Ethanol production in a bioreactor with an integrated membrane distillation module

Ethanol production in a bioreactor with integrated membrane distillation (MD) module has been investigated. A hydrophobic capillary polypropylene membrane (Accurel PP V8/2 HF), with an external/internal diameter ratio, d _out/d _in = 8.6 mm/5.5 mm and pore size 0.2 μm, was used in these studies. The products (mainly ethanol and acetic acid) formed during the fermentation of sugar with Saccharomyces cerevisiae inhibited the process. These products were selectively removed from the fermentation broth by the MD process, which increased the efficiency of the conversion of sugar to alcohol from 0.45 g to 0.5 g EtOH per g of fermented sucrose. The bioreactor efficiency also increased by almost 30 %. Separation of alcohol by the MD generates a higher yield of ethanol in the permeate than in the broth. The enrichment coefficient amounted to 4-8, and depended on the ethanol concentration in the broth. The separated solutions did not wet the membrane in use for 2500 h of the MD experiments and the retention of inorganic solutes was close to 100 %.     

Rapid fermentation of beer using an immobilized yeast multistage bioreactor

The characteristics of yeast sulfite metabolism in a multistage bioreactor system for beer fermentation were investigated. No sulfite was produced in the continuous stirred-tank reactor (CSTR). However, large amounts were produced in the packed-bed reactor (PBR). Production of sulfite in the PBR seems to be inevitable when it is operated continuously. In order to control the sulfite level in the young beer, the yeast needs to be reactivated into the growth phase. One possible strategy to achieve this is to aerate and periodically remove yeast clogged in the reactor once every 6–7 months before the sulfite level exceeds a given concentration (e.g., 20 mg/L). It was confirmed that sulfite production is closely related to the growth condition of the yeast and is therefore important to consider in the control strategy for sulfite when using the immobilized yeast reactor for beer production.     

Mass cultivation of catharanthus roseus cells using a nonmechanically agitated bioreactor

Batch suspension cultures ofCatharanthus roseus G. Don were grown in a 5 L LKB Ultraferm fermenter, converted to operate as an airlift bioreactor, to test the suitability of such a system for the mass culture of plant cells. Results show that the airlift system has considerable merits as a culture vessel for such a purpose, including: conversion rates of carbohydrate substrate to cell mass equivalent to > 50% under optimum conditions. (Operating under these conditions, growth rates of approximately 0.4 d^-1 are typical). In the absence of the mechanical shear normally associated with mechanically driven bioreactors, the gently agitated environment of the airlift vessel proves to be an ideal system for the growth of fragile plant cells. Use of a nozzle sparger reduces the possibility of a high mass transfer coefficient, except at very high gassing rates, thereby eliminating any interference with the growth rate caused by high rates of gaseous exchange.     

Rapid fermentation of beer using an immobilized yeast multistage bioreactor system

A multistage bioreactor system for rapid beer fermentation was developed. The main fermentation process, which conventionally requires 7 d, could be shortened to 2 d by this system. The concentration of esters and higher alcohols are major factors in brewery fermentation, their production being closely related to the yeast growth phase. Yeast metabolism was successfully subdivided into a growth and a restricted phase through a combination of a continuous stirredtank reactor (CSTR) and an immobilized yeast packed-bed reactor (PBR). Production of higher alcohols was high in the CSTR because of its association with the level of biosynthetic activityde novo. A small amount was also produced in the PBR, however, possibly a result of an overflow in carbohydrate metabolism. Ester formation mainly occurred in the PBR, a linear increase in the level of ester being observed with flow through the PBR. The reactor system control strategy was to maximize the level of both higher alcohol and ester formation. The CSTR/PBR control range, based on extract consumption, was varied between 1:1 and 1:2. A ratio of 1:1 tended to create a flat beer, whereas a ratio 1:2 gave a beer of richer quality. Amino acid uptake by the yeast directly contributed to a reduction in the wort pH, whereas no relation could be observed between the level of organic acid production and pH.     

Characterization of an immobilized yeast cells fluidized-bed bioreactor for ethanol fermentation

The operational characterization of a fluidized-bed bioreactor for ethanol fermentation using Ca-alginate immobilized yeast cells is described. An additional air stream is supplied to the fermenter to ensure and maintain satisfactory fluidization behavior of beads and to avoid slug formation. The influence of physical properties such as bead density and liquid density on the fluidization quality and stability are discussed.     

