Biochemical conversions by yeast fermentation at high cell densities

Claim 2

In a continuous process of biochemical conversion of a carbon energy substrate to products of fermentation comprising yeast cells and extracellular products which comprises culturing at least one yeast under aerobic aqueous fermentation conditions, in aqueous ferment comprising a cellular phase and an aqueous extracellular phase, in fermentation means employing effective amounts of a yeast-assimilable carbon energy substrate, assimilable nitrogen source, water, molecular oxygen, and mineral salts, and withdrawing said aqueous ferment as effluent for recovery therefrom of said products of fermentation, wherein the improvement comprises feeding said mineral salts to the aqueous ferment in amounts sufficient to maintain in said aqueous ferment the following elements in at least the designated weights per liter of aqueous ferment: P-1.9 g, K-1 g, Mg-0.15 g, Ca-0.06 g, S-0.1 g, Fe-6 mg, Zn-2 mg, Cu-0.6 mg, and Mn-0.6 mg, thereby producing at least one product of fermentation and maintaining a yeast cell density in said aqueous ferment of at least about 60 to 160 grams, on a dried basis, per liter of said aqueous ferment; said fermentative means being a fermenter free from physical means to remove liquid medium from said aqueous ferment without removing cells.

Claim 3

The process according to claim 1 wherein said yeast is selected from the group of genera consisting of Candida, Hansenula, Torulopsis, Saccharomyces, Pichia, Debaryomyces, and Brettanomyces.

Claim 4

The process according to claim 2 wherein the yeast is selected from the group of genera consisting of Candida, Hansenula, Torulopsis, Pichia, and Saccharomyces.

Claim 5

The process according to claim 2 wherein said yeast is selected from the group of species consisting of: ______________________________________ Brettanomyces petrophilium, Hansenula holstii, Candida boidinii, Pichia farinosa, Candida lipolytica, Pichia polymorpha, Candida mycoderma, Pichia membranaefaciens, Candida utilis, Pichia pinus, Candida stellatoidea, Pichia pastoris, Candida robusta, Pichia trebalophila, Candida claussenii, Saccharomyces cerevisiae, Candida rugosa, Saccharomyces fragilis, Candida tropicalis, Saccharomyces rosei, Debaryomyces hansenii, Saccharomyces acidifaciens, Hansenula minuta, Saccharomyces elegans, Hansenula saturnus, Saccharomyces rouxii, Hansenula californica, Saccharomyces lactis, Hansenula mrakii, Torulopsis sonorensis, Hansenula silvicola, Torulopsis candida, Hansenula polymorpha, Torulopsis bolmii, Hansenula wickerhamii, Torulopsis versatilis, Hansenula capsulata, Torulopsis glabrata, Hansenula glucozyma, Torulopsis molishiana, Hansenula henricii, Torulopsis nemodendra, Hansenula nonfermentans, Torulopsis nitratophila, Hansenula philodendra, Torulopsis pinus, and Torulopsis bombicola. ______________________________________

Claim 6

The process according to claim 4 maintaining in each liter of said aqueous ferment: P 1.9 to 20 g, K 1 to 20 g, Mg 0.15 to 3 g, Ca 0.06 to 1.6 g, S 0.1 to 8 g, Fe 6 to 140 mg, Zn 2 to 100 mg, Cu 0.6 to 16 mg, and Mn 0.6 to 20 mg.

Claim 7

The process according to claim 5 maintaining in each liter of said aqueous ferment about: P 2.2 to 10 g, K 1.5 to 10 g, Mg 0.3 to 1.2 g, Ca 0.08 to 0.8 g, S 0.2 to 5 g, Fe 9 to 80 mg, Zn 3 to 40 mg, Cu 1 to 10 mg, and Mn 0.9 to 8 mg.

