Enhanced production of lipids containing polyenoic fatty acid by very hugh density cultures of eukaryotic microbes in fermentors

1. A process for producing microbial lipids comprising:

a) growing microorganisms of the order Thraustochytriales in a fermentation medium comprising a carbon source and a nitrogen source to increase the biomass density of the fermentation medium to at least 100 g/L on a dry cell weight basis, wherein:

i) the fermentation medium temperature is at least 20° C.;

ii) the fermentation medium pH is from about pH 5 to about pH 11;

iii) the carbon and nitrogen sources are added at rates sufficient to increase the biomass density of the fermentation medium to at least 100 g/L; and,

iv) wherein at least a portion of the carbon source is added during the growing of microorganisms to a biomass density of at least 100 g/L;

b) limiting a nutrient source other than carbon in the fermentation medium to induce lipid production by the microorganisms after reaching a biomass density of 100 g/L, while maintaining a biomass density of at least 100 g/L on a dry cell weight basis;

wherein the primary use of the carbon source by the microorganisms is to produce lipids after induction of lipid production and when the biomass density of the fermentation medium is at least 100 g/L on a dry cell weight basis; and

c) recovering the lipids, wherein greater than about 15% of the lipids are polyunsaturated lipids.

2. The process of claim 1 , wherein the process is a fed-batch process.

3. The process of claim 1 , wherein the growing microorganisms of the order Thraustochytriales is to increase the biomass density of the fermentation medium to at least 150 g/L on a dry cell weight basis.

4. The process of claim 1 , wherein the process produces lipids at an average rate of at least 0.5 grams per liter of fermentation medium per hour of the fermentation.

5. The process of claim 1 , wherein the microorganisms are selected from the group consisting of Thraustochytrium, Schizochytrium , and mixtures thereof.

6. The process of claim 1 , wherein the process produces on average at least 0.2 grams of docosahexaenoic acid per liter of fermentation medium per hour of the fermentation.

7. The process of claim 1 , wherein the process is a batch or continuous process with respect to at least one nutrient.

8. The process of claim 1 , wherein during the limiting of a nutrient source other than carbon, at least some of the carbon source is added and the nutrient source other than carbon is a nitrogen source.

9. The process of claim 1 , wherein the process is conducted for at least 90 hours, wherein the dissolved oxygen level in the fermentation medium is maintained at about 8% during the first 24 hours, about 4% from the 24th hour to the 40th hour, and about 0.5% or less from the 40th hour to the end of the fermentation process.

10. The process of claim 1 , wherein the dissolved oxygen level in the fermentation medium is at about 0.5% or less after 40 hours of the process until the end of the fermentation process.

11. The process of claim 8 , wherein the carbon source comprises a carbohydrate.

12. The process of claim 1 , wherein the nutrient source other than carbon comprises a nitrogen source.

13. The process of claim 12 , wherein the nitrogen source comprises an inorganic ammonium salt.

14. The process of claim 12 , wherein the nitrogen source comprises ammonium hydroxide.

15. The process of claim 1 , wherein pH of the fermentation medium is controlled by a limiting nutrient source.

16. The process of claim 1 , wherein the process produces at least 15% of the total lipids produced by the microorganisms as docosahexaenoic acid.

17. The process of claim 1 , wherein the process produces lipids at an average rate of at least 0.5 grams per liter of fermentation medium per hour of the fermentation and wherein the total amount of omega-3 and omega-6 fatty acids is at least 20% of the lipids.

18. The process of claim 1 , wherein the process produces lipids at an average rate of at least 0.5 grams per liter of fermentation medium per hour of the fermentation and wherein at least 25% of the lipids is docosahexaenoic acid.

19. The process of claim 1 , wherein the microorganisms are capable of producing polyenoic fatty acids or other lipids which can be produced under aerobic conditions.

20. The process of claim 1 , wherein the microorganisms are capable of producing polyenoic fatty acids or other lipids which can be produced under aerobic conditions, and wherein the microorganisms are grown in a fed-batch process.

21. The process of claim 1 , wherein the dissolved oxygen in the fermentation medium is controlled.

22. The process of claim 1 , wherein the process produces on average at least 0.2 grams of docosahexaenoic acid per liter of fermentation medium per hour of the fermentation.

23. The process of claim 1 , further comprising:

removing water from the fermentation medium to provide dry microorganisms; and

isolating the lipids from the dry microorganisms, wherein at least 15% of the microbial lipids are polyunsaturated lipids.

24. The process of claim 1 , further comprising:

treating the fermentation medium to permeabilize, lyse or rupture the microbial cells; and

recovering the lipids from the fermentation medium by gravity separation, wherein at least 15% of the microbial lipids are polyunsaturated lipids.

25. The process of claim 1 , further comprising:

evaporating water from the fermentation medium without prior centrifugation to provide dry microorganisms; and

isolating the lipids from the dry microorganisms wherein at least 15% of the microbial lipids are polyunsaturated lipids.

26. The process of claim 1 , wherein a level of dissolved oxygen is less than about 3% of saturation in the fermentation medium during at least a portion of said limiting a nutrient source other than carbon.

27. The process of claim 1 , wherein a level of dissolved oxygen is less than about 1% of saturation in the fermentation medium during at least a portion of said limiting a nutrient source other than carbon.

28. The process of claim 1 , wherein the microorganisms are Schizochytrium.