Production of advanced biofuels in engineered E. coli

Production of advanced biofuels in engineered E. coli

COCHBI-1053; NO. OF PAGES 8 Available online at www.sciencedirect.com Production of advanced biofuels in engineered E. coli Miao Wen, Brooks B Bond-...

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Production of advanced biofuels in engineered E. coli Miao Wen, Brooks B Bond-Watts and Michelle CY Chang Commercial fermentation processes have long taken advantage of the synthetic power of living systems to rapidly and efficiently transform simple carbon sources into complex molecules. In this regard, the ability of yeasts to produce ethanol from glucose at exceptionally high yields has served as a key feature in its use as a fuel, but is also limited by the poor molecular properties of ethanol as a fuel such as high water miscibility and low energy density. Advances in metabolic engineering and synthetic biology allow us to begin constructing new high-flux pathways for production of next generation biofuels that are key to building a sustainable pipeline for liquid transportation fuels. Addresses Departments of Chemistry and Molecular & Cell Biology, University of California, Berkeley, CA 94720-1460, USA Corresponding author: Chang, Michelle CY ([email protected])

Current Opinion in Chemical Biology 2013, 17:xx–yy This review comes from a themed issue on Energy Edited by Stephen Mayfield and Michael D Burkart

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Introduction Living systems offer a unique solution to targeted chemical synthesis, providing a diverse array of transformations to build inexpensive and sustainable routes to the production of fine and commodity chemicals from simple renewable carbon sources like glucose [1–6]. One major area in which microbial synthesis has been tapped is the production of liquid transportation fuels from renewable plant biomass carbon sources. In this case, the domestication of yeasts throughout human history has allowed the establishment of strains that produce ethanol at near quantitative yield from glucose, which make it the dominant biofuel to date on the basis of the direct relationship between yield and net economic, energy, and carbon balance for fuels [7,8]. However, the low energy density and high water miscibility of ethanol create major limitations in developing a sustainable biofuel pipeline [9–12]. Thus, the development of microbial strains with the ability to produce drop-in gasoline or diesel additives and replacements, — such as longer chain alcohols, esters, and alkanes, — would allow us to begin stepping beyond these issues (Figure 1a). www.sciencedirect.com

A major roadblock in the development of new fermentation processes is that naturally occurring microbial hosts that combine production of desirable gasoline and diesel targets with the efficiency of yeast fermentation have yet to be identified. In this regard, advances in metabolic engineering and synthetic biology offer the opportunity to engineer pathways for the production of advanced biofuel targets in a well-studied and industrially relevant host [13–16]. One challenge is that the metabolic logic underlying the design of high-flux pathways for these advanced targets is quite different from the production of ethanol, which has several advantageous features for high yield. First, ethanol is made directly from pyruvate as a fermentation product that balances the redox requirements of glycolysis (Figure 1b). As a result, its production is required for survival of the host under anaerobic conditions, allowing glycolysis to continue as the sole source of ATP, which generates a selective pressure for quantitative yield from glucose and limits the spread of carbon through the metabolic network. Furthermore, the first step in its biogenesis is the decarboxylation of pyruvate, creating an irreversible sink to drive the pathway equilibrium to completion and immediately commit carbon to its production. In contrast, next-generation fuels are assembled from building blocks derived from pathways that extend beyond glycolysis, which makes their biosynthesis more complex as this aspect greatly expands both the number of metabolic transformations and competing pathways involved (Figure 1b). In addition, the biosynthetic pathways for the production of these advanced targets require many more steps than for ethanol and therefore more components to manage in order to engineer high flux to the end product. In this context, we will discuss the construction of several different engineered pathways for the production of advanced biofuel targets in Escherichia coli.

Production of short-chain alcohols from branched amino acids The addition of two carbons to ethanol to make a C4 alcohol greatly reduces its solubility in water (7 g/L) while also increasing its energy density [13]. Thus, C4 and other short-chain alcohols are currently regarded as the next-generation biofuel to replace ethanol. Besides the energetic benefits, they can also be blended at high percentage with gasoline to meet future government mandates or perhaps even be used as a drop-in fuel for traditional combustion engines [17,18]. Isobutanol has been observed as trace products of microbial amino acid metabolism through the Erlich degradation pathway for 2-keto acids, which are converted to alcohols in two steps (Figure 2a) [19,20]. Like for ethanol production, this Current Opinion in Chemical Biology 2013, 17:1–8

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The production of advanced biofuels. (a) Structures of advanced fuel targets compared to ethanol. (b) Pathways to advanced biofuels from building blocks derived from central metabolism.

