Bioconversion of coal-derived synthesis gas to liquid fuels. Final report, September 29, 1992--December 27, 1994

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The proposed research project consists of an integrated, two-stage fermentation and a highly energy-efficient product separation scheme. In the first fermentation, Butyribacterium methylotrophicum converts carbon monoxide (CO) into butyric acid and acetic acids which are then converted into butanol, ethanol, and a small amount of acetone in the second stage fermentation by Clostridium acetobutylicum. An advanced separation system process, based on pervaporation, removes the alcohols from the fermentation broth as they are formed, along with some of the hydrogen sulfide (H{sub 2}S), to minimize possible inhibition of the fermentations. This bioconversion process offers a critical advantage over conventional, catalytic processes for synthesis gas conversion: the microorganisms are several orders of magnitude more sulfur tolerant than metallic catalysts. The catalysts require sulfur removal to the parts per million level, while the microorganisms are unaffected by H{sub 2}S and carbonyl sulfide (COS) at one part per hundred--roughly the composition of sulfur in raw synthesis gas. During the two-year course of this project, the following major objectives have been accomplished: demonstrated long-term cell recycle of continuous fermentation of synthesis gas; demonstrated cell immobilization of Butyribacterium methylotrophicum; identified trickle-bed reactor as a viable alternative fermentation method; modulated metabolic pathways to increase C4 formation during synthesis gas fermentation; recovered carbon and electrons from H{sub 2} and CO{sub 2} with pathway modulation for increased C4 production; developed bacterial strains with improved selectivity for butyrate fermentation; demonstrated two-stage CO to alcohol fermentation; and concentrated alcohol from solventogenic fermentation by pervaporation.