsorption process. In various embodiments, the hydrogen removal process 220 removes at least a portion of the hydrogen through the use of both a membrane separation module and a pressure swing adsorption process.

[0085] In a particular example, the inoculum reactor 230 and the bioreactor systems 240, 250 are The C1-containing gaseous substrate fed is at least partially derived from an industrial source. Or industrial sources include carbohydrate fermentation, gas fermentation, cement production, pulp and paper, steelmaking, Petroleum refining and related processes, petrochemical manufacturing, coking, anaerobic or aerobic digestion, Syngas, natural gas extraction, petroleum extraction, aluminum, copper, and / or ferroalloy production Metallurgical processes for the production and / or refining of mineral oils, geological reservoirs, and catalytic processes. The compound is selected from the group consisting of:

[0086] Preferably, the fermentation product 2 produced by the bioreactor systems 240, 250 is 41, 251 is ethanol, acetate, butanol, butyrate, 2,3-butanediol ol, 1,3-butanediol, lactate, butene, butadiene, methyl ethyl keto ethylene, acetone, isopropanol, lipids, 3-hydroxypropionate, isopropanol isoprene, fatty acids, 2-butanol, 1,2-propanediol, 1-propanol, molybdenum Selected from the group consisting of polyethylene glycol, isobutene, and C6 to C14 alcohols. In various examples, at least a portion of the products 241, 251 may be diesel fuel, Jet fuel, gasoline, propylene, nylon 6-6, rubber, and / or plastic sacs In various examples, the at least one fermentation product is further converted into at least one component of the The components 241, 251 are microbial biomass. The syrup may be further processed to produce at least one component of an animal feed.

[0087] In various embodiments, the fermentation broth from one bioreactor 240 is passed through piping means 242 and then fed to another bioreactor 250 in the bioreactor system 240, 250. obtain.

[0088] Figures 3, 4, and 5 show the use of refined uranium as an industrial source of H2-rich C1-containing gaseous substrates. Various embodiments of the present invention are shown that utilize a hydrogen production process in a manufacturing process. The synthesis process, as shown in Figures 3, 4, and 5, includes the following steps: (i) CH4-containing (ii) a reforming process in which a feedstock is converted into a synthesis gas stream comprising CO and H2; ) At least one aqueous gas in which a portion of the CO reacts with water to produce H2 and CO2. (iii) a pressure shift process adapted to recover hydrogen from the gas stream. and a pressurized surface active adsorption (PSA) module.

[0089] FIG. 3 illustrates a process for the production of a refrigerant-based ... At least a portion of the H2-rich C1-containing gaseous substrate is delivered to the piping means 31. The C1-containing gas is then passed through the membrane separation module 350 via the membrane separation module 350. The gaseous substrate is separated into a high pressure CO-rich stream and a low pressure H2-rich stream. At least a portion of the O-rich stream is delivered to an inoculation reactor 370 via piping means 352. At least a portion of the low pressure H2 rich stream is pumped through piping means 351 to the pressure swing In at least one embodiment, the gaseous substrate is fed to a pressure adsorption process 360. The CO is then sent to a compression device before being sent to the swing adsorption process 360. The enriched stream is at least 40% CO, or at least 50% CO, or less. In one embodiment, the pressure of the CO-rich C1-containing stream is at least 15 bar, or at least 20 bar, or at least 25 bar.

[0090] In various embodiments, the process includes multiple water gas shift processes 320, 330 and and / or multiple hydrogen removal processes 350, 340, 360. As shown, the C1-containing gaseous substrate is first introduced into the reforming process 310 via piping means 311. from the water gas shift process 320 to convert at least a portion of the CH4 into CO and and H2. This gas stream may be optionally coupled to a synthesis gas stream via piping means 321. 300 to bypass one or more additional water gas shift processes 330 and one or more hydrogen removal processes It may be fed to a process 340 to separate at least a portion of the hydrogen 341 from the gas stream. This stream is then passed via piping means 342 to one or more further hydrogen removal processes 36 0. The stream from the one or more additional hydrogen removal processes 360 may be sent to The bioreactor 380 may then be fed via piping means 361. At least a portion of the substrate that is not mixed with the water may be optionally passed to a modification process 310 via piping means 362. In various examples, the bioreactor 380 can receive a gaseous substrate and deliver a The fermentation product 381 is produced. Optionally, the inoculum reactor 370 and the bioreactor The exhaust gas from both 380 and 370 may be routed through separate piping means 372, 382 and / or through a mixed flow 37 8 back to the reforming process 310.