Figure 2

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Current Opinion in Chemical Biology

The production of alcohols from amino acid metabolism. (a) Construction of pathways for isobutanol, n-butanol, and n-propanol from amino acid metabolism. (b) The design of a ‘‘+1’’ pathway for linear alcohols inspired by branched chain amino acid biosynthesis. (c) Engineering nitrogen metabolism to produce alcohols from protein hydrolysates (blue, nitrogen flow; grey, carbon flow). Current Opinion in Chemical Biology 2013, 17:1–8

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Production of advanced biofuels in engineered E. coli Wen, Bond-Watts and Chang 3

particular pathway has the advantage that it can also be driven forward by an irreversible decarboxylation. Work from both academic [21] and industrial groups [22] has shown that this pathway can be exploited to produce a broad range of products by engineering endogenous amino acid metabolism as well as the degradation of 2keto acids. The initial insertion of the Erlich degradation pathway consisting of a broad specificity 2-keto acid decarboxylase (KDC) and alcohol dehydrogenase (ADH) resulted in the production of 1-propanol, 1-butanol, isobutanol, 2methyl-1-butanol, 3-methyl-1-butanol, and 2-phenylethanol in E. coli [21]. On the basis of feeding experiments, the limited availability of 2-keto acid precursors was identified as the pathway bottleneck. Isobutanol titers were therefore improved by overexpressing genes converting pyruvate to 2-ketoisovalerate (alsS and ilvCD), the precursor to isobutanol (Figure 2a). Upon deletion of the gene encoding pyruvate-formate lyase to decrease competition for pyruvate, the engineered E. coli host was able to produce 22 g/L of isobutanol at a yield of 86% of the theoretical maximum [21]. In addition to isobutanol, n-butanol and n-propanol can be produced from 2-ketovalerate by engineering its production from the threonine production pathway (Figure 2a) [23]. The high efficiency of this pathway opens the door for expanded engineering applications, such as new host organisms [24,25] or alcohol products [26]. Since the chain length of the alcohols derived from this pathway is limited by the carbon number in the amino acid pathways, a ‘‘+1’’ pathway derived from the chain extension in leucine biosynthesis has been used to increase the size of the 2-keto acid precursors for alcohol production (Figure 2b) [27]. Another interesting advantage of using amino acid precursors for fuel production is that these pathways provide an alternative use for the protein hydrolysates resulting from microbial fermentations. In order to access these substrates, the carbon skeleton must be released from the amino acid rather than being trapped within nitrogen metabolism by engineering nitrogen flux [28]. To start, amino acids were denitrified by introducing three different transamination and deamination cycles, thereby releasing high levels of ammonia (Figure 2c). To divert carbon flux into alcohol synthesis, a metabolic driving force was created by blocking ammonia from re-entry into cell metabolism. By creating this sink, a mixture of alcohols can be produced at high titers (4.0 g/ L) and yields (56% of theoretical yield) from protein sources.

Production of short-chain alcohols from acetyl-CoA In addition to the production of isobutanol from amino acids, n-butanol can be synthesized directly from acetylCoA in an analogous fashion to fatty acid biosynthesis www.sciencedirect.com

(Figure 3a). n-Butanol is naturally produced by Clostridium acetobutylicum as part of its native fermentation pathways as a mixture of acetone, n-butanol, and ethanol (ABE), a process which was first industrialized in the 1920s [29]. In an effort to improve industrial production, this pathway was transplanted directly into yeast and E. coli but was limited to n-butanol production yields of <1% to 10% [15,30–32], which is significantly lower than the yield in the native butanologenic host (45%). These results suggest that the enzymatic pathway from C. acetobutylicum is limited in its ability to produce n-butanol at high flux in heterologous hosts, with studies implicating the enoyl-CoA reduction step as the bottleneck in the pathway [31,33]. The dependence of n-butanol production on the enoylCoA reduction step led our group to further evaluate its role in controlling pathway flux [33]. Interestingly, E. coli native metabolism does not appear to react with butyryl-CoA while feeding of crotonyl-CoA in the presence of the heterologously expressed pathway lead to reversion to its precursor, 3-hydroxybutyryl-CoA. These observations indicate that the enoyl-CoA reduction may be particularly important for drawing carbon away from the reversible and non-committed steps early in the pathway (PhaA, Keq  10 5; Crt, Keq  10 1) and that an effectively irreversible step was required at this node to drive the pathway equilibrium to completion. Since the thermodynamics of the enoyl-CoA reduction step could not be changed, we utilized a kinetic trap approach instead by replacing the native enoyl-CoA reductase (butyryl-CoA dehydrogenase, Bcd) from C. acetobutylicum with trans-enoyl-CoA reductase (Ter), a mechanistically distinct enzyme with a high kinetic barrier to the back reaction related to its use of a single NADH co-factor [33], leading to 1500-fold amplification in titer, compared to our original pathway design, to >4 g/L (41% of theoretical yield). To evaluate the contribution of Ter as a kinetic trap, we took advantage of its ability to biochemically distinguish trans-butenoyl-CoA and cis-butenoylCoA as substrate. Although the catalytic efficiency of Ter with respect to cis-butenoyl-CoA is 105-fold lower compared to trans-butenoyl-CoA, the n-butanol titer only drops by 10-fold with the incorrect stereochemistry, which demonstrates that the kinetic trapping behavior appears to be the key feature of Ter for increasing flux through the synthetic pathway. This effective irreversibility can be further used to amplify n-butanol titers through anaerobic production in engineered E. coli strains with fermentation pathways knocked out, leading to product titers of 30 g/L under fed-batch conditions [34]. n-Butanol can also be produced by engineering the native metabolism of E. coli and deregulating pathways already present in the host. In this regard, the native boxidation machinery has been engineered to proceed in reverse to synthesize rather than degrade fuel-like molecules [35] (Figure 3b). As such, this pathway is quite Current Opinion in Chemical Biology 2013, 17:1–8

