Researchers give yeast a boost to make biofuels from discarded plant matter
The new system streamlines the process of fermenting plant sugar to fuel by helping yeast survive industrial toxins
IMAGE: WHITEHEAD INSTITUTE MEMBER GERALD FINK STANDING IN FRONT OF A FIELD OF THE GRASS MISCANTHUS GIGANTEUS, WHICH IS ANOTHER POTENTIAL SOURCE OF CELLULOSE THAT COULD BE CONVERTED TO ETHANOL.... view more
CREDIT: PHOTO COURTESY OF FELIX LAM
More corn is grown in the United States than any other crop, but we only use a small part of the plant for food and fuel production; once people have harvested the kernels, the inedible leaves, stalks and cobs are left over. If this plant matter, called corn stover, could be efficiently fermented into ethanol the way corn kernels are, stover could be a large-scale, renewable source of fuel.
"Stover is produced in huge amounts, on the scale of petroleum," said Whitehead Institute Member and Massachusetts Institute of Technology (MIT) biology professor Gerald Fink. "But there are enormous technical challenges to using them cheaply to create biofuels and other important chemicals."
And so, year after year, most of the woody corn material is left in the fields to rot.
Now, a new study from Fink and MIT chemical engineering professor Gregory Stephanopolous led by MIT postdoctoral researcher Felix Lam offers a way to more efficiently harness this underutilized fuel source. By changing the growth medium conditions surrounding the common yeast model, baker's yeast Saccharomyces cerevisiae, and adding a gene for a toxin-busting enzyme, they were able to use the yeast to create ethanol and plastics from the woody corn material at near the same efficiency as typical ethanol sources such as corn kernels.
Sugarcoating the issue
For years, the biofuels industry has relied on microorganisms such as yeast to convert the sugars glucose, fructose and sucrose in corn kernels to ethanol, which is then mixed in with traditional gasoline to fuel our cars.
Corn stover and other similar materials are full of sugars as well, in the form of a molecule called cellulose. While these sugars can be converted to biofuels too, it's more difficult since the plants hold onto them tightly, binding the cellulose molecules together in chains and wrapping them in fibrous molecules called lignins. Breaking down these tough casings and disassembling the sugar chains results in a chemical mixture that is challenging for traditional fermentation microorganisms to digest.
To help the organisms along, workers in ethanol production plants pretreat high-cellulose material with an acidic solution to break down these complex molecules so yeast can ferment them. A side effect of this treatment, however, is the production of molecules called aldehydes, which are toxic to yeast. Researchers have explored different ways to reduce the toxicity of the aldehydes in the past, but solutions were limited considering that the whole process needs to cost close to nothing. "This is to make ethanol, which is literally something that we burn," Lam said. "It has to be dirt cheap."
Faced with this economic and scientific problem, industries have cut back on creating ethanol from cellulose-rich materials. "These toxins are one of the biggest limitations to producing biofuels at a low cost." said Gregory Stephanopoulos, who is the Willard Henry Dow Professor of Chemical Engineering at MIT.
Lending yeast a helping hand
To tackle the toxin problem, the researchers decided to focus on the aldehydes produced when acid is added to break down tough molecules. "We don't know the exact mechanism by which aldehydes attack microbes, so then the question was, if we don't really know what it attacks, how do we solve the problem?" Lam said. "So we decided to chemically convert these aldehydes into alcohol forms."
The team began looking for genes that specialized in converting aldehydes to alcohols, and landed on a gene called GRE2. They optimized the gene to make it more efficient through a process called directed evolution, and then introduced it into the yeast typically used for ethanol fermentation, Saccharomyces cerevisiae. When the yeast cells with the evolved GRE2 gene encountered aldehydes, they were able to convert them into alcohols by tacking on extra hydrogen atoms.
The resultant high levels of ethanol and other alcohols produced from the cellulose might have posed a problem in the past, but at this point Lam's past research came into play. In a 2015 paper from Lam, Stephanopoulos and Fink, the researchers developed a system to make yeast more tolerant to a wide range of alcohols, in order to produce greater volumes of the fuel from less yeast. That system involved measuring and adjusting the pH and potassium levels in the yeast's growth media, which chemically stabilized the cell membrane.
By combining this method with their newly modified yeast, "we essentially channeled the aldehyde problem into the alcohol problem, which we had worked on before," Lam said. "We changed and detoxified the aldehydes into a form that we knew how to handle."
When they tested the system, the researchers were able to efficiently make ethanol and even plastic precursors from corn stover, miscanthus and other types of plant matter. "We were able to produce a high volume of ethanol per unit of material using our system," Fink said. "That shows that there's great potential for this to be a cost-effective solution to the chemical and economic issues that arise when creating fuel from cellulose-rich plant materials."
Scaling up
Alternative fuel sources often face challenges when it comes to implementing them on a nationwide scale; electric cars, for example, require a nationwide charging infrastructure in order to be a feasible alternative to gas vehicles.
An essential feature of the researchers' new system is the fact that the infrastructure is already in place; ethanol and other liquid biofuels are compatible with existing gasoline vehicles so require little to no change in the automotive fleet or consumer fueling habits. "Right now [the US produces around] 15 billion gallons of ethanol per year, so it's on a massive scale," he said. "That means there are billions of dollars and many decades worth of infrastructure. If you can plug into that, you can get to market much faster."
And corn stover is just one of many sources of high-cellulose material. Other plants, such as wheat straw and miscanthus, also known as silvergrass, can be grown extremely cheaply. "Right now the main source of cellulose in this country is corn stover," Lam said. "But if there's demand for cellulose because you can now make all these petroleum-based chemicals in a sustainable fashion, then hopefully farmers will start planting miscanthus, and all these super dense straws."
