Yarrowia Fermentation With Formic Acid Feeding for Higher Biomass Yield

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Solution Overview

Problem

Fermentation processes for Yarrowia yeast are energy intensive and emit CO2, and existing methods of adding formate to yeast do not effectively enhance biomass yield as predicted, leading to inefficiencies and potential toxicity.

Innovation Solution

A process involving the fermentation of Yarrowia in a bioreactor with a molar ratio of formic acid to sugar ranging from 1 to 13 mol formic acid/mol monosaccharide, under carbon-limited conditions, utilizing captured and reduced CO2 as formic acid, and integrating electrolysis for sustainable hydrogen and oxygen supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If formate is added to yeast cultures to enhance biomass yield, then biomass cell yield increases for some yeast species, but more formate is needed than predicted due to energetic costs for transport and uncoupling effects

Engineering Contradiction:

Improvebiomass cell yieldVSAvoidenergetic costs for formate transport

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The invention changes the chemical form of the additive from formate (conjugate base) to formic acid, which alters the transport mechanism and energy requirements. Formic acid can be transported into the cell without the same energetic costs as formate, thereby reducing the total amount of additive needed while maintaining or enhancing biomass yield improvement.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the previously harmful or wasteful aspect of formate addition (excessive formate requirements due to uncoupling effects and transport costs) into a benefit by using formic acid, which avoids these problems. The uncoupling effect that wasted energy with formate becomes irrelevant with formic acid, turning a negative into a positive.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If fermentation processes are intensified to improve productivity, then output increases, but CO2 emissions increase due to energy use and microbial metabolism

Engineering Contradiction:

Improvefermentation outputVSAvoidCO2 emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The invention converts the harmful CO2 emission into a beneficial resource by capturing and reducing it to formic acid, which is then fed to the yeast cultures. This transforms waste CO2 into a valuable substrate that enhances biomass yield, simultaneously reducing emissions and improving productivity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention introduces formic acid as an intermediary substance that mediates between CO2 emissions and biomass production. CO2 is converted to formic acid, which then serves as a carbon source and energy booster for the yeast, creating a bridge that converts waste into productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If formate is added at high concentrations to achieve predicted biomass enhancement, then yield improvement is expected, but toxicity issues arise and process efficiency decreases

Engineering Contradiction:

Improvebiomass yield enhancementVSAvoidformate toxicity

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the chemical parameter from formate to formic acid, which has different toxicity characteristics. Formic acid achieves the same or better biomass enhancement at lower concentrations, avoiding the toxicity threshold that limits formate application.

Inventive Principle:

Principle #35Parameter changes

4Quantity of substance

If external hydrogen and oxygen sources are used to support formic acid production, then formic acid supply is ensured, but process complexity and external dependencies increase

Engineering Contradiction:

Improveformic acid supplyVSAvoidexternal hydrogen and oxygen supply systems

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The invention enables the fermentation system to produce its own formic acid in-situ by integrating CO2 capture and reduction directly into the bioreactor system. The yeast metabolism produces CO2, which is immediately converted to formic acid and fed back to the cultures, creating a self-sufficient cycle that eliminates external H2 and O2 supply requirements.

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

This approach increases biomass yield, reduces CO2 emissions, and minimizes the need for external hydrogen and oxygen sources, enhancing process efficiency and sustainability.

Implementation Method 1

a process for fermenting a yeast in the presence of formic acid and glucose

Methodology Applied

Scientific EffectFermentation: Fermentation

Implementation Method 2

In reduction unit 3 the CO2 is reduced to formic acid, utilizing H2

Methodology Applied

Scientific EffectReduction: Reduction

Implementation Method 3

An electrolysis unit 4 can electrolyze water into H2 and O2

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Data Source

PatentUS20250250530A1Process for fermenting yeast

Publication Date: 2025.08.07 DSM IP ASSETS BV

AI summary

The present invention relates to a process for fermenting Yarrowia in a bioreactor, comprising cultivating Yarrowia in a medium, and adding a feed comprising formic acid and a sugar to the medium in a molar ratio of formic acid to sugar of 1 to 13 mol formic acid/mol monosaccharide.