Continuous-flow/stopped-flow system for determination of ascorbic acid using an enzymatic rotating bioreactor

The high sensitivity that can be attained using an enzymatic system and mediated by hydroquinone, has been verified by on-line interfacing of a rotating bioreactor and continuous flow/stopped-flow/continuous-flow processing. Horseradish peroxidase, HRP, [EC 1.11.1.7], immobilized on a rotating disk, in presence of hydrogen peroxide catalyses the oxidation of hydroquinone to p-benzoquinone, whose electrochemical reduction back to hydroquinone is detected on glassy carbon electrode (GCE) surface at −0.15 V. Thus, when l-ascorbic acid is added to the solution, this acid is reduced chemically (p-benzoquinone to hydroquinone) and acts as mediator of HRP, decreasing the peak current obtained proportionally to the increase of its concentration. The recovery of l-ascorbic acid from four samples ranged from 99.09 to 101.10%. This method could be used to determine l-ascorbic acid concentration in the range 12 nM-3.5 μM (r = 0.998). The determination of l-ascorbic acid was possible with a limit of detection of 6 nM in the processing of as many as 25 samples h⁻¹. The method was successfully applied for the analysis of l-ascorbic acid in pharmaceutical formulations.     

Production of (2R,3S)-3-(4-methoxyphenyl)glycidic acid methyl ester using an emulsion bioreactor containing lipase fromSerratia marcescens

An emulsion bioreactor for production of (2R,3S)-3-(4-methoxyphenyl) glycidic acid methyl ester ([-]MPGM) from a racemic mixture ([±]MPGM) using the lipase fromSerratia marcescens has been proposed. Kinetics of hydrolyzing reaction and purification of (-)MPGM from the reaction mixture were investigated to provide a basis for industrial application of this bioreactor. The hydrolyzing reaction in the bioreactor proceeded at a rate that was first order in substrate concentration. The reaction rate was affected by a stirring speed and the ratio of the aqueous phase containing lipase to the toluene phase containing substrate. Phase separation after the enzymatic reaction was accomplished by addition of surfactant to the reaction mixture, and crystalline (-)MPGM with a chemical purity of 100% and optical purity of 100% enantiomeric excess was obtained in a high yield of 40–43% by concentration of the toluene solution.     

Modeling and simulation of cephalosporin C production in a fed-batch tower-type bioreactor

Immobilized cell utilization in tower-type bioreactor is one of the main alternatives being studied to improve the industrial bioprocess. Other alternatives for the production of β-lactam antibiotics, such as a cephalosporin C fed-batch process in an aerated stirred-tank bioreactor with free cells of Cephalosporium acremonium, or a tower-type bioreactor with immobilized cells of this fungus, have proven to be more efficient than the batch process. In the fed-batch process, it is possible to minimize the catabolite repression exerted by the rapidly utilization of carbon sources (such as glucose) in the synthesis of antibiotics by utilizing a suitable flow rate of supplementary medium. In this study, several runs for cephalosporin C production, each lasting 200 h, were conducted in a fed-batch tower-type bioreactor using different hydrolyzed sucrose concentrations. For this study's model, modifications were introduced to take intoaccount the influence of supplementary medium flow rate. The balance equations considered the effect of oxygen limitation inside the bioparticles. In the Monod-type rate equations, cell concentrations, substrate concentrations, and dissolved oxygen were included as reactants affecting the bioreaction rate. The set of differential equations was solved by the numerical method, and the values of the parameters were estimated by the classic nonlinear regression method following Marquardt's procedure with a 95% confidence interval. The simulation results showed that the proposed model fit well with the experimental data, and based on the experimental data and the mathematical model, an optimal mass flow rate to maximize the bioprocess productivity could be proposed.

     

Studies on mass production of transformed Panax ginseng hairy roots in bioreactor

The growth properties of Panax ginseng hairy roots transformed by Agrobacterium rhizogenes were compared between flask and aerated column or stirred bioreactor. In flask cultures, sucrose, initially 30 g/L, was nearly exhausted after 45 d of culture. The pH of the medium dropped from 5.5 to 4.96 after 10 d, but afterward it gradually increased to 6.4. After 45 d, hairy roots grew about 16-folds. The growth rate of hairy roots in air-bubble column or stirred bioreactor cultures was 1.13 (1.11) to 1.23 (1.20) g fresh wt (dry wt)/(g of cells·d), respectively. For both bioreactors, growth was about three times as high as in the flask cultivation.     