In the future, the researchers hope to investigate the potential of modifying yeasts with these anti-toxin genes to create diverse types of biofuels such as diesel that can be used in typical fuel-combusting engines. "If we can [use this system for other fuel types], I think that would go a huge way toward addressing sectors such as ships and heavy machinery that continue to pollute because they have no other electric or non-emitting solution," Lam said.
CAPTION
In a new paper, researchers present a method to more efficiently produce biofuels from woody plant materials such as corn residues and some grasses.
CREDIT
Markus Distelrath/Pixabay
Engineered yeast could expand biofuels'
reach
By making the microbes more tolerant to toxic byproducts, researchers show they can use a wider range of feedstocks, beyond corn.
CAMBRIDGE, MA - Boosting production of biofuels such as ethanol could be an important step toward reducing global consumption of fossil fuels. However, ethanol production is limited in large part by its reliance on corn, which isn't grown in large enough quantities to make up a significant portion of U.S. fuel needs.
To try to expand biofuels' potential impact, a team of MIT engineers has now found a way to expand the use of a wider range of nonfood feedstocks to produce such fuels. At the moment, feedstocks such as straw and woody plants are difficult to use for biofuel production because they first need to be broken down to fermentable sugars, a process that releases numerous byproducts that are toxic to yeast, the microbes most commonly used to produce biofuels.
The MIT researchers developed a way to circumvent that toxicity, making it feasible to use those sources, which are much more plentiful, to produce biofuels. They also showed that this tolerance can be engineered into strains of yeast used to manufacture other chemicals, potentially making it possible to use "cellulosic" woody plant material as a source to make biodiesel or bioplastics.
"What we really want to do is open cellulose feedstocks to almost any product and take advantage of the sheer abundance that cellulose offers," says Felix Lam, an MIT research associate and the lead author of the new study.
Gregory Stephanopoulos, the Willard Henry Dow Professor in Chemical Engineering, and Gerald Fink, the Margaret and Herman Sokol Professor at the Whitehead Institute of Biomedical Research and the American Cancer Society Professor of Genetics in MIT's Department of Biology, are the senior authors of the paper, which appears today in Science Advances.
Boosting tolerance
Currently, around 40 percent of the U.S. corn harvest goes into ethanol. Corn is primarily a food crop that requires a great deal of water and fertilizer, so plant material known as cellulosic biomass is considered an attractive, noncompeting source for renewable fuels and chemicals. This biomass, which includes many types of straw, and parts of the corn plant that typically go unused, could amount to more than 1 billion tons of material per year, according to a U.S. Department of Energy study -- enough to substitute for 30 to 50 percent of the petroleum used for transportation.
However, two major obstacles to using cellulosic biomass are that cellulose first needs to be liberated from the woody lignin, and the cellulose then needs to be further broken down into simple sugars that yeast can use. The particularly aggressive preprocessing needed generates compounds called aldehydes, which are very reactive and can kill yeast cells.
To overcome this, the MIT team built on a technique they had developed several years ago to improve yeast cells' tolerance to a wide range of alcohols, which are also toxic to yeast in large quantities. In that study, they showed that spiking the bioreactor with specific compounds that strengthen the membrane of the yeast helped yeast to survive much longer in high concentrations of ethanol. Using this approach, they were able to improve the traditional fuel ethanol yield of a high-performing strain of yeast by about 80 percent.
In their new study, the researchers engineered yeast so that they could convert the cellulosic byproduct aldehydes into alcohols, allowing them to take advantage of the alcohol tolerance strategy they had already developed. They tested several naturally occurring enzymes that perform this reaction, from several species of yeast, and identified one that worked the best. Then, they used directed evolution to further improve it.
"This enzyme converts aldehydes into alcohols, and we have shown that yeast can be made a lot more tolerant of alcohols as a class than it is of aldehydes, using the other methods we have developed," Stephanopoulos says.
Yeast are generally not very efficient at producing ethanol from toxic cellulosic feedstocks; however, when the researchers expressed this top-performing enzyme and spiked the reactor with the membrane-strengthening additives, the strain more than tripled its cellulosic ethanol production, to levels matching traditional corn ethanol.
Abundant feedstocks
The researchers demonstrated that they could achieve high yields of ethanol with five different types of cellulosic feedstocks, including switchgrass, wheat straw, and corn stover (the leaves, stalks, and husks left behind after the corn is harvested).
"With our engineered strain, you can essentially get maximum cellulosic fermentation from all these feedstocks that are usually very toxic," Lam says. "The great thing about this is it doesn't matter if maybe one season your corn residues aren't that great. You can switch to energy straws, or if you don't have high availability of straws, you can switch to some sort of pulpy, woody residue."
The researchers also engineered their aldehyde-to-ethanol enzyme into a strain of yeast that has been engineered to produce lactic acid, a precursor to bioplastics. As it did with ethanol, this strain was able to produce the same yield of lactic acid from cellulosic materials as it does from corn.
This demonstration suggests that it could be feasible to engineer aldehyde tolerance into strains of yeast that generate other products such as diesel. Biodiesels could potentially have a big impact on industries such as heavy trucking, shipping, or aviation, which lack an emission-free alternative like electrification and require huge amounts of fossil fuel.
"Now we have a tolerance module that you can bolt on to almost any sort of production pathway," Stephanopoulos says. "Our goal is to extend this technology to other organisms that are better suited for the production of these heavy fuels, like oils, diesel, and jet fuel."
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The research was funded by the U.S. Department of Energy and the National Institutes of Health.
Written by Anne Trafton, MIT News Office
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