Gaprin is the trade name of a type of protein-vitamin concentrates produced in the USSR and in the post-Soviet space. A natural gas fermentation protein biomass derived from inactivated cells of non-pathogenic methane-oxidizing yeast[1][2] or bacteria[3]. In addition to a mixture of nutrient salts, amino acids, etc., natural gas is also used as the key component of the nutrient medium of microorganisms.
Historical background
Possible use of the biomass of methane-oxidizing microorganisms as a protein component in the feed of farm animals and in human food began to be considered as a promising area of research in the early 60s of the past century, almost simultaneous, to research on the technology of obtaining protein substances from non-traditional raw materials - oil hydrocarbons and alcohols.
In 1966-1968, a number of reports on the work with methane-oxidizing microorganisms for the purpose of industrial protein synthesis were published, which research was carried out in a number of research institutes and companies:
• Gas Technology Institute (Chicago, USA);
• Institute of Limnology (Max Planck Society, Plön, Germany);
• Northern Illinois Gas Company (USA);
• British Petroleum (United Kingdom);
• Shell International Research (USA, Holland), etc.
In the Soviet Union, work on the creation of an industrial technology for the production of protein substances from natural gas began in 1964 at the VNIISintezbelok Institute practically along with the creation of the institute itself, which primary purpose was to develop the scientific foundations of the technology for the production of feed protein from various types of raw materials, in particular from n- paraffins of oil, natural gas, diesel fuel, synthetic alcohols, etc., and the creation of an industrial technology for the production of protein substances from these types of raw materials.
In 1969, an Intergovernmental Agreement on the development of technologies for the production of microbiological protein from hydrocarbon raw materials was signed between the USSR and the GDR. Within the framework of this agreement, a 20-year program was developed, the ultimate goal of which was the creation of an industrial plant for the microbiological deparaffinization of diesel fuel with the production of feed protein in the city of Schwedt on the territory of the GDR and the creation of the production of feed protein from natural gas of the initial with a capacity of 10,000 tons per year on the territory of the USSR. Based on the results of the pilot plant reaching the indicated capacity, the final Soviet-German (GDR) document was drawn up, reflecting the key materials on the technology developed at the level of the then available technological and hardware solutions.
Testing of biomass from natural gas as a source of protein in animal, poultry, fish feeds were carried out in two main basic stages. The first stage of testing commenced in 1972, using experimental batches of biomass from natural gas. At this stage, studies on the safety and nutritional value of biomass for animals, as well as of animal products obtained by using biomass from natural gas as part of the diets of farm animals, poultry and fish were carried out. On a parallel track, similar tests were carried out by research organizations of the former GDR. The results of these tests allowed to proceed to the second stage of research. Temporary regulatory documents for the production and use of biomass from natural gas were approved. The second stage of testing began in 1984 and included comprehensive zootechnic and veterinary tests, as well as extensive production testing of biomass from natural gas as a microbiological feed additive on a large population of farm animals, poultry and fish in various regions across the country. More than 30 medical and agricultural research institutions, as well as large livestock-rearing farms, poultry factories, and fish farms took part in the tests of biomass from natural gas. The results of the tests carried out within the framework of the second stage confirmed the data on the safety and nutritional value of biomass from natural gas when used as a source of protein in feeding animals, poultry, fish, as well as on the safety of food products obtained by using biomass from natural gas, and validated expediency of production of industrial batches of biomass from natural gas. Initially, temporary regulatory and technical documentation for the product was approved (technical specifications, guidelines on the use of biomass from natural gas). Based on the results of long-term industrial production of biomass from natural gas (1985-1994) and verification of the results of using biomass from natural gas with its widespread application in feeding farm animals, poultry, fish, standing technical specifications for biomass from natural gas (gaprin) and standards for the use of biomass from natural gas in the composition of animal feed and feed mixtures were approved.