Claim 8

The process according to claim 5 wherein said aqueous fermentation conditions include fermentation temperature in the range of 25° C. to 65° C., pH in the range of about 3 to 7, pressure in the range of about 0 to 150 psig, and fermentation time in the range of about 2 to 30 hours based on average retention.

Claim 9

The process according to claim 7 maintaining a cell density of about 70 to 150 grams, on a dried basis, per liter of aqueous ferment.

Claim 10

The process according to claim 7 maintaining a cellular yield of about 30 to 110 grams per 100 grams substrate charged.

Claim 11

The process according to claim 7 wherein said carbon energy substrate is an alcohol of 1 to 4 carbon atoms.

Claim 12

The process according to claim 7 wherein said alcohol is methanol.

Claim 13

The process according to claim 7 or 11 employing as said yeast Pichia pastoris NRRL Y-11430.

Claim 14

The process according to claim 7 or 11 employing as said yeast Pichia pastoris NRRL Y-11431.

Claim 15

The process according to claim 7 or 11 employing as said yeast Hansenula polymorpha NRRL Y-11432.

Claim 16

The process according to claim 7 further comprising the steps of: (a) removing a stream of said aqueous ferment from said fermentation means, (b) separating said removed stream of aqueous ferment into a stream of separated cells, and a stream comprising separated aqueous media containing residual dissolved minerals, (c) water-washing said separated cells and thereby substantially separating said traces of mineral salts from the cells, leaving a wet cell mass, (d) drying said wet cell mass to produce dried cells, and (e) recycling the water-washings and separated aqueous media to said culturing to provide therein at least in part said makeup water and said mineral salts.

Claim 17

The process according to claim 7 further comprising the steps of: removing a portion of said aqueous ferment as fermenter effluent containing said cellular phase, and aqueous extracellular phase including residual mineral salts, and drying said aqueous ferment effluent containing said cellular phase and said aqueous phase, thereby producing a dried cellular product containing residual water-soluble substances including salts.

Claim 18

The process of claim 7 further comprising the steps of: (a) removing a stream of said aqueous ferment effluent from said fermentation means, (b) centrifuging said removed aqueous ferment, thereby producing a stream of concentrated cells, and a stream of lean recycle mineral salts aqueous liquor, (c) water-washing said concentrated cells to produce a stream of water-washings containing further residual mineral salts, and a stream of washed cells, (d) drying said washed cells, and (e) recycling at least a part of at least one of said lean recycle liquor and said water-washings to said aqueous ferment to provide therein at least a portion of said makeup water and mineral salts.

Claim 19

The process according to claim 5 further employing in said aqueous ferment at least one element selected from the group consisting of sodium, cobalt, molybdenum, boron, and selenium.

Claim 20

The process according to claim 18 further employing in said aqueous ferment at least one vitamin.

Claim 21

The process according to claim 19 wherein said vitamin is at least one of biotin or thiamine.

Claim 22

The process according to claim 20 wherein said mineral salts comprise a primary mineral salts medium and a trace mineral salts medium, and wherein said primary mineral salts medium supplies said P, K, Mg, S, and Ca; and said trace mineral salts medium furnishes said Fe, Zn, Mn, and Cu.

Claim 23

The process according to claim 21 wherein said carbon energy substrate is methanol or ethanol.

Claim 24

The process according to claim 22 further comprising the steps of: admixing said vitamin with an aqueous solution of said methanol or ethanol, adding said trace mineral salts medium thereto; and feeding the resulting admixture into said aqueous ferment separately from said primary mineral salts medium.

Claim 25

The process according to claim 1 wherein said carbon energy substrate is selected from the group consisting of carbohydrates, alkenes, alcohols, ketones, aldehydes, acids, and esters, of 1 to 20 carbon atoms per molecule; α-olefins of C 14 to C 18 ; and normal paraffins of 10 to 20 carbon atoms per molecule.

Claim 26

The process according to claim 24 wherein said carbon energy substrate is said carbohydrate, and is selected from the group consisting of glucose, fructose, galactose, lactose, sucrose, starch, dextrin, and mixtures.