[0091] In various embodiments, the inoculum reactor 370 and the bioreactor 380 are whereby the inoculum reactor 370 is configured to receive a CO-rich C1-containing gaseous substrate The inoculum is then fermented to produce an inoculum, which is then delivered to the bioreactor via piping means 371. This inoculum is then fed into the bioreactor 380. By utilizing this inoculum in the bioreactor 380, This improves product selectivity and stability of the fermentation process.

[0092] In another embodiment, as shown in FIG. 4, H2-rich C1 from the reforming process 410 is The containing stream is pressure swept through piping means 412 located upstream of the inoculum reactor 470. The C1-containing stream is then passed to a pressure swing adsorption process 450. The pressure swing adsorption process 450 converts the C1-containing stream into a high The low pressure CO2-rich stream is , may be sent to a compression device before being sent to the inoculation reactor 470 via piping means 452. In one embodiment, the CO-rich stream sent to the inoculum reactor 470 is at least 30% CO, or at least 40% CO, or at least 50% CO, or at least The separated hydrogen is delivered from the pressure swing adsorption process 450 through a pipeline. The effluent may be fed via means 451 to another pressure swing adsorption process 460. In the present invention, the process includes multiple water gas shift processes 420, 430 and / or multiple The hydrogen removal processes 450, 440, 460 may include:

[0093] As shown in FIG. 4, the C1-containing gaseous substrate is first introduced into the reforming From the process 410, a water gas shift process 420 is sent to convert at least one of the CH A portion of the synthesis gas may be converted into a synthesis gas stream containing CO and H2. This gas stream is then piped to one or more further water gas shift processes 430 via stage 421; 430 is fed via piping means 431 to a hydrogen removal process 440 for removing hydrogen 441 from the gas stream. This flow may then be passed through piping means 442 to one or more The hydrogen may be passed to one or more additional hydrogen removal processes 460. The flow from the source 460 is passed via piping means 461 to a bioreactor 480 for fermentation. At least a portion of the substrate that is not fed to the bioreactor may be optionally fed through a piping means. 462 to the reformulation process 410. 80 receives a gaseous substrate and produces one or more fermentation products 481. Optionally, an inoculum Exhaust gas from both the reactor 470 and the bioreactor 480 is routed through separate piping means 472. , 482 and / or returned to the reforming process 410 via the combined stream 478.

[0094] In various embodiments, the inoculum reactor 470 and the bioreactor 480 are whereby the inoculum reactor 470 is configured to receive a CO-rich C1-containing gaseous substrate The inoculum is then fermented to produce an inoculum, which is then delivered to the bioreactor via piping means 471. This inoculum is then fed into the bioreactor 480. By utilizing this inoculum in the bioreactor 480, This improves product selectivity and stability of the fermentation process.

[0095] In another embodiment, as shown in FIG. 5, the C1-containing stream from the reforming process 510 is Before being sent to either the inoculum reactor 570 and / or the bioreactor 580, In various examples, the C The hydrogen-containing stream may be fed to a compression device prior to and / or during the hydrogen removal process. The C1-containing stream can be reduced by passing the C1-containing stream through multiple hydrogen removal processes. The O composition may be further concentrated.

[0096] In various embodiments, the process includes multiple water gas shift processes 520, 530. , in combination with multiple hydrogen removal processes 540, 550, 560. As shown, the C1-containing gaseous substrate is first introduced into the reforming process 51 via piping means 511. 0 to a water gas shift process 520 to convert at least a portion of the CH4 to CO and H2. This gas stream can then be delivered via piping means 521 to and one or more further water gas shift processes 530, and one or more hydrogen removal processes 531 to the process 540 for extracting at least one of hydrogen 541 from the gas stream. A portion may then be separated off from the flow via piping means 542 to one or more further The hydrogen may be passed to a hydrogen removal process 560. This flow may be sent via piping means 561 to a bioreactor 580 for fermentation. At least a portion of the substrate that is not fed to the bioreactor is optionally routed through piping means 562. to a subsequent hydrogen removal process 550, and optionally, further hydrogen via piping means 551. and finally to the inoculation reactor 570 via piping means 591. to generate an inoculum.

[0097] In various examples, the bioreactor 580 receives a gaseous substrate and generates one or more fermentation organisms. Optionally, both the inoculum reactor 570 and the bioreactor 580 may be The exhaust gas from the The result may be sent back to the quality process 510.