Radiation Crosslinking of an Acrylamide–Sodium Acrylate Copolymer in Aqueous Solutions

The effect of concentration of an acrylamide–sodium acrylate copolymer in an aqueous solution on the crosslinking of macromolecules by the action of ionizing radiation was studied. It was shown that the efficiency of radiation crosslinking of the copolymer increased with an increase in the concentration of solution subject to irradiation, which was tentatively explained in terms of the existence of fluctuative entanglement network ensuring the approaching of macroradical sites and, thus, facilitating the combination reactions of macroradicals.     

Operability and feasibility of ethanol production by immobilizedZymomonas mobilis in a fluidized-bed bioreactor

Studies have been carried out using immobilized Z.mobilis in fluidized-bed bioreactors and have emphasized operation during high productivity and conversion. The bacteria are immobilized within small uniform beads (~1 to 1.5-mm diam) of K-carrageenan at cell loadings of 15-50 g (dry wt)/L. Conversion and productivity were measured under a variety of conditions, including feedstocks, flow rates, temperature, pH, and column sizes (up to 2.5 m tall). Volumetric productivities of 50-120 g EtOH/h-L reactor volume have been achieved. Productivities of 60 g/h-L are demonstrated from a 15% feed with residual glucose concentrations of less than 0.1% and 7.4% EtOH in the tallest fermentor. Among feeds of 10, 15, and 20% dextrose, the 15% gave the highest productivity and avoided substrate inhibition. A temperature of 30°C and pH 5 were the optimum conditions. The ethanol yield was shown to be nearly constant at 0.49 g EtOH/g glucose, or 97% of the theoretical under a variety of conditions and transients. The biocatalyst beads have been shown to remain active for two months. Nonsterile feed has been used for weeks without detrimental contamination. The advantages of this advanced bioreactor system over conventional batch technology are discussed.     

Continuous production of butanol by clostridium acetobutylicum immobilized in a fibrous bed bioreactor

We explored the influence of dilution rate and pH in continuous cultures of Clostridium acetobutylicum. A 200-mL fibrous bed bioreactor was used to produce high cell density and butyrate concentrations at pH 5.4 and 35°C. By feeding glucose and butyrate as a cosubstrate, the fermentation was maintained in the solventogenesis phase, and the optimal butanol productivity of 4.6g/(L h) and a yield of 0.42 g/g were obtained at a dilution rate of 0.9h⁻¹ and pH 4.3. Compared to the conventional acetone-butanol-ethanol fermentation, the new fermentation process greatly improved butanol yield, making butanol production from corn an attractive alternative to ethanol fermentation.     

Analysis of pharmaceuticals in wastewater and removal using a membrane bioreactor

Much attention has recently been devoted to the life and behaviour of pharmaceuticals in the water cycle. In this study the behaviour of several pharmaceutical products in different therapeutic categories (analgesics and anti-inflammatory drugs, lipid regulators, antibiotics, etc.) was monitored during treatment of wastewater in a laboratory-scale membrane bioreactor (MBR). The results were compared with removal in a conventional activated-sludge (CAS) process in a wastewater-treatment facility. The performance of an MBR was monitored for approximately two months to investigate the long-term operational stability of the system and possible effects of solids retention time on the efficiency of removal of target compounds. Pharmaceuticals were, in general, removed to a greater extent by the MBR integrated system than during the CAS process. For most of the compounds investigated the performance of MBR treatment was better (removal rates >80%) and effluent concentrations of, e.g., diclofenac, ketoprofen, ranitidine, gemfibrozil, bezafibrate, pravastatin, and ofloxacin were steadier than for the conventional system. Occasionally removal efficiency was very similar, and high, for both treatments (e.g. for ibuprofen, naproxen, acetaminophen, paroxetine, and hydrochlorothiazide). The antiepileptic drug carbamazepine was the most persistent pharmaceutical and it passed through both the MBR and CAS systems untransformed. Because there was no washout of biomass from the reactor, high-quality effluent in terms of chemical oxygen demand (COD), ammonium content (N-NH₄), total suspended solids (TSS), and total organic carbon (TOC) was obtained.     