Claim 27

The process according to claim 24 wherein said carbon energy substrate is said normal paraffin, and is selected from the group consisting of decane, undecane, dodecane, tridecane, tetradecane, pentadecane, hexadecane, octadecane, eicosane, and mixtures.

Claim 28

The process according to claim 24 wherein said carbon energy substrate is said alcohol, ketone, aldehyde, acid, or ester, and is selected from the group consisting of methanol, ethanol, ethylene glycol, propylene glycol, 1-propanol, 2-propanol, glycerol, 1-butanol, 2-butanol, 3-methyl-1-butanol, 1-pentanol, 2-hexanol, 1,7-heptanediol, 1-octanol, 2-decanol, 1-hexadecanol, 1-eicosanol, acetone, 2-butanone, 4-methyl-2-pentanone, 2-decanone, 3-pentadecanone, 2-eicosanone, formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, hexanal, 7-methyloctanal, tetradecanal, eicosanal, acetic acid, propionic acid, butyric acid, glutaric acid, 5-methylhexanoic acid, azelaic acid, dodecanoic acid, eicosanoic acid, methyl formate, methyl acetate, ethyl acetate, propyl butyrate, isopropyl hexanoate, hexyl 5-methyloctanoate, octyl dodecanoate, and mixtures.

Claim 29

In a fermentation process of producing yeast cells wherein at least one yeast is cultured in fermentation means characterized as being free from physical means to remove liquid medium from said aqueous ferment without removing cells, under aqueous aerobic fermentation conditions in an aqueous ferment comprising yeast cells and aqueous liquor employing yeast-assimilable carbon energy substrate, assimilable nitrogen source, water, oxygen, and mineral salts, removing aqueous ferment as effluent from said fermenter means, and recovering the so-produced yeast cells as a single cell protein product, wherein said carbon energy substrate is selected from the group consisting of carbohydrates, alcohols, ketones, aldehydes, acids, and esters, of 1 to 20 carbon atoms per molecule; and normal paraffins of 10 to 20 carbon atoms per molecule, wherein the improvement comprises: employing as said yeast a species selected from the group consisting of Pichia pastoris NRRL Y-11430, Pichia pastoris NRRL Y-11431, and Hansenula polymorpha NRRL Y-11432; and feeding sufficient said mineral salts to said aqueous ferment at a rate effective to maintain in said aqueous ferment the following elements in at least the designated minimum amounts, per liter of aqueous ferment: P 1.9 g, K 1 g, Mg 0.15 g, Ca 0.06 g, S 0.1 g, Fe 6 mg, Zn 2 mg, Cu 0.6 mg, and Mn 0.6 mg, thereby maintaining a cell density in said aqueous ferment of about 60 to 160 grams, on a dried basis, per liter of aqueous ferment.

Claim 30

In a fermentation process of producing yeast cells wherein at least one yeast is cultured in fermentation means characterized as being free from physical means to remove liquid medium from said aqueous ferment without removing cells, under aqueous aerobic fermentation conditions in an aqueous ferment comprising yeast cells and aqueous liquor employing yeast-assimilable carbon energy substrate, assimilable nitrogen source, water, oxygen, and mineral salts, removing aqueous ferment as effluent from said fermenter means, and recovering the so-produced yeast cells as a single cell protein product, wherein said carbon energy substrate is selected from the group consisting of carbohydrates, alcohols, ketones, aldehydes, acids, and esters, of 1 to 20 carbon atoms per molecule; and normal paraffins of 10 to 20 carbon atoms per molecule, wherein the improvement comprises: employing as said yeast a species selected from the group consisting of Pichia pastoris NRRL Y-11430, Pichia pastoris NRRL Y-11431, and Hansenula polymorpha NRRL Y-11432; and feeding sufficient said mineral salts to said aqueous ferment at a rate effective to maintain in said aqueous ferment the following elements in at least the designated minimum amounts, per liter of aqueous ferment: P 1.9 g, K 1 g, Mg 0.15 g, Ca 0.06 g, S 0.1 g, Fe 6 mg, Zn 2 mg, Cu 0.6 mg, and Mn 0.6 mg, thereby maintaining a cell density in said aqueous ferment of about 60 to 160 grams, on a dried basis, per liter of aqueous ferment.

