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Enhanced production of microbial cellulose
Jeffrey Catchmark, Kuan‐Chen Cheng and Ali DemirciDepartment of Agricultural and Biological Engineering
Pennsylvania State University
2009 International Conference on Nanotechnology for the Forest Products
IndustryJune 23‐26, 2009
Center for NanoCellulosics
1) Introduction2) Difference between plant and microbial cellulose3) Microbial cellulose production methods4) Approaches for improving the production yield of microbial cellulose:
Culture additivesPlastic composite supports (PCS)
5) Conclusions
Overview
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The forest products industry generates more than $200 billion in sales per year, employs ~1.0 million people (many in rural America), and ranks among gthe top 10 domestic manufacturing sectors in contribution to the GDP.Uses 400‐500 million acres of land (U.S.).Consumes ~ 4 billion trees per year (globally).This industry produces many renewable and sustainable products which are essential to our daily life: – Paper, packaging, wood, wood chip and fiber composite materials.
The Forest Products Industry
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Wood is composed of 3 major compounds:Wood is 40%‐50% Cellulose, 25%‐35% Hemicellulose and 20%‐25% Lignin.Cellulose: high molecular weight linear chain polysaccharide, β‐linked 1,4 glucan (glucose) residues (10’s of thousands of units long).Hemicellulose: lower molecular weight branched chain polysaccharides produced from other 6‐carbon sugars including galactose and mannose, as well as five carbon sugars including xylose and arabinose (hundreds of units long).Lignin: complex high molecular weight polymer built upon phenylpropane units. Lignin is phenolic (aromatic compound derived from the 6 carbon compound benzene ring with at least 1 hydroxyl group per ring). Lignin serves as a binding agent and provides wood with its stiffness. Cellulose without lignin and hemicellulose is like cotton fabric!
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Cellulose used in the FPI is purified from wood
Microbial cellulose
Pure, no hemicellulose or lignin needed to be removed and biomass/culture media relatively simple to remove. Longer fiber length (200,000 glucose units) and higher crystallinity.Can be grown to any shape.
Advantages
DisadvantagesExpensive: sugar and culture media.Production scale‐up difficult.Insolubility and aggregation of cellulose product limits the bioreactor design and yield.
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Microbial cellulose products
Ultrafiltration membranes
Klemm et al, 2001 Svensson et al., 2005
Czaja, 2006
Gyre, 2008
Materials for wound care and tissue engineering Artificial blood vessels
Diet foods and dessertsCellulose nanowhiskers
Future products:
Nata de coco
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Plant cellulose vs. microbial cellulose
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U.S. Department of Energy Genome Programs, http://genomics.energy.gov. “Genomics:GTL Transforming Cellulosic Biomass,ʺ U.S. Department of Energy Office of Science and Office of Energy Efficiency and Renewable Energy, June 2006, http://genomicsgtl.energy.gov/biofuels/ and U.S. DOE
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U.S. Department of Energy Genome Programs, http://genomics.energy.gov. “Genomics:GTL Transforming Cellulosic Biomass,ʺ U.S. Department of Energy Office of Science and Office of Energy Efficiency and Renewable Energy, June 2006, http://genomicsgtl.energy.gov/biofuels/ and U.S. DOE
Center for NanoCellulosics
Plant cellulose synthesis
Takao Itoh, Satoshi Kimura and R. Malcolm Brown, Jr., Theoretical considerations of immunogold labeling of cellulose synthesizing terminal complexes, Cellulose 11: 385–394, 2004.
6 cellulose synthase enzymes per feature for a total of 36 in the 25nm diameter complex
A single cellulose synthase enzyme
66
66
66
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Microbial cellulose synthesis
Takao Itoh, Satoshi Kimura and R. Malcolm Brown, Jr., Theoretical considerations of immunogold labeling of cellulose synthesizing terminal complexes, Cellulose 11: 385–394, 2004.R. Malcolm Brown, et. al., Cellulose Biosynthesis in Acetobacter xylinum: Visualization of the Site of Synthesis and Direct Measurement of the in vivo Process, PNAS 73:4565‐4569, 1976.
Not clear if each feature represents one or more cellulose synthase enzymes.
