Integrated methanol synthesis and fermentation system
The present disclosure relates to an integrated methanol synthesis and fermentation system for the production of whole cells and biomolecules, and methods of using the same. In one embodiment, a system comprises a methanol synthesis apparatus adapted to produce unrefined methanol; a mixing apparatus adapted to receive unrefined methanol from the methanol synthesis apparatus; and a metering apparatus having at least one first input port in communication with mixing apparatus and at least one second output port in communication with a fermentation vessel.
1 . A method of producing whole cells, the method comprising:
providing, by a media mixing apparatus, a growth medium comprising unrefined methanol generated by a methanol synthesis apparatus;
metering the growth medium into a fermentation vessel comprising an aqueous fermentation medium;
introducing an oxygen-containing gas into the aqueous fermentation medium within the fermentation vessel and expanding a population of methylotrophic organisms within the aqueous fermentation medium;
extracting a portion of the aqueous fermentation medium comprising the whole cells;
concentrating the whole cells into a first stream and whole cell-depleted fermentation medium into a second stream;
introducing the first stream into a drying apparatus to dry the whole cells;
recycling an output stream from the drying apparatus to the methanol synthesis apparatus and the media mixing apparatus, wherein the output stream from the drying apparatus comprises low temperature steam; and
directing the output stream to a cooling tower to condense the low temperature steam to an aqueous liquid prior to recycling the output stream from the drying apparatus to the methanol synthesis apparatus and/or the media mixing apparatus.
2 . The method of claim 1 , wherein the unrefined methanol is derived from the methanol synthesis apparatus without being subjected to a distillation process, or by being subjected to a subset of steps of the distillation process.
3 . The method of claim 1 , wherein the oxygen-containing gas is introduced into the aqueous fermentation medium via jet aeration, surface aeration, or fine bubble diffusers, and wherein the oxygen-containing gas comprises air, a mixture of oxygen and at least one other gas, or purified oxygen.
4 . The method of claim 3 , wherein the oxygen-containing gas is introduced into the aqueous fermentation medium in a form of bubbles having a median diameter of less than about 200 nm.
5 . The method of claim 1 , wherein the methylotrophic organisms comprise one or more of Pichia pastoris, Methylophilus methylotrophus, Methylobacterium extorquens, Methylomonas methanolica , or Pseudomonas methanolica.
6 . The method of claim 1 , wherein the methylotrophic organisms utilize a ribose monophosphate pathway, a serine pathway, an alcohol oxidase 1 pathway, and/or an alcohol oxidase 2 pathway.
7 . The method of claim 1 , further comprising:
reintroducing at least a portion of the second stream into the fermentation vessel.
8 . The method of claim 7 , further comprising:
passing the portion of the aqueous fermentation medium through a filter comprising pores, wherein the pores have an average diameter of less than average diameters of the whole cells.
9 . The method of claim 7 , wherein concentrating the whole cells into the first stream comprises exposing the aqueous fermentation medium to centrifugal force.
10 . The method of claim 7 , further comprising:
drying the concentrated whole cells by the drying apparatus via exposure to superheated steam.
11 . The method of claim 10 , wherein the superheated steam is derived from the methanol synthesis apparatus.
12 . The method of claim 7 , further comprising:
drying the concentrated whole cells by the drying apparatus via exposure to hot gas; or
lysing the whole cells via exposure to the hot gas.
13 . The method of claim 12 , wherein the hot gas is generated from steam from the methanol synthesis apparatus.
14 . The method of claim 7 , further comprising:
drying the concentrated whole cells via spray drying, microwave drying, freeze drying, or lyophilization.
15 . The method of claim 1 , further comprising:
extracting a carbon dioxide-containing waste gas mixture evolved from the whole cells in the fermentation vessel; and
separating carbon dioxide from other gases within the waste gas mixture into a concentrated carbon dioxide gas stream and a carbon dioxide-depleted gas stream.
16 . The method of claim 15 , wherein the carbon dioxide is separated from the other gases via exposure to molecules comprising one or more amine moieties or exposure to size selective molecular sieves or zeolites.