PROCESS FOR RECOVERING CARBOXYLIC ACIDES FROM A FERMENTATION BROTH

WIPO Patent Application WO/2000/020620

A2

Carboxylic acids are recovered from a fermentation broth by adjusting the viscosity of the fermentation broth and then contacting the fermentation broth with a liquid extractant to extract the carboxylic acids from the broth.

JP3310008	OLIGOSACCHARIDE OXIDASE, PRODUCTION OF OLIGOSACCHARIDE OXIDASE, DETERMINATION OF OLIGOSACCHARIDE, PRODUCTION OF OLIGOSACCHARIDE ACID AND DETERMINATION OF AMYLASE ACTIVITY
WO/2012/036003	PRODUCTION METHOD FOR CHEMICALS BY CONTINUOUS FERMENTATION
JP2001231589	METHOD OF FERMENTING LACTIC ACID

Vice, Gilbert H. (445 Wellesley Cincinnati, OH, 45224, US)
Staley, Michael D. (10541 Lemarie Drive Cincinnati, OH, 25241, US)
Rebrovic, Louis (5195 Jay Drew Drive Shandon, OH, 45063, US)
Kozak, William G. (129 Katherine Way Hatfield, PA, 19440, US)

PCT/US1999/020901

April 13, 2000

October 05, 1999

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COGNIS CORPORATION (Suite 200 2500 Renaissance Boulevard Gulph Mill, PA, 19406, US)

C12P7/40; C12P7/44; C12P7/40; (IPC1-7): C12P17/00; C12P7/40; C12P7/42; C12P7/44; C12P7/46; C12P7/48; C12P7/50; C12P7/52; C12P7/54; C12P7/56; C12P7/58; C12P17/16; C12P17/18

Drach, John E. (Cognis Corporation Suite 200 2500 Renaissance Boulevard Gulph Mills, PA, 19406, US)
Trzaska, Steven J. (Cognis Corporation 2500 Renaissance Boulevard Gulph Mills, PA, 19406, US)

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the chromosomal POX5 gene and the chromosomal POX4A and POX4B genes are disrupted in a culture medium comprised of a nitrogen source, an organic substrate and a cosubstrate wherein said substrate is selected from the group consisting of a saturated aliphatic compound having at least one terminal methyl group, a terminal carboxyl group and/or a terminal functional group which is oxidizable to a carboxyl group by biooxidation, an unsaturated aliphatic compound having at least one internal carbon-carbon double bond and at least one terminal methyl group, a terminal carboxyl group and/or a terminal functional group which is oxidizable to a carboxyl group by biooxidation and combinations thereof; (2) adjusting the viscosity of the fermentation broth to form a flowable liquid ; (3) contacting the fermentation broth with a liquid extractant suitable for the extraction of the carboxylic acid.22. The process of claim

1.	21 wherein said substrate is an unsaturated aliphatic compound having at least one internal carboncarbon double bond and at least one terminal methyl group, a terminal carboxyl group and/or a terminal functional group which is oxidizable to a carboxyl group by biooxidation.

2.	23 The process of claim 22 wherein the process further comprises the step of reacting the product of step (3) with an oxidizing agent to produce one or more polycarboxylic acids.

3.	24 The process of claim 21 wherein step (3) further comprises adjusting the pH of the fermentation broth prior to the extraction.

4.	The process of claim 21 wherein the viscosity of the fermentation broth is adjusted by heating said broth to from at least about 50°C to about 75°C.

5.	The process of claim 25 wherein the viscosity of the fermentation broth is adjusted by heating said broth to from about 60°C to about 75°C.

6.

The process of claim 21 wherein the extractant is selected from the group consisting of C7C16 straight chain hydrocarbons, C8C16 branched chain hydrocarbons, linear and branched alcohols, ketones, aromatic compounds, chlorinated alkanes, dialkyl ethers, alkylcarbonates, esters of the formula: ROOCR', wherein R is a C1C10 linear or branched alkyl or alkenyl group, or a substituted or unsubstituted phenyl group and wherein R'is a C1C10 linear or branched alkyl or alkenyl group, or a substituted or unsubstituted phenyl group, and combinations thereof.

7.	The process of claim 27 wherein the extractant is 1octanol.

8.	The process of claim 27 wherein the extractant is 2octanol.

9.	The process of claim 21 wherein the broth is contacted by the extractant in a continuous manner.

10.	The process of claim 21 wherein the pH of the fermentation broth is adjusted to from about 1.5 to about 7, prior to contacting the broth with the liquid extractant.