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Plant vs. microbial cellulose
36 joined cellulose synthase proteins (rosette) produce cellulose nanofibers in plants.
~28nm
Bacteria have 1‐6 cellulose synthase proteins.
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Implications: cellulose nanowhiskers
Hydrolyzed Acetobacter xylinum celluloseFiber size: ~10‐15nm × ~1‐3microns
Concentrated hydrolyzed Whatman CF11 cellulose (cotton)Fiber size: ~25nm+ × 0.2‐0.5 microns
Cellulose hydrolyzed in 63% H2SO4 at 47C for 130min.
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Cellulose synthase complexes
Why have cellulose synthase complexes formed?Create a crystalline cellulose fibrilAchieve mechanical strengthAchieve resistance to enzymatic attackOthers…
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Microbial cellulose production processes
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Microbial cellulose production
Most common production processes are static cultures and submerged agitated cultures.Oxygen delivery to bacteria a major factor.
Pellicle (Static)
Bioreactor (agitated)
Flask (agitated)
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Bioreactor production
Unlike static and flask cultivation, bioreactors offer additional control over process parameters:• Agitation• Temperature• Dissolved oxygen• pH
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Rotating disc reactors (Serafica, 1997) Rotating plates pass through the media providing oxygen and nutrients.Can control environment and introduce additives.
Other production approaches
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Silicone membrane (Yoshino et al., 1996)
Microbial cellulose
Spray chamber (Hornung, et al., 2006)
Other production approaches
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Research objectives
Enhance production of microbial cellulose in submerged culture by:
Incorporating additivesIncorporating a solid nutrient support
Evaluate the properties of cellulose produced.
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Dynamic Dynamic mechanic mechanic analysisanalysis
Material strength
Thermo Thermo Gravimetric Gravimetric
(TGA)(TGA)
Thermostability
FESEMFESEM
BC structure
TGA XRD
FE‐SEMDMA
XX--ray ray diffractiondiffraction
Crystallinity;Crystal size
Characterization
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AdditivesMicrocrystalline cellulose
Sodium alginateSodium
carboxymethylcellulose (CMC)Agar
0.2, 0.5% (w/v)
5 day cultivation in 250 ml flasks
Harvest cellulose and analyze
Removal of cells and media (0.1 N, NaOH )
Experimental design: effect of additives
Bacterial strain: Acetobacter xylinum(ATCC 700178) Medium:CSL‐Fru medium (Kouda et al. 1997)
Cellulose producing bacteria first reported by Adrian Brown while working with Bacterium aceti in 1886.
Center for NanoCellulosics
0
1
2
3
4
56
7
8
9
10
Control
0.2% avic
el0.5
% avicel
0.2% C
MC
0.5% C
MC
0.2% sodiu
m alginate
0.5% sodiu
m alginate
0.2% A
gar
Types and concentration of additives
Wei
ght o
f BC
(g/L
)
Bacterial cellulose production by A. xylinum in CSL-Fru medium containing Microcrystalline cellulose, CMC, sodium alginate or agar in 250 ml flasks.
7.3 g/L
Results: cellulose yield
Center for NanoCellulosics
1.3 g/L
5.6×improvement
0
2
4
6
8
10
0.0 0.2 0.5 0.8 1.0
CMC concentration (%; w/v)
Wei
ght o
f BC
(g/L
)
Bacterial cellulose production by A. xylinum in CSL-Fru medium containing different concentration of CMC in 250 ml flasks.
8.2 g/L
Results: cellulose yield with CMC
6.3×improvement
1.3 g/L
Center for NanoCellulosics
FESEM images of freeze dried microbial cellulose produced . (a) Control; (b) 0.2% CMC; (c) 0.5% CMC; (d) 0.8% CMC; and (e) 1% CMC addition.
Results: FESEM of cellulose‐CMC materials
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(a) (b) (c)
(d) (e)
Results: cellulose crystallinity
• The decrease in crystallinity is responsible for the increased cellulose yield, as shown by Haigler (J Cell Biol 94(1):64‐69, 1982), where cellulose crystallization is shown to be a rate limiting step in cellulose production.