[0098] In various embodiments, the inoculum reactor 570 and the bioreactor 580 are whereby the inoculum reactor 570 is configured to receive a CO-rich C1-containing gaseous substrate The inoculum is then fermented to produce an inoculum, which is then delivered to the bioreactor via piping means 571. This inoculum is then fed into the bioreactor 580. By utilizing this inoculum in the bioreactor 580, This improves product selectivity and stability of the fermentation process.

[0099] Figures 3, 4, and 5 are representative examples of integration with hydrogen production processes, but current applications It should be understood that the present invention is not limited to integration with a hydrogen production process. EXAMPLES

[0100] The following examples further illustrate the invention, but it will be understood that the invention may be practiced in any manner whatsoever. However, it should not be construed as limiting its scope.

[0101] Example 1 This example is based on a mixture of 68% by volume H2, 3.8% by volume CO, 26% by volume CO2, and Two trials were performed in which a gaseous substrate containing 1% by volume of N2 and a H2:CO molar ratio of 18:1 was provided. The only difference between the operating parameters of the two reactors is the Figure 6a and Figure 6b show the CO2-rich conditions. Metabolite and gas profiles of the first bioreactor receiving the inoculum produced under Figures 7a and 7b show the results of the experiments using the inoculum produced under H2-rich conditions. Metabolite and gas profiles of the first bioreactor were shown. , which consumes H2, CO, and CO2 with similar efficiency, but is inoculated from the H2-rich inoculated reactor. The reactor that received the seed material (FIG. 7a) showed reduced selectivity towards ethanol.

[0102] Example 2 This example illustrates the effect of inoculation on the respiration of a sample from an inoculation reactor operated under different gas conditions. Figures 8a and 8b demonstrate the comparative performance of the actors with the following gas composition: 48% by volume H 2, generated using 40 vol.% CO, 2 vol.% CO2, and 10 vol.% N2. The metabolite and gas profiles of the fermentation inoculated with the culture received from the inoculum were shown. Figures 9a and 9b show the culture medium received from an inoculum produced under CO2-rich conditions. Metabolite and gas profiles of fermentations inoculated with CO2-rich gas inoculation are shown. The ethanol selectivity demonstrated by the reactor, fed from the actor (Figure 9a), was H 2 enriched inoculated reactor (Fig. 8a) was much higher than that of the reactor that received inoculum from the

[0103] All references cited herein, including publications, patent applications, and patents, are hereby incorporated by reference. The cited documents are individually and specifically indicated to be incorporated by reference in their entirety. The bodies are incorporated herein by reference to the same extent as if set forth herein. Any reference to prior art in this specification is to the extent that such prior art is in any national field of endeavor. is not a recognition that the information contained herein is part of the common general knowledge in isn't it.

[0104] In the context of describing the present invention (particularly in the context of the claims that follow), the term The use of "a" and "an" and "the" and similar referents refers to other Unless otherwise indicated or clearly contradicted by the context, both the singular and the plural The terms "comprising," "having," " "including," and "containing" " refers to open-ended terms (i.e., "including but not limited to"), unless otherwise noted. The term "consisting essentially of" shall be construed as meaning "not The scope of a composition, process, or method may be limited to a particular material or step, or to a composition, process, or method. The invention is limited to those that do not materially affect the basic and novel characteristics of the process or method. The use of a verb (e.g., "or") refers to one or both of the alternatives, or any combination of these. As used herein, the term "about" should be understood to mean , unless otherwise indicated, means ±20% of the indicated range, value, or structure.

[0105] The recitation of ranges of values ​​herein includes each separate value falling within the range, unless otherwise indicated herein. are merely intended to serve as a shorthand way of referring to the values ​​individually, and each separate value Each of the above-mentioned compounds is incorporated herein by reference as if it were individually recited herein. Any concentration range, percentage range, ratio range, integer range, size range, or thickness range may be used. Unless otherwise indicated, any integer value within the range recited and, where appropriate, its fractional part. This should be understood to include numbers (such as integer tenths and hundredths).

[0106] All methods described herein are intended to be illustrative unless otherwise indicated herein or by context. Unless clearly indicated to the contrary, the steps may be performed in any suitable order. The use of any and all examples or exemplary language (e.g., "such as") will serve to better illustrate the invention. It is intended merely to provide clarity and does not limit the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention. should not be interpreted as such.

