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.     

Continuous production of butanol from starch-based packing peanuts

Acetone, butanol, ethanol (ABE, or solvents) were produced from starch-based packing peanuts in batch and continuous reactors. In a batch reactor, 18.9 g/L of total ABE was produced from 80 g/L packing peanuts in 110 h of fermentation. The initial and final starch concentrations were 69.6 and 11.1 g/L, respectively. In this fermentation, ABE yield and productivity of 0.32 and 0.17 g/(L·h) were obtained, respectively. Compared to the batch fermentation, continuous fermentation of 40 g/L of starch-based packing peanuts in P2 medium resulted in a maximum solvent production of 8.4 g/L at a dilution rate of 0.033 h⁻¹. This resulted in a productivity of 0.27 g/(L·h). However, the reactor was not stable and fermentation deteriorated with time. Continuous fermentation of 35 g/L of starch solution resulted in a similar performance. These studies were performed in a vertical column reactor using Clostridium beijerinckii BA101 and P2 medium. It is anticipated that prolonged exposure of culture to acrylamide, which is formed during boiling/autoclaving of starch, affects the fermentation negatively.     

Response ofClostridium Acetobutylicum to the presence of mixed extractants

The volumetric productivity of many fermentations is productlimited.In situ removal of these products with liquid organic extractants is limited by either a low product distribution coefficient or toxicity of the extractant. This paper presents results from studies using mixed extractants, namely mixtures of toxic extractants that have high distribution coefficients for the product and nontoxic extractants that have low distribution coefficients. The production of butanol byClostridium acetobutylicum was chosen as a model system for these studies. The mechanisms of toxicity of mixed extractants and the observed responses to their presence are discussed.     

Continuous production of L-aspartic acid

For the continuous production ofl-aspartic acid from fumaric acid and ammonia by the action of aspartase, the enzyme extracted fromEscherichia coli orE. coli cells having high aspartase activity were immobilized by various methods. In 1973 we succeeded in the industrial production ofl-aspartic acid usingE. coli cells immobilized with polyacrylamide gel. For the improvement of this process, we developed a novel technique using κ-carrageenan as the immobilizing matrix forE. coli cells. Further, EAPc-7 strain, having higher aspartase activity, was contracted from the parentE. coli by continuous cultivation with a definite medium. The aspartase activity was about seven times higher than that of the parent cells. In 1982 we changed from the conventional method to the improved method, using EAPc-7 strain immobilized with κ-carrageenan.     

Immobilized plant cells

Plant cells have been immobilized in alginate, where they have been shown to retain their biological activity. Such systems can be utilized for bioconversions.     

Reasons for the high stability of fumarase activity ofBrevibacterium flavum cells immobilized with k-carrageenan gel

Whole cells ofBrevibacterium flavum having high fumarase activity were immobilized using K-carrageenan. The reason for the high stability of fumarase activity of immobilized cells was investigated. One of main reasons for stabilizing fumarase activity by immobilization using K-carrageenan against organic solvents such as ethanol and acetone was the lower concentration of these solvents in the carrageenan gel compared with that in outer bulk solution. The stabilization of fumarase activity in the immobilized cells against protein-denaturing reagents was found to be related to rheological properties of K-carrageenan gel. Another reason for stabilizing fumarase activity by immobilization with K-carrageenan was to protect the cells from lysis. When immobilized cells were freeze-thawed, their fumarase activity increased and operation stability decreased. Therefore, one reason for the high decay of fumarase activity caused by the freeze-thawing may be a change in the pore size of the K-carrageenan gel. Fumarase activity and the operational stability of immobilized cells was found to depend on gelling conditions. Therefore, the steric structure of the K-carrageenan gel may be related to the decay of fumarase activity.     

Immobilized cells in microbial nitrate reduction

The microorganismPseudomonas denitrificans was immobilized in alginate. These immobilized cells were capable of reducing 0.8 mg NO ₃ ^- /min/g wet weight of cells.     

Citric acid production with alginate bead entrappedAspergillus niger ATCC 9142

Aspergillus niger ATCC 9142 mycelium was entrapped in calcium alginate beads and employed in an air-lift completely stirred reactor for continuous production of citric acid. Maximum yield obtained from 10% (w/v) sucrose was 12 g dm^-3 with about 40% fermentation efficiency. Maximum rate of production 70 mg g^-1 h^-1 was about five times that obtained in classical batch fermentation.     