Center for NanoCellulosics
U.S. Department of Energy Genome Programs, http://genomics.energy.gov. “Genomics:GTL Transforming Cellulosic Biomass,ʺ U.S. Department of Energy Office of Science and Office of Energy Efficiency and Renewable Energy, June 2006, http://genomicsgtl.energy.gov/biofuels/ and U.S. DOE
Center for NanoCellulosics
Microbial cellulose synthesis
Takao Itoh, Satoshi Kimura and R. Malcolm Brown, Jr., Theoretical considerations of immunogold labeling of cellulose synthesizing terminal complexes, Cellulose 11: 385–394, 2004.R. Malcolm Brown, et. al., Cellulose Biosynthesis in Acetobacter xylinum: Visualization of the Site of Synthesis and Direct Measurement of the in vivo Process, PNAS 73:4565‐4569, 1976.
Not clear if each feature represents one or more cellulose synthase enzymes.
Center for NanoCellulosics
Derivative of the TGA curves of control BC and CMC-altered BC.
Results: thermogravimetric analysis
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0 100 200 300 400 500 600 700
Temperature (oC)
Der
iv. W
eigh
t (%
/o C)
ControlCMC 0.2%CMC 0.5%CMc 0.8%CMC 1.0%
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Temp. ramp 10°C/min.
Results of tensile test of BC. (A) Stress at break; (B) Strain at break; (C) Young’s modulus.
(A)
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
Pellicle 0% CMC 0.2% CMC 0.5% CMC 0.8% CMC 1.0% CMCTypes of BC sample
Stra
in a
t bre
ak (%
)
(B)
(C)
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Results: mechanical analysis
Results: aggregation of product
0.8% CMC No CMC
Addition of CMC in bioreactor culture may prevent aggregation
while also substantially improving yield
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Conclusions: effects of additives
The optimal CMC concentration is around 0.8% (w/v), where cellulose production reached 8.2 g/L, a 6.3×improvement over the control.
The crystallinity and crystal size of the cellulose decrease when cultured in 0.8% CMC.
The aggregation of cellulose is prevented when cultured in 0.8% CMC.
The decrease in crystallinity and/or aggregation is believed to be responsible for the substantial improvement in cellulose production yield.
Center for NanoCellulosics
Experiment: solid nutrient support
Biofilm reactor cultivation uses a solid nutrient support to form a stable biofilm (bacteria colonies).
PCS –Plastic composite (nutrient) support
Advantages:Release nutrients locally.Cells grow on the solid surface.Increase biomass in the reactor.Reduces the risk of washing out cells during continuous fermentation.Eliminating need for re‐inoculation during repeated‐batch fermentation.
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Experiment: solid nutrient support
Biofilm reactor cultivation uses a solid nutrient support to form a stable biofilm (bacteria colonies).
PCS –Plastic composite (nutrient) support
Applications: production ofNisinEthanolLactic acidCellulases Amylases Lipaseslignin peroxidases
and wastewater treatmentCenter for NanoCellulosics
PCS solid nutrient support fabrication
Extruder
PCS
Mix
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PCS solid nutrient support fabrication
Experiment: PCS solid nutrient support
Selection of suitable PCS with different nutrition composition (flask study)
Production of cellulose in a PCS biofilm reactor
Harvest cellulose and analyze
Removal of cells and media (0.1 N, NaOH )
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Results: selection of PCS composition
0.00.51.01.52.02.53.03.54.04.5
Contro
l SSB+
SF+ SFB SFR SFYSFY
B+SFY
R+SR+
SY+SYB+SFY
BRSFY
B
Types of PCS
Bio
mas
s(x1
03 g/g
PC
S)
02468
1012141618
Contro
lSup
portSB+
SF+ SFB SFR SFYSFY
B+SFY
R+SR+
SY+SYB+SFY
BRSFY
B
Type of PCS
Cel
lulo
se(g
/L)
Results of Biomass and cellulose production with 13 different PCS materials.
Based on the availability and nutrient leaching rate, we chose SFYR + as optimal PCS for Biofilmreactor study.