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Figure 3

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The production of n-butanol from acetyl-CoA. (a) A synthetic pathway for the production of n-butanol on the basis of the clostridial pathway. (b) nButanol production by enabling reversal b-fatty acid oxidation. The outside cycle (black) depicts enzymes possibly involved in n-butanol synthetis. The inner cycle (grey) depicts enzymes in the b-fatty acid oxidation pathway.

similar in its reaction chemistry to the pathways inspired by C. acetobutylicum described above, which are also ATP-independent on the basis of the use of a thiolase to avoid the utilization of malonyl-CoA. An active pathway was constructed by manipulating b-oxidation pathway regulators and catabolic repressors, and overexpressing an endogenous aldehyde dehydrogenases. Titers were further improved by overexpression of various enzymes in the pathway, increasing n-butanol titer to 2 g/L. It is interesting to note that the catalytic activity at each node along the n-butanol pathway is Current Opinion in Chemical Biology 2013, 17:1–8

approximately the same, which suggests that the buildup of pathway intermediates is prevented. In combination with the thermodynamic driving force from diffusion of butanol into bulk media, the carbon is pulled into the engineered n-butanol pathway despite the reversibility of first thiolase-dependent reaction.

Production of diesel targets from acetyl-CoA Beyond gasoline targets, longer-chain products in the diesel range (C12–C20) provide the largest benefit for increasing energy density and reducing the energetic cost www.sciencedirect.com

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Figure 4 (a)

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The production of biodiesel from acetyl-CoA. (a) Biosynthesis and tailoring of fatty acids (TE, thioesterase; ACL, acyl-CoA ligase). (b) Engineering the isoprenoid pathway for the production of biodiesels.

for product separation. Two major metabolic routes to hydrocarbons of this chain length have been engineered from fatty acid biosynthesis and the isoprenoid pathway, both of which utilize the acetyl-CoA building block to build the backbone (Figure 1b). However, each pathway offers different advantages with respect to fuel production in terms of yields and product diversity. Fatty acid esters derived from plant oils are already in use today as biodiesels, but are costly to produce from an agricultural perspective [36]. Thus, microbial fermentation provides an option with greater potential for longterm sustainability. Overall, the engineering of fatty acidderived biodiesels breaks down into two phases, biosynthesis of fatty acids and their tailoring to produce the desired product (Figure 4a). Fatty acid biosynthesis is highly regulated at several different points because the intermediate acyl-ACP is primarily converted to membrane phospholipids. One of the most important control www.sciencedirect.com

points is the feedback inhibition by fatty-acyl ACPs of acetyl-CoA carboxylase (ACCase), which catalyzes the ATP-dependent carboxylation of acetyl-CoA to form malonyl-CoA as the first committed step in fatty acid biosynthesis [37]. Two approaches have been taken to increase the malonyl-CoA pool by overexpressing the ACCase [38] as well as an acyl-ACP thioesterase to release the free fatty acid product [38,39]. Since free fatty acids are degraded back to acetyl-CoA, the b-oxidation pathway is also blocked by deletion of either fadD or fadE. The productivity of these engineered strains has been found to increase the free fatty acid content of E. coli by 20–40-fold to produce 1200–1500 mg/L of product at yields that are 6–14% of the theoretical limit [38,39]. Although these genetic modifications substantially increase the free fatty acid content, additional cell-free [40] and in vitro [41] studies of fatty acid biosynthesis have the potential to provide new insight into additional strategies to amplify fatty acid titers and yields. Current Opinion in Chemical Biology 2013, 17:1–8