In 1966-1968, a number of reports on the work with methane-oxidizing microorganisms for the purpose of industrial protein synthesis were published, which research was carried out in a number of research institutes and companies:
• Gas Technology Institute (Chicago, USA);
• Institute of Limnology (Max Planck Society, Plön, Germany);
• Northern Illinois Gas Company (USA);
• British Petroleum (United Kingdom);
• Shell International Research (USA, Holland), etc.
In the Soviet Union, work on the creation of an industrial technology for the production of protein substances from natural gas began in 1964 at the VNIISintezbelok Institute practically along with the creation of the institute itself, which primary purpose was to develop the scientific foundations of the technology for the production of feed protein from various types of raw materials, in particular from n- paraffins of oil, natural gas, diesel fuel, synthetic alcohols, etc., and the creation of an industrial technology for the production of protein substances from these types of raw materials.
In 1969, an Intergovernmental Agreement on the development of technologies for the production of microbiological protein from hydrocarbon raw materials was signed between the USSR and the GDR. Within the framework of this agreement, a 20-year program was developed, the ultimate goal of which was the creation of an industrial plant for the microbiological deparaffinization of diesel fuel with the production of feed protein in the city of Schwedt on the territory of the GDR and the creation of the production of feed protein from natural gas of the initial with a capacity of 10,000 tons per year on the territory of the USSR. Based on the results of the pilot plant reaching the indicated capacity, the final Soviet-German (GDR) document was drawn up, reflecting the key materials on the technology developed at the level of the then available technological and hardware solutions.
Testing of biomass from natural gas as a source of protein in animal, poultry, fish feeds were carried out in two main basic stages. The first stage of testing commenced in 1972, using experimental batches of biomass from natural gas. At this stage, studies on the safety and nutritional value of biomass for animals, as well as of animal products obtained by using biomass from natural gas as part of the diets of farm animals, poultry and fish were carried out. On a parallel track, similar tests were carried out by research organizations of the former GDR. The results of these tests allowed to proceed to the second stage of research. Temporary regulatory documents for the production and use of biomass from natural gas were approved. The second stage of testing began in 1984 and included comprehensive zootechnic and veterinary tests, as well as extensive production testing of biomass from natural gas as a microbiological feed additive on a large population of farm animals, poultry and fish in various regions across the country. More than 30 medical and agricultural research institutions, as well as large livestock-rearing farms, poultry factories, and fish farms took part in the tests of biomass from natural gas. The results of the tests carried out within the framework of the second stage confirmed the data on the safety and nutritional value of biomass from natural gas when used as a source of protein in feeding animals, poultry, fish, as well as on the safety of food products obtained by using biomass from natural gas, and validated expediency of production of industrial batches of biomass from natural gas. Initially, temporary regulatory and technical documentation for the product was approved (technical specifications, guidelines on the use of biomass from natural gas). Based on the results of long-term industrial production of biomass from natural gas (1985-1994) and verification of the results of using biomass from natural gas with its widespread application in feeding farm animals, poultry, fish, standing technical specifications for biomass from natural gas (gaprin) and standards for the use of biomass from natural gas in the composition of animal feed and feed mixtures were approved.
Stages of implementation of the technology in the USSR and the Russian Federation
From the mid-60s of the 20th century, research on the use of natural gas as a raw material for the production of microbial protein was initiated. A methane-oxidizing culture was selected and research on experimental plants in pilot industrial conditions was carried out. In the late 70s of the past century, industrial production was organized in the village of Svetly Yar. In 1983, a pilot plant for the production of biomass from natural gas with a capacity of 10,000 tons of product per year was launched at the Svetloyarsk plant of protein and vitamin concentrates (in 1983, it was known as the Soyuzprombelok Plant). Within 2 years, the plant commenced commercial operations. In 1988-1994, this facility produced about 1000 tons of biomass from natural gas per month. Later, a second similar module was designed at the plant and the total design capacity of production was estimated to comprise 30 thousand tons of feed protein per year. A total of about 40 thousand tons of biomass from natural gas was produced and sold in the period through to 1994, both for Russian households and for export supplies to Bulgaria, Israel, Turkey and Malaysia.