S: dried, ground, soybean hulls
F: defatted soybean flour
Y: yeast extract
R: dried bovine red blood cell
+: w/ mineralsCenter for NanoCellulosics
Results: selection of PCS composition
0.00.51.01.52.02.53.03.54.04.5
Contro
l SSB+
SF+ SFB SFR SFYSFY
B+SFY
R+SR+
SY+SYB+SFY
BRSFY
B
Types of PCS
Bio
mas
s(x1
03 g/g
PC
S)
02468
1012141618
Contro
lSup
portSB+
SF+ SFB SFR SFYSFY
B+SFY
R+SR+
SY+SYB+SFY
BRSFY
B
Type of PCS
Cel
lulo
se(g
/L)
Results of Biomass and cellulose production with 13 different PCS materials.
Based on the availability and nutrient leaching rate, we chose SFYR + as optimal PCS for Biofilmreactor study.
S: dried, ground, soybean hulls
F: defatted soybean flour
Y: yeast extract
R: dried bovine red blood cell
+: w/ mineralsCenter for NanoCellulosics
Results: selection of PCS composition
0.00.51.01.52.02.53.03.54.04.5
Contro
l SSB+
SF+ SFB SFR SFYSFY
B+SFY
R+SR+
SY+SYB+SFY
BRSFY
B
Types of PCS
Bio
mas
s(x1
03 g/g
PC
S)
02468
1012141618
Contro
lSup
portSB+
SF+ SFB SFR SFYSFY
B+SFY
R+SR+
SY+SYB+SFY
BRSFY
B
Type of PCS
Cel
lulo
se(g
/L)
Results of Biomass and cellulose production with 13 different PCS materials.
Based on the availability and nutrient leaching rate, we chose SFYR + as optimal PCS for Biofilmreactor study.
S: dried, ground, soybean hulls
F: defatted soybean flour
Y: yeast extract
R: dried bovine red blood cell
+: w/ mineralsCenter for NanoCellulosics
Results: yield and crystallinity
The PCS biofilm reactor yielded BC production (7.05 g/L) that was 2.5‐fold greater than the control (2.82 g/L).
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Cellulose grown on the PCS shaft after 120 hr cultivation.
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Results: FESEM
Bars are 1 micron (top right) and 50 microns (bottom right)
0.00.20.40.60.81.01.21.41.6
0 200 400 600 800Tempertature (oC)
Der
iv. W
eigh
t (%
/o C)
ControlPCS grown BC
Derivative TGA patterns of BC from PCS biofilm and suspended-cell reactor.
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Results: thermogravimetric analysis
Temp. ramp 10°C/min.
0
5
10
15
20
25
30
35
40
PCS grow n BC Cont rolType of BC pell icle
Stre
ss a
t br
eak
(MPa
)
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
PCS grown BC Control
Type of BC
Stra
in a
t br
eak
(%)
0
500
1000
1500
2000
2500
3000
PCS grow n BC Cont rolType of BC
Youn
g's
mod
ulus
(MPa
)
Results of tensile test of BC. (A) Stress at break; (B) Strain at break; (C) Young’s modulus.
(A)
(C)
(B)
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Results: mechanical analysis
Conclusions: PCS solid nutrient supportThe PCS biofilm reactor using SFYR+ type PCS yielded cellulose production of 7.05 g/L, which was 2.5‐fold greater than the control.
XRD results demonstrated that PCS‐grown cellulose exhibited higher crystallinity (93%) and similar crystal size (5.2 nm) to the control.
TGA results indicated that PCS‐grown cellulose exhibited higher decomposition temperature compared to the control but PCS support material incorporation is expected to be a contributing factor.
DMA results showed that cellulose from the PCS biofilm reactor increased its mechanical property values, i.e., stress at break and Young’s modulus when compared to the control cellulose but PCS support material incorporation is expected to be a contributing factor.
Center for NanoCellulosics
Acknowledgments
This work was supported in part by a seed grant from the collegeof Agricultural sciences at the Pennsylvania State University and the Pennsylvania Experiment Station.
Students and collaborators:
Kuan‐Chen ChengPh.D. StudentAgricultural and Biological Engineering, Penn State University
Dr. Ali DemirciAssociate ProfessorAgricultural and Biological Engineering, Penn State University
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Thank You!
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