Mixing and phase hold-ups variations due to gas production in anaerobic fluidized-bed digesters: influence on reactor performance

The influence of mixing and phase hold-ups on gas-producing fluidized-bed reactors was investigated and compared with an ideal flow reactor performance (CSTR). The liquid flow in the anaerobic fluidized bed reactor could be described by the classical axially dispersed plug flow model according to measurements of residence time distribution. Gas effervescence in the fluidized bed was responsible for bed contraction and for important gas hold-up, which reduced the contact time between the liquid and the bioparticles. These results were used to support the modeling of large-scale fluidized-bed reactors. The biological kinetics were determined on a 180-L reactor treating wine distillery wastewater where the overall total organic carbon uptake velocity could be described by a Monod model. The outlet concentration and the concentration profile in the reactor appeared to be greatly influenced by hydrodynamic limitations. The biogas effervescence modifies the mixing characteristics and the phase hold-ups. Bed contraction and gas hold-up data are reported and correlated with liquid and gas velocities. It is shown that the reactor performance can be affected by 10% to 15%, depending on the mode of operation and recycle ratio used. At high organic loading rates, reactor performance is particularly sensitive to gas effervescence effects. Copyright 1998 John Wiley & Sons, Inc.     

Analysis of a continuous, aerobic, fixed-film bioreactor. II. Dynamic behavior

The dynamic analysis of a continuous, aerobic, fixed-film bioreactor has been performed. Rigorous mathematical models have been developed for a fluidized-bed fermentor with biofilm growth. The transient performance of the reactor is appraised in terms of outlet penicillin concentration for constant, as well as variable carbon substrate feed rates. The effect of the reactor oxygen transfer capacity is elucidated for those cases employing substrate feeding strategies. The results show that penicillin production in a continuous, fixed-film bioreactor reaches a maximum with processing time, but subsequently decreases as cell mass accumulates and substrate deficiencies occur. The maximum production level can be maintained for increased operating times if the substrate supply is continuously increased. The duration of this prolonged production is a direct function of the rate of increase and the operating time at which the increase is initiated. The oxygen transfer capacity of the reactor was found to be important to the effectiveness of a feeding strategy.     

Biofilm reactors: an experimental and modeling study of wastewater denitrification in fluidized-bed reactors of activated carbon particles

A fluidized-bed biofilm reactor using activated carbon particles of 1.69 mm diameter as the support for biomass growth and molasses as the carbon source is used for wastewater denitrification.The start-up of the reactor was successfully achieved in 1 week by using a liquor from garden soil leaching as the inoculum and a superficial velocity u(0) = 5u(mf). Typical biofilm thickness is 800 mum; therefore covered activated carbon particles have 3.3 mm in diameter.Reactor hydrodynamics was studied by tracer (KCl solution) experiments. The analysis based on residence time distribution theory involved a model with axial dispersion flow and tracer diffusion with linear adsorption inside the biofilm. Peclet numbers higher than 100 were found, allowing the plug flow assumption for the reactor model.Experimental profiles of nitrate and nitrite species were explained by a kinetic model of two consecutive zero-order reactions coupled with substrate diffusion inside the biofilm. Under the operating conditons used thick biofilms were obtained working in a diffusion-controlled regime.Comparison is made with results obtained in the same reactor with sand particles as the support for biomass growth. Activated carbon as the support has the following advantages: good adsorptive characteristics, homogeneous biofilm thickness along the reactor, and easy restart-up of the reactor. (c) 1992 John Wiley & Sons, Inc.     

Countercurrent multistage fluidized bed reactor for immobilized biocatalysts: I. Modeling and simulation

For the application of immobilized enzymes, fixed bed reactors are used almost exclusively. Fixed bed reactors have specific disadvantages, especially for processes with a deactivating catalyst. Therefore, we have studied a novel reactor type with continuous transport of the immobilized biocatalyst. Flow of biocatalyst is countercurrent to the substrate solution. Because of a stagewise reactor design, back-mixing of biocatalyst is very limited and transport is nearly plug flow. The reactor operates at a constant flow rate and conversion, due to constant holdup of catalytic activity. The reactor performance is compared with a configuration of fixed bed reactors. For reactions in the first-order regime, enzyme requirements in this new reactor are slightly less than for fixed bed processes. The multistage fluidized bed appears to be an attractive reactor design to use biocatalyst to a low residual activity. However, nonuniformity of the particles might affect plug flow transport of the biocatalyst. A laboratory scale reactor and experiments are described in Part II(1) of this series. Hydrodynamic design aspects of a multistage fluidized bed are discussed in more detail in Part III.(2).     

Effluent recirculation to improve perchlorate reduction in a fixed biofilm reactor

The effect of effluent recirculation on perchlorate reduction in a nominally plug-flow fixed biofilm reactor was studied in two cases: influent concentrations of 10 and 400 microg/L at low hydraulic loading rates (1.9 and 37.5 m(3)/m(2)/day without and with recirculation, respectively) and after a step increase in perchlorate concentration to 1,000 microg/L at the higher hydraulic loading rate (5 and 100 m(3)/m(2)/day without and with recirculation, respectively). Complete perchlorate reduction was sustained for influent concentrations of 400 and 10 microg/L in both flow regimes at the lower hydraulic loading rates. Reactor tracer profiles showed that biofilm diffusion had a more significant effect on mass transfer in the plug flow reactor compared with recirculation. The recirculation bioreactor acclimated more rapidly to increased hydraulic and perchlorate mass loading rates with significantly lower effluent perchlorate compared to the plug flow reactor: 16 microg/L versus 46 microg/L, respectively, although complete perchlorate removal was not achieved in either flow regime after 21 days acclimation to the higher loading. Total biofilm mass was more uniformly distributed in the recirculation reactor which may have contributed to better performance under increased perchlorate loading.     