In 1991-1992, the crisis in the Russian economy and in the biotechnology industry caused further construction to be abandoned and production ceased in May 1994. Similar work on the creation of a technology for the production of feed protein from natural gas was carried out by Statoil (Norway). In 1990, Statoil considered the possibility of purchasing the technology for this production from the USSR. Later, Statoil acquired Dansk Bioprotein (Odense, Denmark), which brought this development to the level of pilot production. The main difference between the Dansk Bioprotein technology and the technology for obtaining biomass from natural gas developed in the USSR lies in the gas supply system - the Soviet-Russian technology provided for the partial use of methane in the process of biomass production from natural gas to obtain optimal processing methods and the subsequent use of non-utilized gases as energy raw materials. The Danish technology was aimed at maximizing the utilization of methane in the technological process with emission of exhaust gases into the atmosphere. At one time, Statoil (Norway), together with DuPont Bio-Based Materials (USA) were the only companies that produced bioproteins from natural gas on a large industrial scale. A product similar to gaprin, which was produced at this European-based enterprise, was approved for use and became widely used in agriculture in the EU countries. However, the production was shut down in 2004-2005.
In 1991-1992, the crisis in the Russian economy and in the biotechnology industry caused further construction to be abandoned and production ceased in May 1994. Similar work on the creation of a technology for the production of feed protein from natural gas was carried out by Statoil (Norway). In 1990, Statoil considered the possibility of purchasing the technology for this production from the USSR. Later, Statoil acquired Dansk Bioprotein (Odense, Denmark), which brought this development to the level of pilot production. The main difference between the Dansk Bioprotein technology and the technology for obtaining biomass from natural gas developed in the USSR lies in the gas supply system - the Soviet-Russian technology provided for the partial use of methane in the process of biomass production from natural gas to obtain optimal processing methods and the subsequent use of non-utilized gases as energy raw materials. The Danish technology was aimed at maximizing the utilization of methane in the technological process with emission of exhaust gases into the atmosphere. At one time, Statoil (Norway), together with DuPont Bio-Based Materials (USA) were the only companies that produced bioproteins from natural gas on a large industrial scale. A product similar to gaprin, which was produced at this European-based enterprise, was approved for use and became widely used in agriculture in the EU countries. However, the production was shut down in 2004-2005.
Analysis of existing technologies for the production of microbiological protein and similar products
In the early 1960s, the development of technologies and industry for the production of microbiological protein or single cell protein (SCP) started in the leading industrial countries in parallel. The key factor determining the rapid development of the microbiological industry was the increase in the global population, which was about 4 billion people at the time, and the consequent impending shortage of protein in the diet. Today, there are several main processes that are used in various microbiological production of food and feed protein:
• ICI (England) has developed a technology and constructed a plant in Bellingham (England) for the production of high-protein biomass of Methylophilus methylotrophus bacteria grown on methanol with a capacity of 50,000 tons / year. Pruteen product brand name. The bulk of the protein was intended for feed purposes, but some was processed into highly purified protein isolates, which were used as food components due to their high emulsifying, water-retaining and gel-forming properties. The process consists of the stages of fermentation, isolation of cells by flocculation and drying of the finished product in the form of granules. The company also developed a number of technologies that made it possible to produce acidic protein hydrolysate, enzymatic protein hydrolysate, RNA for the production of food flavoring additives (5`GMF and 5`IMF) from the biomass obtained. The production of 1 ton of protein requires 2.6-2.8 tons of methanol.