Determination of phenol and catechol concentrations with oxygen probes coated with immobilized enzymes or immobilized cells

The enzyme phenol 2-hydroxylase was immobilized on Sepharose and used in conjunction with an O₂ electrode for quantitating phenol. Similarly, catechol 1,2-oxygenase was used for quantitating catechol. A third probe was prepared by immobilization ofTrichosporon cutaneum cells rather than purified phenol 2-hydroxylase for phenol quantitation. The whole cell system gave results comparable to the immobilized enzyme system.     

Affinity chromatographic purification of lentil lectin using immobilized yeast cells

A model system for evaluating macroporous supports containing immobilized whole cells in affinity Chromatographic applications is described. Whole cells were immobilized in a polyacrylamide network in a two-step polymerization process. The affinity system discussed consists of immobilized cells ofSaccharomyces cervisiae in the purification of lentil lectin fromLens culinaris.     

Butanol production by Clostridium beijerinckii BA101 in an immobilized cell biofilm reactor

Acetone butanol ethanol was produced in a continuous immobilized cell (biofilm) plug-flow reactor inoculated with Clostridium beijerinckii BA101. To achieve high reactor productivity, C. beijerinckii BA101 cells were immobilized by adsorption onto clay brick. The continuous plug-flow reactor offers high productivities owing to reduced butanol inhibition and increased cell concentration. Although high productivity was achieved, it was at the expense of low sugar utilization (30.3%). To increase sugar utilization, the reactor effluent was recycled. However, this approach is complicated by butanol toxicity. The effluent was recycled after removal of butanol by pervaporation to reduce butanol toxicity in the reactor. Recycling of butanolfree effluent resulted in a sugar utilization of 100.7% in addition to high productivity of 10.2g/(L·h) at a dilution rate of 1.5 h⁻¹. A dilution rate of 2.0h⁻¹ resulted in a reactor productivity of 16.2g/(L·h) and sugar utilization of 101.4%. It is anticipated that this reactor-recovery system would be economical for butanol production when using C. beijerinckii BA101.     

Production of acetone butanol ethanol from degermed corn using Clostridium beijerinckii BA101

In this article we report on acetone butanol ethanol (ABE) fermentation characteristics of degermed corn when using Clostridium beijerinckii BA101. Recent economic studies suggested that recovery of germ from corn and hence corn oil would help to make the ABE fermentation process more economical. C. beijerinckii BA101 ferments corn mash efficiently to produce ABE under appropriate nutritional and environmental conditions. Corn mash contains germ/corn oil that is, possibly, ancillary to the production of butanol during the ABE fermentation process. Since the presence of corn oil is not a critical factor in solvent fermentation, it can be removed and this will allow for byproduct credit. Batch fermentation of degermed corn resulted in 8.93 g/L of total ABE production as compared with 24.80 g/L of total ABE when supplemented with P2 medium nutrients. During the course of the germ separation process, corn steeping is required prior to grinding and removing the germ. It is likely that some nutrients from the corn are leached out during the steeping process. This may reduce the rate of fermentation and impact the final concentration of butanol/ABE that can be achieved. Fermentation of degermed corn with corn steep liquor resulted in the production of 19.28 g/L of ABE.     

High-productivity continuous biofilm reactor for butanol production

Corn steep liquor (CSL), a byproduct of the corn wet-milling process, was used in an immobilized cell continuous biofilm reactor to replace the expensive P2 medium ingredients. The use of CSL resulted in the production of 6.29 g/L of total acetone-butanol-ethanol (ABE) as compared with 6.86 g/L in a control experiment. These studies were performed at a dilution rate of 0.32 h⁻¹. The productivities in the control and CSL experiment were 2.19 and 2.01 g/(L·h), respectively. Although the use of CSL resulted in a 10% decrease in productivity, it is viewed that its application would be economical compared to P2 medium. Hence, CSL may be used to replace the P2 medium. It was also demonstrated that inclusion of butyrate into the feed was beneficial to the butanol fermentation. A control experiment produced 4.77 g/L of total ABE, and the experiment with supplemented sodium butyrate produced 5.70 g/L of total ABE. The butanol concentration increased from 3.14 to 4.04 g/L. Inclusion of acetate in the feed medium of the immobilized cell biofilm reactor was not found to be beneficial for the ABE fermentation, as reported for the batch ABE fermentation. Names are necessary to report factually on available data. However, the USDA neither guarantees nor warrants the standard of the product, and the use of the names by USDA implies no approval of the product to the exclusion of others that may also be suitable.     