Claim 31

The process according to claim 28 wherein said carbon energy substrate is said carbohydrate and is selected from the group consisting of glucose, fructose, galactose, lactose, sucrose, starch, dextrin, and mixtures.

Claim 32

The process according to claim 28 wherein said carbon energy substrate is said normal paraffin, and is selected from the group consisting of decane, undecane, dodecane, tridecane, tetradecane, pentadecane, hexadecane, octadecane, eicosane, and mixtures.

Claim 33

The process according to claim 28 wherein said carbon energy substrate is said alcohol, ketone, aldehyde, acid, or ester, and is selected from the group consisting of methanol, ethanol, ethylene glycol, propylene glycol, 1-propanol, 2-propanol, glycerol, 1-butanol, 2-butanol, 3-methyl-1-butanol, 1-pentanol, 2-hexanol, 1,7-heptanediol, 1-octanol, 2-decanol, 1-hexadecanol, 1-eicosanol, acetone, 2-butanone, 4-methyl-2-pentanone, 2-decanone, 3-pentadecanone, 2-eicosanone, formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, hexanal, 7-methyloctanal, tetradecanal, eicosanal, acetic acid, propionic acid, butyric acid, glutaric acid, 5-methylhexanoic acid, azelaic acid, dodecanoic acid, eicosanoic acid, methyl formate, methyl acetate, ethyl acetate, propyl butyrate, isopropyl hexanoate, hexyl 5-methyloctanoate, octyl dodecanoate, and mixtures.

Claim 34

The process according to claim 28 wherein said carbon energy substrate is an alcohol of 1 to 4 carbon atoms.

Claim 35

The process according to claim 32 maintaining in each liter of said aqueous ferment: P 1.9 to 20 g, K 1 to 20 g, Mg 0.15 to 3 g, Ca 0.06 to 1.6 g, S 0.1 to 8 g, Fe 6 to 140 mg, Zn 2 to 100 mg, Cu 0.6 to 16 mg, and Mn 0.6 to 20 mg.

Claim 36

The process according to claim 33 maintaining in each liter of said aqueous ferment: P 2.2 to 10 g, K 1.5 to 10 g, Mg 0.3 to 1.2 g, Ca 0.08 to 0.8 g, S 0.2 to 5 g, Fe 9 to 80 mg, Zn 3 to 40 mg, Cu 1 to 10 mg, and Mn 0.9 to 8 mg.

Claim 37

The process according to claim 34 wherein said alcohol is methanol or ethanol.

Claim 38

The process according to claim 35 further employing in said aqueous ferment at least one of the group consisting of sodium, cobalt, molybdenum, boron, and selenium.

Claim 39

The process according to claim 35 further employing in said aqueous ferment at least one vitamin.

Claim 40

The process according to claim 37 wherein said vitamin is biotin, thiamine, or both.

Claim 41

The process according to claim 38 wherein said mineral salts comprises a primary mineral salts medium and a trace mineral salts medium, and wherein said primary mineral salts medium supplies said P, K, Mg, S, and Ca, and said trace mineral salts medium furnishes said Fe, Zn, Mn, and Cu; and said process further comprises the steps of: admixing said vitamin with an aqueous solution of said methanol or ethanol, adding the trace mineral salts medium thereto, and feeding the resulting trace mineral salts medium/vitamin admixture into said aqueous ferment separately from said primary mineral salts medium.