• The Danish firm Dansk Bioprotein has been developing a process for obtaining microbial protein from gas since 1976. The dynamics of the firm's development witnessed 2 periods, which allowed it to quickly reach the level that existed in the USSR. Initially, the company used a culture of methane-oxidizing Methylomonas methylosinus bacteria to develop the technological process, which could not provide high performance due to the biochemical characteristics of carbon metabolism in bacterial cells as claimed by our microbiologists. In 1990-1991, specialists in this field were invited from the former GDR and from the VNIISintezbelok Institute to the company to conduct research in Denmark. 2-3 years into the work, the Danish firm made great progress in developing the technology and was bought by the Norwegian company Statoil to implement the development on an industrial scale. The creation of a fundamentally new fermenter made it possible to create a pilot plant for the production of the Bioprotein feed product. It is characteristic feature that the documentation for the finished Bioprotein product, which passed registration in Brussels, specifies the Methylococcus capsulatus bacteria as the producer organism, which were used in joint research with the GDR to develop this technology. Since labeling and standardization of strains was not yet developed and implemented during this period, one can only assume that this strain is similar to the one proposed in the documentation for the production of biomass from natural gas, which indicates that the chosen direction of technology development is correct, since at least 50% of success in biotechnology is achieved due to correctly selected microorganisms
• ICI (England) has developed a technology and constructed a plant in Bellingham (England) for the production of high-protein biomass of Methylophilus methylotrophus bacteria grown on methanol with a capacity of 50,000 tons / year. Pruteen product brand name. The bulk of the protein was intended for feed purposes, but some was processed into highly purified protein isolates, which were used as food components due to their high emulsifying, water-retaining and gel-forming properties. The process consists of the stages of fermentation, isolation of cells by flocculation and drying of the finished product in the form of granules. The company also developed a number of technologies that made it possible to produce acidic protein hydrolysate, enzymatic protein hydrolysate, RNA for the production of food flavoring additives (5`GMF and 5`IMF) from the biomass obtained. The production of 1 ton of protein requires 2.6-2.8 tons of methanol.
• The Danish firm Dansk Bioprotein has been developing a process for obtaining microbial protein from gas since 1976. The dynamics of the firm's development witnessed 2 periods, which allowed it to quickly reach the level that existed in the USSR. Initially, the company used a culture of methane-oxidizing Methylomonas methylosinus bacteria to develop the technological process, which could not provide high performance due to the biochemical characteristics of carbon metabolism in bacterial cells as claimed by our microbiologists. In 1990-1991, specialists in this field were invited from the former GDR and from the VNIISintezbelok Institute to the company to conduct research in Denmark. 2-3 years into the work, the Danish firm made great progress in developing the technology and was bought by the Norwegian company Statoil to implement the development on an industrial scale. The creation of a fundamentally new fermenter made it possible to create a pilot plant for the production of the Bioprotein feed product. It is characteristic feature that the documentation for the finished Bioprotein product, which passed registration in Brussels, specifies the Methylococcus capsulatus bacteria as the producer organism, which were used in joint research with the GDR to develop this technology. Since labeling and standardization of strains was not yet developed and implemented during this period, one can only assume that this strain is similar to the one proposed in the documentation for the production of biomass from natural gas, which indicates that the chosen direction of technology development is correct, since at least 50% of success in biotechnology is achieved due to correctly selected microorganisms
Modern development
In recent years, the global industry community has once again begun paying special attention to the issue of obtaining microbial protein based on natural gas.
Thus, according to Frost & Sullivan, the global biotechnology market will grow from $270 billion in 2018 to $600 billion by 2020. Norway, Denmark, England are especially active in the development in this field, and the United States announced that they have already begun construction of a plant with a capacity of 200 thousand tons of gas-based microbial protein per year.
In Russia, the existing capacities of the microbiological industry for the production of microbial protein based on hydrocarbon raw materials have been destroyed, but the scientific and technological groundwork remains.
The most successful and productive work on the resumption of the production of microbial protein based on natural gas at the modern level of industrial technology in the country was carried out by GIPROBIOSINTEZ LLC.