Application of magnetic immobilized microorganisms

Magnetic calcium alginate yeast beads, made by incorporation of magnetite or colloidal magnetic liquid, Ferrofluidℳ, exhibited catalytic behavior similar to that of their nonmagnetic counterparts. The magnetic immobilized preparations’ shortterm performance, long-term operational stability, and capacity forin situ activation were unaffected by the inclusion of magnetic material. The magnetic quality of the alginate beads provides manipulatory advantages.     

Continuous production of lactic acid in a cell recycle reactor

The production of lactic acid from glucose has been demonstrated using a CSTR (continuous stirred-tank reactor) with cell recycle. Studies were conducted withLactobacillus delbrueckii at a fermentation temperature of 42°C and a pH of 6.25. A cell density of 140 g dry weight/L and a volumetric productivity of 150 g/L.h, with complete glucose consumption, were obtained. It was not possible to obtain a lactic acid concentration above 60 g/L because of product inhibition. A cell purge was not necessary to maintain high viability bacteria culture or to obtain a steady state. At steady state the net cell growth appeared to be negligible. The specific glucose consumption for cell maintenance was 0.33 g glucose/g cells-h.     

Stabilization of fumarase activity ofBrevibacterium flavum cells by immobilization with k-carrageenan

Whole cells ofBrevibacterium flavum having fumarase activity were immobilized using K-carrageenan. The stabilities of fumarase activity in the immobilized cells against external factors, including heat, pH, organic solvents, and protein denaturing reagents, were compared with those of free cells and native enzyme. The stabilities of fumarase activity in immobillized cells against external factors were highest, and those of native enzyme were lowest. In the “gel-state,” K-carrageenan-immobilized cells showed a much higher stabilization effect for external factors than “sol-state” immobilized cells.     

Gibberellic acid production by free and immobilized cells in different culture systems

Gibberellic acid production was studied in different fermentation systems. Free and immobilized cells of Gibberella fujikuroi cultures in shakeflask, stirred and fixed-bed reactors were evaluated for the production of gibberellic acid (GA₃). Gibberellic acid production with free cells cultured in a stirred reactor reached 0.206 g/L and a yield of 0.078 g of GA₃/g biomass.     

Cephalexin synthesis using immobilizedXanthomonas citri cells

For continuous production of cephalexin, whole cells ofXanthomonas citri were immobilized by entrapment in polyacrylamide gel and kappa-carrageenan gel. It wasfound that cells immobilized with kappa-carrageenan showed better thermal stability compared to those immobilized by polyacrylamide gel. The cells immobilized with kappa-carrageenan were treated with glutaraldehyde and hexamethylenediamine to prevent gel destruction during prolonged operation. By immobilizing intact cells, the optimal temperature for the synthetic enzyme reaction shifted higher by 8°C and the optimal pH became broader around 6.2 In continuous operation, the immobilized cells retained better operational stability at 25 than at 37°C, and also showed maximal conversion up to 83% at 25°C.     

Denitrification and removal of heavy metals from waste water by immobilized microorganisms

Pseudomonas fluorescens, immobilized on soft polyvinyl chloride granules containing up to 35% softeners as carbon source, was used for simultaneous removal of nitrate and heavy metals. In typical continuous column operation, a 100 mg/L nitrate input solution was reduced to a 20 mg/L output at a feeding rate of 1500 mL/h, with a capacity of 14 kg/day/m³, and with an efficiency of 79%. In the same column, Pb(NO₃)₂ concentration was reduced from 1.0 to 0.05−0.1 mg/L and ZnSO₄ concentration was reduced from 10 to 5 mg/L.Pseudomonas aeruginosa immobilized on an O₂ plasma-treated melt blown polypropylene web was used for removing 95% of a 1.7 nCi PuCl₄ activity from a nuclear plant waste water in a batch operation.     

Ethanol production by yeast cells immobilized in open-pore agar

An open-pore agar matrix has been shown to be suitable for the entrapment of microbial whole cells required for use in reactions that involve cell growth and gas evolution. Beads of porous agar with entrapped yeast cells have been used for the continuous fermentation of sugar cane molasses to ethanol, without apparent bead rupture, even after periods of 3 mo of use. The agar gel does not erode during prolonged operation, unlike porous gelatin cross-linked with glutaraldehyde.