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A variety of strategies have been explored for converting fatty acids into different biofuels, such as alcohols, esters, and alkanes (Figure 1a). As fatty acid esters are already currently in use, initial efforts have focused on engineering their production in vivo rather relying on post-fermentation chemical processing. In this regard, a pathway for the production of fatty acid ethyl esters (FAEE) has been incorporated into fatty acid overproduction strains by insertion of an acyl-CoA ligase and a broad-specificity acyltransferase [42,43] along with two enzymes to provide ethanol for transesterification (Figure 4a) [39]. Since extension of the pathway to the FAEE drops productivity twofold to 700 mg/L, it is likely that metabolic imbalance related to rapid accumulation of ethanol and secretion of free fatty acids is limiting in this system. Therefore, a dynamic sensor-regulator system was designed to tune the expression of the ethanol and FAEE production modules in response to acyl-CoA availability. Upon introduction of a FadR-based biosensor, the extracellular accumulation of free fatty acid decreased and led to an overall increase of FAEE production from 9.4% to 28% of the maximum theoretical yield [44]. To expand the promise of utilizing engineered E. coli for biodiesel production on an industrially relevant scale, a consolidated bioprocess has been developed to allow the FAEE-producing E. coli to use cellulose and hemicellulose from ionic liquid-pretreated switchgrass as carbon source at 80% of estimated theoretical yield [45]. Beyond fatty acid esters, the fermentation product that would most closely reproduce diesel is a mixture of alkanes. Alkanes have been reported in a diversity of microorganisms, including cyanobacteria, and are found to contain an odd number of carbons. Since heptadecane is the most abundant alkane reported, it appears that alkanes are derived from the ‘‘n 1’’ decarbonylation of aldehydes. The two genes involved in this process were found in Synechococcus elongatus by comparative genome analysis and used to engineer the alkane production in E. coli [46]. In conjunction with the identification of a gene involved in ‘‘n + 1’’ pathways [47], these discoveries provide promise for our ability to access deoxygenated hydrocarbons through this pathway. Isoprenoids are another class of hydrocarbons made in biological systems that could serve as biodiesels. It has been demonstrated that E. coli is able to produce sesquiterpene at high titer (27 g/L) when a heterologous mevalonate pathway is introduced to bypass the regulation of native deoxyxylulose-5-phosphate pathway the (Figure 4b) [48]. Because of the modularity of isoprenoid biosynthesis, this strain can also be utilized for the production of any C15 product by simply changing the terpene synthase. In this regard, bisabolane, the hydrogenated product of bisabolene, has been demonstrated to be a biosynthetic alternative to D2 diesel fuel (Figure 4b) [49]. Since terpene synthases catalyze the cyclization of FPP with loss of pyrophosphate, they have been found to Current Opinion in Chemical Biology 2013, 17:1–8

act as an irreversible sink that controls product titers. Thus, five bisabolene synthases from plants were screened for their productivity for bisabolene. Upon codon-optimization of the best candidate, bisabolene could be produced at 900 mg/L and isolated for reduction to the biodiesel product. Because of the strong influence of the terpene synthase on productivity, further discovery or engineering efforts to optimize their activity will allow the construction of strains with higher fuel yields.

Conclusions Advanced biofuels offer significant advantages in terms of fuel properties and process design, however these pathways remain challenging to engineer with the efficiency and robust performance of yeast ethanol production. Towards this goal, high-flux pathways for production of both gasoline and diesel range fuels can be constructed with the introduction of a sink or driving force to push the pathway equilibrium to completion. In addition, advances in downstream chemical processing of shorter chain products can allow upgrading of these fuels for biodiesel production [50,51].

Acknowledgements Research in our laboratory is funded by the generous support of the University of California, Berkeley, the Energy Biosciences Institute, the Camille and Henry Dreyfus Foundation, the Arnold and Mabel Beckman Foundation, the Dow Sustainable Products and Solutions Program, the Agilent Foundation, the Hellman Family Foundation, the National Science Foundation, the National Institutes of Health, the Department of Energy, and the Defense Advanced Research Projects Agency.

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Please cite this article in press as: Wen M, et al.: Production of advanced biofuels in engineered E. coli, Curr Opin Chem Biol (2013), http://dx.doi.org/10.1016/j.cbpa.2013.03.034