11.	The process of claim 31 wherein the pH of the broth is adjusted to about 5 to about 6.

12.	The process of claim 31 wherein the pH of the broth is adjusted by the addition of a mineral acid.

13.	The process of claim 33 wherein the mineral acid is selected from the group consisting of arsenic, hydrobromic, hydrochloric, chloric, iodic, nitric, nitrous, phosphoric, phosphorous, hypophosphorous, pyrophosphoric, sulfuric, sulfurous, thiosulfuric, tellurous and combinations thereof.

14.	The process of claim 33 wherein the pH of the broth is adjusted by the addition of an acid having a pKa value of less than the pKa value of the carboxylic acid to be recovered from the fermentation broth.

15.	The process of claim 33 wherein the process further comprises the step of heating the broth to about just below the boiling point of the liquid extractant prior to the extraction step.

16.	The process of claim 21 further comprising the step of cooling the extractant after the extraction is complete.

17.	The process of claim 21 wherein said carboxylic acid is a polycarboxylic acid.

18.	The process of claim 38 wherein said polycarboxylic acid is a dicarboxylic acid.

19.

The process of claim 39 wherein said dicarboxylic acid is selected from the group consisting of oxalic acid, maleic acid, succinic acid, glutaric, adipic acid, pimelic acid, phthalic acid, azelaic acid, sebacic acid, dodecanedioic acid, brassylic acid, 9octadecenedioic acid, C36dimer acid and combinations thereof.

20.	The process of claim 21 wherein said C. tropicalis cell is H5343.

21.	The process of claim 21 wherein the substrate is oleic acid.

22.	The process of claim 22 wherein the oxidizing agent is ozone.

23.	The product of the process of claim 21.

24.

A process for making azelaic acid comprising the steps of: (1) fermenting a betaoxidation blocked C. tropicalis cell wherein both copies of the chromosomal POX5 gene and the chromosomal POX4A and POX4B genes are disrupted in a culture medium comprised of a nitrogen source, oleic acid and a cosubstrate; (2) adjusting the viscosity of the fermentation broth to form a flowable liquid ; (3) extracting the 9octadecenedioic acid with a liquid extractant; (4) reacting the product of step (3) with an oxidizing agent to produce azelaic acid.