Claim 42

The process according to claim 38 wherein said aqueous fermentation conditions include fermentation temperature in the range of 25° C. to 65° C., pH in the range of about 3 to 7, pressure in the range of about 0 to 150 psig, and fermentation time in the range of about 2 to 30 hours based on average retention.

Claim 43

The process according to claim 40 wherein said alcohol is methanol.

Claim 44

The process according to claim 41 further comprising the steps of: water-washing said aqueous ferment effluent by admixture thereof with water, separating aqueous liquor including mineral salts remaining in the separated media from the cells, leaving a wet cell mass, drying the wet cell mass to produce dried cells, and recycling the water-washings and separated mineral salts to said aqueous ferment to provide therein at least in part said makeup water and said mineral salts.

Claim 45

The process according to claim 41 further comprising the step of drying the aqueous ferment effluent from said culturing including cells and residual mineral salts, thereby producing a dried cell product containing residual water-soluble substances including mineral salts.

Claim 46

The process of claim 41 further comprising the steps of: centrifuging said removed aqueous ferment effluent, thereby producing a stream of concentrated cells, and a stream of lean recycle liquor, water-washing said concentrated cells, separating water-washings from said cells to produce a stream of water-washings containing residual mineral salts, and a stream of washed cells, drying said washed cells, and recycling at least in part at least one of said lean recycle liquor and said water-washings to said aqueous ferment to provide therein at least a portion of said makeup water and said mineral salts.

Claim 47

The process according to claim 35 maintaining a cell density of about 70 to 150 grams, on a dried basis, per liter of aqueous ferment.

Claim 48

The process according to claim 35 maintaining a cellular yield of about 30 to 110 grams per 100 grams substrate charged.

Claim 51

The process of claim 47 wherein said yeast is said Pichia pastoris NRRL Y-11430.

Claim 52

The process according to any of claims 48, 66, or 67 wherein said alcohol contains 1 to 4 carbon atoms per molecule.

Claim 53

The process according to claim 49 wherein said alcohol is methanol.

Claim 54

The process according to claim 47 wherein said yeast is said Pichia pastoris NRRL Y-11431.

Claim 55

The process according to claim 47 wherein said yeast is said Hansenula polymorpha NRRL Y-11432.

Claim 56

The process according to claim 47 wherein said carbon energy substrate is selected from the group consisting of alcohols, ketones, esters, ethers, acids, and aldehydes, which are substantially water-soluble and contain up to about 10 carbon atoms per molecule.

Claim 57

In a continuous process of biochemical conversion wherein a carbon energy substrate is converted to products of fermentation, which comprises culturing at least one yeast under aerobic aqueous fermentation conditions, in aqueous ferment comprising a cellular phase and an aqueous extracellular phase, employing a yeast-assimilable carbon energy substrate, assimilable nitrogen source, water, molecular oxygen, and mineral salts, wherein the improvement comprises: employing a yeast selected from the group consisting of Pichia pastoris NRRL Y-11430, Pichia pastoris NRRL Y-11431, and Hansenula polymorpha NRRL Y-11432, and feeding said mineral salts to said aqueous ferment in an amount sufficient to maintain in said aqueous ferment the following elements in at least the designated amounts per liter of aqueous ferment: P 1.9 g, K 1 g, Mg 0.15 g, Ca 0.06 g, S 0.1 g, Fe 6 mg, Zn 2 mg, Cu 0.6 mg, and Mn 0.6 mg, and said carbon energy substrate in amounts required for maximum growth of cells, maintaining a yeast cell density in said aqueous ferment of about 60 to 160 grams on a dried basis per liter of said aqueous ferment, and producing at least one product of fermentation.

