Engineered Microorganisms for Mid-Chain Oleochemical Synthesis

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Solution Overview

Problem

Current biological gas-to-liquid (GTL) technologies face challenges in producing mid- to long-chain lipid-based chemicals and oleochemicals efficiently, as they are limited by short carbon chain production, sensitivity to impurities, and low tolerance for syngas constituents, leading to high costs and environmental impacts.

Innovation Solution

Engineered microorganisms, such as Rhodococcus opacus and Cupriavidus necator, are developed to convert CO2 and syngas into higher value mid- to long-chain oleochemicals and monomers, utilizing genetic modifications to enhance lipid biosynthesis pathways and tolerate varying syngas ratios, thereby producing targeted products with increased efficiency and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If current biological GTL technologies are used to produce lipid-based chemicals, then carbon fixation occurs, but the production is limited to short carbon chain lengths

Engineering Contradiction:

Improvecarbon chain lengthVSAvoidproduction efficiency

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent modifies the biochemical parameters of microorganisms by introducing heterologous genes (e.g., fas gene from Arabidopsis thaliana) to alter fatty acid biosynthesis pathways. This enables the production of mid- to long-chain fatty acids (C10-C20) instead of being limited to short-chain products, directly addressing the carbon chain length limitation while maintaining biological productivity

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional biological GTL processes are employed, then carbon conversion occurs, but sensitivity to impurities and low tolerance for syngas constituents result in high costs

Engineering Contradiction:

Improvetolerance to syngas constituentsVSAvoidoperational cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent genetically engineers microorganisms to change their physiological parameters, specifically enhancing their tolerance to syngas constituents like CO2, CO, and H2. The modified strains can withstand varying gas compositions and impurities without requiring costly purification steps, thereby reducing operational costs while maintaining reliable carbon conversion

Inventive Principle:

Principle #35Parameter changes

3Productivity

If traditional algal systems are used for hydrocarbon production, then photosynthetic carbon fixation occurs, but insufficient yields limit economic feasibility

Engineering Contradiction:

Improvehydrocarbon yieldVSAvoideconomic feasibility

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces photosynthetic carbon fixation (used in algal systems) with chemosynthetic carbon fixation using engineered bacteria. This substitution enables higher productivity by utilizing heterologous fatty acid biosynthesis pathways that can achieve yields of 50-80% of total cellular mass as lipids, making the process economically feasible compared to traditional algal systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If heterotrophic fermentation systems are employed, then sugar feedstock conversion occurs, but food versus fuel conflict and environmental impacts arise

Engineering Contradiction:

Improveorganic compound productionVSAvoidenvironmental impact

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent enables microorganisms to use gaseous carbon sources (CO2, CO, H2) directly for carbon fixation and lipid synthesis, making the system self-sufficient without requiring sugar feedstocks. This eliminates the food versus fuel conflict and reduces environmental impacts associated with agricultural feedstock production, while maintaining high productivity in organic compound production

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The engineered microorganisms enable the cost-effective synthesis of long-chain oleochemicals and fuels, competing with petrochemical prices, while reducing environmental impacts and operational costs, and producing a narrower range of carbon chain lengths with improved product recovery.

Implementation Method 1

the bacteria of the invention can be genetically engineered for use in the methods or other aspects of the invention described herein... methods of fixing carbon from gas input into useful organic molecules

Methodology Applied

Scientific EffectCarbon fixation: Photosynthesis

Implementation Method 2

utilizing genetic modifications to enhance lipid biosynthesis pathways and tolerate varying syngas ratios, thereby producing targeted products with increased efficiency and flexibility

Methodology Applied

Scientific EffectLipid biosynthesis: Fermentation

Implementation Method 3

Methodology Applied

Scientific EffectMetabolic adaptation: Fermentation

Data Source

PatentUS9879290B2Industrial fatty acid engineering general system for modifying fatty acids

Publication Date: 2018.01.30 KIVERDI INC

AI summary

Compositions and methods for a hybrid biological and chemical process utilizing chemotrophic microorganisms that converts syngas and/or gaseous CO2 and/or a mixture of CO2 gas and H2 gas into one or more desaturated hydrocarbons, unsaturated fatty acids, hydroxy acids, or diacids.