25.	The process of claim 45 wherein the oxidizing agent is ozone.

INTERNATIONALSEARCHREPORTInternationalapplicationNo PCT/US99/20901 C(Continuation).DOCUMENTSCONSIDEREDTOBERELEVANT Category* Citationofdocument,withindication,whereappropriate,oftherele vantpassagesRelevanttoclaimNo. XWO94/10122A1(SABARINOetal.)11May1994(11.05.94).20,44 -----Seeentiredocument Y1-19,21-43and 45-46 XBUDAVARIetal.TheMerckIndex,TwelfthEdition,1996,pages20,44 ---30,155-156,223,392,761,911,940-941,973,974,1186,1345,---- --- Y1378-1379,1446,15151-19,21-43and 45-46 XUS5,254,466A(PICATAGGIOetal.)19OCTOBER199320,44 --- (19.10.93)seeentiredocument Y1-19,21-43,and 45-46 XPRESCOTT&DUNNIndustrialMicrobiology,AviPublishing20,44 Company,Westport,Connecticut,G.Reed,Ed.,1982,pages446,--- Y447,729and8021-19,21-43and 45-46 XUS4,170,595A(WESTLEYetal.)09October1979(09.10.79),20,44 -----seeentiredocument,especially,col.7,lines49-60--- Y1-19,21-43and 45-46 XUS2,813,113A(GOEBELetal.)12November1957(12.11.57),20and44 col. 1 Y45-46 INTERNATIONALSEARCHREPORTInternationalapplicationNo. PCT/US99/20901 BoxIObservationswherecertainclaimswerefoundunsearchable(Cont inuationofitem1offirstsheet) Thisinternationalreporthasnotbeenestablishedinrespectofcerta inclaimsunderArticle17(2Xa)forthefollowingreasons: 1.gClaimsNos.: becausetheyrelatetosubjectmatternotrequiredtobesearchedbythi sAuthority,namely: 2.2 ClaimsNos.: becausetheyrelatetopartsoftheinternationalapplicationthatdon otcomplywiththeprescribedrequirementstosuch anextentthatnomeaningfulinternationalsearchcanbecarriedout,s pecifically: 3.ClaimsNos.: becausetheyaredependentclaimsandarenotdraftedinaccordancewit hthesecondandthirdsentencesofRule6.4(a). Box 11 Observationswhereunityofinventionislacking(Continuationofite m2offirstsheet) ThisInternationalSearchingAuthorityfoundmultipleinventionsin thisinternationalapplication,asfollows: PleaseSeeExtraSheet. 1.As all wquixdadditionalsearchfeesweretimelypaidbytheapplicant,thisi nternationalsearchreportcoversallsearchable u claims. 2.FAsallsearchableclaimscouldbesearchedwithouteffortjustifyi nganadditionalfee,thisAuthoritydidnotinvitepayment ofanyadditionalfee. 3.Asonlysomeoftherequiredadditionalsearchfeesweretimelypaidb ytheapplicant,thisinternationalsearchreportcovers onlythoseclaimsforwhichfeeswerepaid,specificallyclaimsNos.: 4.| Norequiredadditionalsearchfeesweretimelypaidbytheapplicant.C onsequently,thisinternationalsearchreportis restrictedtotheinventionfirstmentionedintheclaims;itiscovere dbyclaimsNos.: RemarkonProtestTheadditionalsearchfeeswereaccompaniedbytheap plicant'sprotest. Noprotestaccompaniedthepaymentofadditionalsearchfees. INTERNATIONALSEARCHREPORTInternationalapplicationNo. PCT/US99/2090 1 A.CLASSIFICATIONOFSUBJECTMATTER: IPC(7): C12P 7/50,7/48,7/46,7/44,7/42;C07C63/00,63/04,63/33,63/64, 65/00,65/32,57/03,53/08,53/122,53/124,53/126 A.CLASSIFICATIONOFSUBJECTMATTER: USCL: 435/119,118,117,136,137,138,139,140,141,142,143,144,145,146, 172.1,172.3; 601,609,553,433,590;554/224,124 BOX11.OBSERVATIONSWHEREUNITYOFINVENTIONWASLACKING ThisISAfoundmultiple inventionsasfollows: Thisapplicationcontainsthefollowinginventionsorgroupsofinven tionswhicharenotsolinkedastoformasingle inventiveconceptunderPCTRule13.1. Inorderforallinventionstobesearched,theappropriateadditional searchfees mustbepaid. GroupI,claims1-19,drawntoaprocessofrecoveringacarboxylicacid byalteringviscosityofthesolution. GroupII,claim(s)20and44,drawntoanycarboxylicacid,respectivel yanyaliphaticcarboxylicacidproducedby fermentation. GroupIII,claims21-43and44-46,drawntoaprocessofproducinganali phaticcarboxylicacidbyfermentationwith C.tropicalis. TheinventionslistedasGroups1-111donotrelatetoasinglegenerali nventiveconceptunderPCTRule13.1 because,underPCTRule13.2,theylackthesameorcorrespondingspeci altechnicalfeaturesforthefollowingreasons: First,theinventionsofgroups1-111donotmatchapermittedcategory asPCTRule13.2doesnotprovidefor multiplemethodsinonecategory.Twopatentablydistinctprocessesl ackingacommoninventiveconceptareclaimed, i.e.,aprocessofrecoveringanycarboxylicacidfromafermentationw ithanymicroorganismandaprocessofusinga specificmicrobialstrainhavingspecificpropertiesfortheproduct ionofaliphaticcarboxylicacidsunderspecific fermentationconditions. Second,acommoninventiveconceptislackingbetweengroupsIorIIIan dgroupII,inviewofTheMerck Index,whichdemonstratesthatthecompositionsofGroup11,i.e.,car boxylicacidsoraliphaticcarboxylicacids,lack novelty.See,e.g.,IndustrialMicrobiology,pages446-447,729and8 02,fortheproductionofvariouscarboxylicacids, suchaslactic,pyruvic,citricandaceticacids.Therefore,thesecom positionslackthosetechnicalfeaturesthatdefinea contributionwhicheachoftheinventionsconsideredasawhole,makes overthepriorart. NocommoninventiveconceptissharedamonggroupsIandIIandIIIand11 ,sincetheprocessofGroupIor ofGroupIIIasclaimedisnotspeciallyadaptedforthemanufactureoft heproductsofGroupIIasclaimed,asshownby thecitedreferences.Therefore,atechnicalrelationshipislacking amongtheclaimedinventionsinvolvingoneormore specialtechnicalfeatures.

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