Claim 58

In a continuous process of biochemical conversion wherein a carbon energy substrate is converted to products of fermentation, which comprises culturing at least one yeast under aerobic aqueous fermentation conditions, in aqueous ferment comprising a cellular phase and an aqueous extracellular phase, employing a yeast-assimilable carbon energy substrate, assimilable nitrogen source, water, molecular oxygen, and mineral salts, wherein the improvement comprises: employing a yeast selected from the group consisting of Pichia pastoris NRRL Y-11430, Pichia pastoris NRRL Y-11431, and Hansenula polymorpha NRRL Y-11432, and feeding said mineral salts to said aqueous ferment in an amount sufficient to maintain in said aqueous ferment the following elements in at least the designated amounts per liter of aqueous ferment: P 1.9 g, K 1 g, Mg 0.15 g, Ca 0.06 g, S 0.1 g, Fe 6 mg, Zn 2 mg, Cu 0.6 mg, and Mn 0.6 mg, and said carbon energy substrate in amounts required for maximum growth of cells, maintaining a yeast cell density in said aqueous ferment of about 60 to 160 grams on a dried basis per liter of said aqueous ferment, and producing at least one product of fermentation.

Claim 59

The process of claim 54 wherein said carbon energy substrate is methanol.

Claim 60

The process according to claim 55 wherein said biochemical conversion employs as said carbon energy substrate methanol, ethanol, or glucose, and produces fermentation products comprising carbon dioxide and single cell protein.

Claim 61

A fermentation process of producing yeast protein product, which comprises culturing a yeast under aqueous aerobic fermentation conditions, in aqueous ferment comprising yeast cells and aqueous liquor, employing yeast-assimilable carbon energy substrate, assimilable nitrogen source, water, oxygen, and mineral salts comprising a primary salts medium and a trace mineral salts, feeding sufficient said mineral salts to said aqueous ferment to maintain the following elements in at least the minimum amount, per liter of aqueous ferment: P 1.9 g, K 1 g, Mg 0.15 g, Ca 0.06 g, S 0.1 g, Fe 6 mg, Zn 2 mg, Cu 0.6 mg, and Mn 0.6 mg, thereby maintaining a cell density in said aqueous ferment of about 60 to 160 grams, on a dried basis, per liter of aqueous ferment, employing a fermenter characterized as being free from physical means to remove liquid medium from said aqueous ferment without removing cells, and recovering the resulting yeast microorganisms, wherein said carbon energy substrate is selected from the group consisting of carbohydrates, alcohols, ketones, aldehydes, acids, and esters, of 1 to 20 carbon atoms per molecule; and normal paraffins of 10 to 20 carbon atoms per molecule.

Claim 62

A fermentation process of producing yeast protein product, which comprises culturing a yeast under aqueous aerobic fermentation conditions, in aqueous ferment comprising yeast cells and aqueous liquor, employing yeast-assimilable carbon energy substrate, assimilable nitrogen source, water, oxygen, and mineral salts comprising a primary salts medium and a trace mineral salts, feeding sufficient said mineral salts to said aqueous ferment to maintain the following elements in at least the minimum amount, per liter of aqueous ferment: P 1.9 g, K 1 g, Mg 0.15 g, Ca 0.06 g, S 0.1 g, Fe 6 mg, Zn 2 mg, Cu 0.6 mg, and Mn 0.6 mg, thereby maintaining a cell density in said aqueous ferment of about 60 to 160 grams, on a dried basis, per liter of aqueous ferment, employing a fermenter characterized as being free from physical means to remove liquid medium from said aqueous ferment without removing cells, and recovering the resulting yeast microorganisms, wherein said carbon energy substrate is selected from the group consisting of carbohydrates, alcohols, ketones, aldehydes, acids, and esters, of 1 to 20 carbon atoms per molecule; and normal paraffins of 10 to 20 carbon atoms per molecule.

Claim 63

The process according to claim 57 wherein said yeast is selected from the group consisting of Pichia pastoris NRRL Y-11430, Pichia pastoris NRRL Y-11431, and Hansenula polymorpha NRRL Y-11432, and said carbon energy substrate is methanol or ethanol.