[0107] Preferred embodiments of the present invention are described herein. Variations of these preferred embodiments may become apparent to those skilled in the art upon reading the above description. The inventors anticipate that those skilled in the art will adopt such variations as necessary, and the inventors intend for the invention to be carried out otherwise than as specifically described herein. Accordingly, the present invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations of the preferred embodiments is encompassed by the present invention unless otherwise indicated herein or clearly contradicted by context. The invention described in this specification may include the following aspects. [1] 1. A method for producing one or more fermentation products, comprising: a. providing a CO2-enriched C1-containing gaseous substrate to an inoculum reactor comprising a liquid nutrient medium containing a culture of one or more C1-fixing microorganisms; b. fermenting the CO-rich C1-containing gaseous substrate to produce an inoculum; c. delivering at least a portion of the inoculum to a bioreactor system, the bioreactor system comprising at least one bioreactor containing a culture of one or more C1 fixing microorganisms in a liquid nutrient medium; d. delivering a H2-enriched C1-containing gaseous substrate to the bioreactor system; e. fermenting the H2-rich C1-containing gaseous substrate to produce at least one fermentation product. [2] The method according to [1] above, wherein the CO-rich C1-containing gaseous substrate comprises H2 in a H2:CO molar ratio of less than 1:1. [3] The method according to [1] above, wherein the CO-rich C1-containing gaseous substrate comprises H2 in a H2:CO molar ratio of less than 0.5:1. [4] The method according to the above-mentioned [1], wherein the CO-rich C1-containing gaseous substrate contains H2 in a H2:CO molar ratio of 0.02:1 to 1:1. [5] The method according to [1] above, wherein the H2-rich C1-containing gaseous substrate contains H2 in a H2:CO molar ratio of at least 1.1:1. [6] The method according to the above-mentioned [1], wherein the H2-rich C1-containing gaseous substrate contains H2 in a H2:CO molar ratio of 1.1:1 to 6:1. [7] The method according to [1] above, wherein the C1 fixing microorganism is a carboxydotrophic bacterium. [8] The method according to [7] above, wherein the carboxydotrophic bacterium is selected from the group consisting of Moorella, Clostridium, Ruminococcus, Acetobacterium, Eubacterium, Butyribacterium, Oxobacter, Methanosarcina, and Desulfotomaculum. [9] The method according to [7] above, wherein the carboxydotrophic bacterium is Clostridium autoethanogenum.

[10] The method according to [1] above, wherein the bioreactor system comprises one or more primary bioreactors connected to one or more secondary bioreactors.

[11] 1. A method for producing one or more fermentation products, comprising: a. delivering at least a portion of a C1-containing gaseous substrate to an inoculum reactor and at least a portion of said C1-containing gaseous substrate to a bioreactor; b. fermenting the C1-containing gaseous substrate in the inoculum reactor to produce an inoculum; c. directing at least a portion of the inoculum to at least one bioreactor; d. fermenting the C1-containing gaseous substrate in the bioreactor to produce at least one fermentation product; e. The method, wherein the C1-containing gaseous substrate fed to the inoculum reactor is subjected to at least one H2 removal process prior to being fed to the inoculum reactor.

[12] 12. The method of claim 11, wherein the C1-containing gaseous substrate fed to the inoculum reactor comprises H2 in a H2:CO molar ratio of less than 1:1.

[13] The method according to

[11] above, wherein the C1-containing gaseous substrate fed to the inoculum reactor comprises H2 in a H2:CO molar ratio of less than 0.8:1.

[14] 12. The method of claim 11, wherein the C1-containing gaseous substrate fed to the inoculum reactor comprises H2 in a H2:CO molar ratio of less than 0.5:1.

[15] The method according to

[11] above, wherein the C1-containing gaseous substrate fed to the inoculum reactor contains H2 in a H2:CO molar ratio of 0.02:1 to 1:1.

[16] The method according to

[11] above, wherein the H2 removal process comprises at least one pressure swing adsorption process.

[17] The method according to

[11] above, wherein the H2 removal process comprises at least one membrane separation module.

[18] The method according to

[11] above, wherein at least a portion of the C1-containing gaseous substrate is derived from an industrial source.

[19] 18. The method according to claim 17, wherein the industrial source is selected from the group consisting of carbohydrate fermentation, gas fermentation, cement production, pulp and paper making, steel making, petroleum refining and related processes, petrochemical manufacturing, coke making, anaerobic or aerobic digestion, synthesis gas, natural gas extraction, petroleum extraction, metallurgical processes for the production and / or refining of aluminum, copper, and / or ferroalloys, geological reservoirs, and catalytic processes.

