Polyketide Synthase Dicarboxylic Acid Fermentation

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Solution Overview

Problem

The large-scale production of dicarboxylic acids, crucial for manufacturing polymers like nylon and polyesters, relies heavily on petroleum-derived materials, necessitating a more sustainable fermentation-based method using polyketide synthases.

Innovation Solution

Development of a polyketide synthase (PKS) capable of synthesizing dicarboxylic acids, including diketide and triketide-diacids, through recombinant nucleic acids and host cells, allowing for the production of these acids via fermentation, which can then be used to produce nylon or polyesters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If petroleum-based materials are used for dicarboxylic acid production, then large-scale production capability is maintained, but dependence on petroleum and environmental sustainability deteriorate

Engineering Contradiction:

Improvelarge-scale production capabilityVSAvoiddependence on petroleum

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the fundamental parameter of feedstock source from petroleum-derived chemicals to fermentation-based renewable resources. By utilizing polyketide synthases in microbial fermentation systems, the process transforms the chemical production pathway while maintaining scalability through industrial fermentation techniques.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the chemical synthesis mechanism (petroleum refining and chemical conversion) with a biological mechanism (fermentation using polyketide synthases). This substitution enables sustainable production while maintaining the capability for large-scale output through controlled fermentation processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If fermentation-based methods using polyketide synthases are developed, then sustainability and reduction of petroleum dependence are improved, but production scale and commercial viability may deteriorate

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoidproduction scale

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The invention employs polyketide synthases that can produce multiple different dicarboxylic acids (adipic acid, suberic acid, azelaic acid, etc.) from a single fermentation platform. This multi-functionality allows the system to address various polymer production needs while maintaining a unified sustainable production approach, enhancing commercial viability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention utilizes dynamic fermentation processes where production conditions, microbial strains, and substrate feeds can be adjusted to optimize output levels. This dynamic control enables scaling from laboratory to industrial production while maintaining sustainability benefits.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If diverse dicarboxylic acids are produced through PKS, then versatility and product range are improved, but process complexity and manufacturing difficulty may deteriorate

Engineering Contradiction:

Improveproduct diversityVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention segments the production of different dicarboxylic acids into distinct fermentation processes or modular bioreactor systems. Each PKS variant can be optimized for specific diacid production, allowing independent process development and scale-up while maintaining overall system versatility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses polyketide synthases as intermediary enzymes that convert common fermentation substrates into diverse dicarboxylic acid products. This intermediary biological system simplifies the overall process by providing a unified entry point (fermentation) to multiple valuable chemical products.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach enables the production of diverse dicarboxylic acids, reducing dependence on petroleum-based materials and providing a sustainable method for manufacturing polymers like nylon and polyesters.

Implementation Method 1

generate the diacids by a fermentation process involving the use of polyketide synthases

Methodology Applied

Scientific EffectFermentation: Fermentation

Implementation Method 2

polyketide synthases (PKS) capable of synthesizing a dicarboxylic acid (diacid)

Methodology Applied

Scientific EffectEnzyme catalysis: Enzyme

Data Source

PatentUS9040282B2Producing dicarboxylic acids using polyketide synthases

Publication Date: 2015.05.26 RGT UNIV OF CALIFORNIA

AI summary

The present invention provides for a polyketide synthase (PKS) capable of synthesizing a dicarboxylic acid (diacid). Such diacids include diketide-diacids and triketide-diacids. The invention includes recombinant nucleic acid encoding the PKS, and host cells comprising the PKS. The invention also includes methods for producing the diacids.