A strain of methane-oxidizing Methylococcus capsulatus GBS-15 bacteria was obtained from an enrichment culture of obligate methane-oxidizing microorganisms with subsequent stepwise autoselection in a continuous cultivation process.
As a result of this selection, a strain was obtained that can be used both as part of an association and individually when cultured under industrial conditions on natural gas. The strain is deposited in the All-Russian Collection of Industrial Microorganisms.
The Methylococcus capsulatus GBS-15 strain demonstrates a high technological potential, in particular:
• increased resistance to co-oxidation products of natural gas methane homologues, which makes it possible to use natural gas of various compositions and expand raw materials for the industrial implementation of the process;
• the ability to heterotropheous fixation of carbon dioxide, which provides a lower economic substrate (methane) consumption rate;
• resistance to phages;
• resistance to short-term changes in temperature and pressure
• The strain is competitive with respect to other types of methane-oxidizing bacteria
• the strain is thermotolerant.
The strain is not pathogenic, genetically modified and or containing genes from other organisms.
Thus, according to Frost & Sullivan, the global biotechnology market will grow from $270 billion in 2018 to $600 billion by 2020. Norway, Denmark, England are especially active in the development in this field, and the United States announced that they have already begun construction of a plant with a capacity of 200 thousand tons of gas-based microbial protein per year.
In Russia, the existing capacities of the microbiological industry for the production of microbial protein based on hydrocarbon raw materials have been destroyed, but the scientific and technological groundwork remains.
The most successful and productive work on the resumption of the production of microbial protein based on natural gas at the modern level of industrial technology in the country was carried out by GIPROBIOSINTEZ LLC.
A strain of methane-oxidizing Methylococcus capsulatus GBS-15 bacteria was obtained from an enrichment culture of obligate methane-oxidizing microorganisms with subsequent stepwise autoselection in a continuous cultivation process.
As a result of this selection, a strain was obtained that can be used both as part of an association and individually when cultured under industrial conditions on natural gas. The strain is deposited in the All-Russian Collection of Industrial Microorganisms.
The Methylococcus capsulatus GBS-15 strain demonstrates a high technological potential, in particular:
• increased resistance to co-oxidation products of natural gas methane homologues, which makes it possible to use natural gas of various compositions and expand raw materials for the industrial implementation of the process;
• the ability to heterotropheous fixation of carbon dioxide, which provides a lower economic substrate (methane) consumption rate;
• resistance to phages;
• resistance to short-term changes in temperature and pressure
• The strain is competitive with respect to other types of methane-oxidizing bacteria
• the strain is thermotolerant.
The strain is not pathogenic, genetically modified and or containing genes from other organisms.
Patents
• The strain of methane-oxidizing Methylococcus capsulatus GBS-15™ bacteria for obtaining microbial protein mass
• Composite fermenter in the plant for the production of biomass of aerobic microorganisms
• Installation for the production of biomass of aerobic microorganisms
• A device for growing microorganisms
• Fermentation unit for methane-assimilating microorganisms
• Drainage channel recirculator in the composite fermenter in the plant for the production of biomass of aerobic microorganisms
• A fluid pipeline in the composite fermenter in the plant for the production of biomass of aerobic microorganisms
• Composite fermenter in the plant for the production of biomass of aerobic microorganisms
• Installation for the production of biomass of aerobic microorganisms
• A device for growing microorganisms
• Fermentation unit for methane-assimilating microorganisms
• Drainage channel recirculator in the composite fermenter in the plant for the production of biomass of aerobic microorganisms
• A fluid pipeline in the composite fermenter in the plant for the production of biomass of aerobic microorganisms
Health hazard
In accordance with GOST 12.1.005-88, MAC for gaprin in the air of the working area is 0.3 mg/m³ (protein control is required).
By potential health effects, gaprin belongs to hazard class 2 (GOST 12.1.007-76).
By potential health effects, gaprin belongs to hazard class 2 (GOST 12.1.007-76).