[20] The method of claim 11, wherein the at least one fermentation product is selected from the group consisting of ethanol, acetate, butanol, butyrate, 2,3-butanediol, 1,3-butanediol, lactate, butene, butadiene, methyl ethyl ketone, ethylene, acetone, isopropanol, lipids, 3-hydroxypropionate, isoprene, fatty acids, 2-butanol, 1,2-propanediol, 1-propanol, monoethylene glycol, isobutene, and C6 to C14 alcohols. [twenty one] 20. The method of claim 19, wherein the one or more fermentation products are further converted to at least one component of diesel fuel, jet fuel, gasoline, propylene, nylon 6-6, rubber, and / or resin. [twenty two] The method according to

[11] above, wherein at least one fermentation product is a microbial biomass. [twenty three] The method according to

[22] above, wherein the microbial biomass is processed to produce at least one component of an animal feed.

Claims

1. below: a. CO and H ２ producing a synthesis gas comprising: b. Sending the synthesis gas to a hydrogen separation process to produce a CO-rich C1-containing gaseous substrate and H ２ generating a C1-containing gaseous substrate enriched with C1; c) passing the CO-rich C1-containing gaseous substrate to an inoculum reactor containing a culture of at least one C1-fixing microorganism in a liquid nutrient medium; d. fermenting the CO-rich C1-containing gaseous substrate to produce an inoculum; e. directing at least a portion of said inoculum to a bioreactor system, said bioreactor system comprising at least one bioreactor containing a culture of at least one C1 fixed microorganism of step c in a liquid nutrient medium; f. Said H ２ sending the C1-rich gaseous substrate to at least one bioreactor of step e; and g. The H ２ fermenting the C1-rich gaseous substrate to produce at least one fermentation product. A method comprising:

11. The method of claim 10, wherein said CO-rich C1-containing gaseous substrate comprises H 2 in a H 2 :CO molar ratio of less than 1:1, and said H 2 -rich C1-containing gaseous substrate comprises H 2 in a H 2 :CO molar ratio of at least 1.1:

1.

2. Step b. sends the synthesis gas to a first water-gas shift reactor, where at least a portion of the CO reacts with water to produce CO. ２ and H ２ and then extracting CO from the first water-gas shift reactor. ２ and H ２ 10. The method of claim 1 further comprising the step of passing a gas stream comprising:

3. CO from the first water gas shift reactor. ２ and H ２ 3. The method of claim 2, further comprising the steps of passing the gas stream comprising:

4. The method of claim 1 , wherein the hydrogen separation process comprises a membrane separation module.

5. The H from the membrane separation module ２ At least a portion of the C1-rich gaseous substrate is sent to a pressure swing adsorption (PSA) reactor to produce a hydrogen stream and CO and H ２ 5. The method of claim 4, further comprising generating a gaseous substrate which is delivered to the bioreactor.

6. The method of claim 1 , wherein the hydrogen separation process is a PSA process.

7. The CO-rich C1-containing gaseous substrate has a ratio of H to CO of less than 0.5:

1. ２ :CO molar ratio, H ２ The method of claim 1 , comprising:

8. The H ２ The C1-containing gaseous substrate is mixed with H ２ :CO molar ratio, H ２ The method of claim 1 , comprising:

9. The method of claim 1 , wherein the at least one C1-fixing microorganism is a carboxydotrophic bacterium.

10. 10. The method of claim 9, wherein the carboxydotrophic bacterium is selected from the group consisting of Moorella, Clostridium, Ruminococcus, Acetobacterium, Eubacterium, Butyribacterium, Oxobacter, Methanosarcina, and Desulfotomaculum.

11. 11. The method of claim 10, wherein the carboxydotrophic bacterium is Clostridium autoethanogenum.

12. 10. The method of claim 1, wherein the synthesis gas is produced from steam methane reforming, steam naphtha reforming, petroleum coke gasification, dry methane reforming, and mixtures thereof.

13. 2. The method of claim 1, wherein the at least one fermentation product is selected from ethanol, acetate, butanol, butyrate, 2,3-butanediol, 1,3-butanediol, lactate, butene, butadiene, methyl ethyl ketone, ethylene, acetone, isopropanol, lipids, 3-hydroxypropionate, isoprene, fatty acids, 2-butanol, 1,2-propanediol, 1-propanol, monoethylene glycol, isobutene, C6 to C14 alcohols, and mixtures thereof.

14. 14. The method of claim 13, wherein the at least one fermentation product is further converted to at least one component of diesel fuel, jet fuel, gasoline, propylene, nylon 6-6, rubber, and / or resin.

15. The method of claim 1 , wherein the at least one fermentation product is a microbial biomass.

16. 16. The method of claim 15, wherein the microbial biomass is processed to produce at least one component of an animal feed.

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