Bioconversion of sugars to ethanol in an immobilized cell packed bed bioreactor - dynamic response to perturbations in process parameters

Saccharomyces cerevisiae cells ionically adsorbed onto hexamethylene-diamine-treated bagasse (maximum cell loading 0.410 g cells per gram of carrier, dry basis) were used in a packed bed bioreactor at 30 ± 1 °C with sucrose medium (pH 5.0). The dynamic behaviour resulting from perturbations in feed sugar concentration and feed flow rate was studied during the continuous bioconversion of sugar to ethanol. The time-dependent partial differential equations were solved numerically by the Crank-Nicolson method and the experimental data fit well with those computed from the model.The RNA and total protein levels and alcohol dehydrogenase enzyme activity during the transient phase were monitored in a continuous stirred tank bioreactor (free cells) and their levels provide a reasonable explanation of the experimentally observed behaviour.     

Biological production of acetaldehyde from ethanol using non-growingPichia pastoris whole cells

Acetaldehyde has been produced biologically using whole-cellPichia pastoris in a semibatch fermentor. Ethanol and air were fed continuously, and the product, acetaldehyde, was removed by the air stream. Operation of the reactor exceeded 100 h, maintaining high alcohol oxidase activity. Low cell-mass concentration (9.9 g/L) minimized product inhibition. Ethanol concentration in the broth, oxygen concentration in the air, and pH were evaluated for their effects on the fermentation process.     

Solar energy in production of L-glutamate through visible light active photocatalyst--redox enzyme coupled bioreactor

A new potentially promising visible-light driven photobioreactor synthesizes fine chemical via photobiocatalysis by generating NADH in a non-enzymatic light-driven process and coupling it to the enzymatic dark reaction catalysis.     

Continuous production of succinic acid by a fumarate-reducing bacterium immobilized in a hollow-fiber bioreactor

Enterococcus faecalis RKY1, a fumarate-reducing bacterium, was immobilized in an asymmetric hollow-fiber bioreactor (HFBR) for the continuous production of succinic acid. The cells were inoculated into the shell side of the HFBR, which was operated in transverse mode. Since the pH values in the HFBR declined during continuous operation to about 5.7, it was necessary to change the feed pH from 7.0 to 8.0 after 24 h of operation in order to enhance production of succinic acid. During continuous operation with a medium containing fumarate and glycerol, the productivity of succinate was 3.0–10.9 g/(L·h) with an initial concentration of 30 g/L of fumarate, 4.9–14.9 g/(L·h) with 50 g/L of fumarate, and 7.2–17.1 g/(L·h) with 80 g/L of fumarate for dilution rates between 0.1 and 0.4 h⁻¹. The maximum productivity of succinate obtained by the HFBR (17.1 g of succinate /[L·h]) was 1.7 times higher than that of the batch bioconversions (9.9 g of succinate /[L·h]) with 80 g/L of fumarate. Furthermore, the long-term stability of the HFBR was demonstrated with a continuously efficient production of succinate for more than 15 d (360 h).     

Methane production in a 100-L upflow bioreactor by anaerobic digestion of farm waste

Manure waste from dairy farms has been used for methane production for decades, however, problems such as digester failure are routine. The problem has been investigated in small scale (1-2 L) digesters in the laboratory; however, very little scale-up to intermediate scales are available. We report production of methane in a 100-L digester and the results of an investigation into the effect of partial mixing induced by gas upflow/recirculation in the digester. The digester was operated for a period of about 70 d (with 16-d hydraulic retention time) with and without the mixing induced by gas recirculation through an internal draft tube. The results show a clear effect of mixing on digester operation. Without any mixing, the digester performance deteriorated within 30-50 d, whereas with mixing continuous production of methane was observed. This study demonstrates the importance of mixing and its critical role in design of large scale anaerobic digesters.     

Methane production in a 100-L upflow bioreactor by anaerobic digestion of farm waste

Manure waste from dairy farms has been used for methane production for decades, however, problems such as digester failure are routine. The problem has been investigated in small scale (1–2 L) digesters in the laboratory; however, very little scale-up to intermediate scales are available. We report production of methane in a 100-L digester and the results of an investigation into the effect of partial mixing induced by gas upflow/recirculation in the digester. The digester was operated for a period of about 70 d (with 16-d hydraulic retention time) with and without the mixing induced by gas recirculation through an internal draft tube. The results show a clear effect of mixing on digester operation. Without any mixing, the digester performance deteriorated within 30–50 d, whereas with mixing continuous production of methane was observed. This study demonstrates the importance of mixing and its critical role in design of large scale anaerobic digesters.