Comparative performance of biofilm reactor types

Development of a unified model of biofilm-reactor kinetics is based on substrate-utilization kinetics, mass transport, biofilm growth, and reactor analysis. The model is applied to steady-state conditions for complete-mix, fixed-bed, and fluidized-bed reactors with and without recycle. The results of modeling experiments demonstrate that simple loading factors and kinetic relationships are insufficient to describe the performance of a variety of biofilm processes. Instead, the interactions among utilization kinetics, biofilm growth, and reactor configuration determine the performance. For example, fluidized-bed reactors can achieve superior performance to complete-mix and fixed-bed reactors because the biofilm is evenly distributed throughout the reactor while the liquid regime has plug-flow characteristics. When it is possible, experimental results which demonstrate key concepts are presented.     

Optimization of a reactor assembly for the production of 6-APA from penicillin-V

The design and operation of an industrial penicillin-V deacylation reactor is simulated, using a kinetic expression and mass transport parameters for the immobilized enzyme particles which were determined experimentally in a previous study. It is desirable to use a series of equalsized plug flow reactors with pH control at the entrance to each reactor, and with a possibility of recycling reactant in each reactor. These measures are necessary to avoid a steep pH profile through the reactor; the deacylation reaction is accompanied by an increase of acidity of the reaction medium, and H(+) is a strong inhibitor and may deactivate the enzyme. The optimization study which is carried out at a fixed penicillin conversion of x = 0.99 shows that it is uneconomical to use penicillin feed concentrations above 150mM-175mM, and that the buffer concentration in the reaction medium should not be less than 50mM-75mM. Increasing the number of reactors from 4 to 8 or 10 leads to higher productivity of 6-APA, and a moderate recycle in the first couple of reactors diminishes the sharp decrease in pH which will be found in a straight plug flow reactor operation of the equipment. Higher pumping costs and lower productivity are unavoidable drawbacks of an operation mode where the separation costs for the product mixture are desired to be low.     

Modeling of biofilm reactors with consecutive reactions

Modeling of biofilm reactors has been carried out by several authors. Most of the models use first-order or zero-order kinetics, because of the simplicity of the solution of the mathematical problem. However, the reaction kinetics for many practical situations is a non-linear Monod kinetics, which requires numerical solutions. This paper deals with the modeling of biofilm reactors and effectiveness factor calculations for a biofilm particle with Monod kinetics and two consecutive reactions. The model is applied to biological denitrification in a fluidized bed bioreactor, in which the liquid phase is assumed to be in plug flow. Effectiveness factors of biofilm are numerically calculated by solving the system of ODES by orthogonal collocation. Axial concentration profiles of nitrate and nitrite species are calculated and compared with experimental results.     

Antibiotics production in a fluidized bed reactor utilizing a transverse magnetic field

A mathematical model is developed to describe the performance of a three-phase fluidized bed reactor utilizing a transverse magnetic field. The model is based on the axially dispersed plug flow model for the bulk of liquid phase and on the Michaelis-Menten kinetics. The model equations are solved by the explicit finite difference method from transient to steady state conditions. The results of the numerical simulation indicate that the magnetic field increases the degree of bioconversion. The mathematical model is experimentally verified in a three-phase fluidized bed reactor with Penicillium chrysogenum immobilized on magnetic beads. The experimental results are well described by the developed model when the reactor operates in the stabilized regime. At low and relatively high magnetic field intensities certain discrepancy in the model solution is observed when the model over estimates the product concentration.     

Moving-Medium Biofilm Reactors

Four moving-medium biofilm reactors treating wastewater were reviewed in this paper: the rotating biological contactor (RBC), the moving bed biofilm reactor (MBBR), the vertically moving biofilm reactor (VMBR) and the fluidized-bed reactor (FBR). The RBC process has been applied widely. MBBR is a good process for upgrading current wastewater treatment systems. VMBR is suitable for treating small wastewater flows. FBR can maximize pollutant removals and minimize sludge production.     

Heterogeneous biofilm activity in a segregated anaerobic fluidized bed bioreactor

Bed segregation in a fluidized bed bioreactor profoundly influenced biofilm thickness and microbial activities of the biofilm along the bed height. Bioparticles coated with a thin biofilm, observed at the bottom of the reactor, had a higher specific activity in propylene glycol and n-propanol degradation than in thick biofilms developed at the top of the reactor. Although no significant difference was observed in specific activity for propionate and acetate along the reactor flow axis, more total propionate and acetate conversion occurred in regions of thicker biofilm accumulation.     

Countercurrent multistage fluidized bed reactor for immobilized biocatalysts: III. Hydrodynamic aspects

In Parts I and II of this series we described the modelling, design, and operation of a multistage fluidized bed reactor (MFBR) for immobilized biocatalysts. This article deals with those aspects of the MFBR which are different from single-stage fluidized beds which are operated in batch mode with respect to the solids. The semicontinuous transport of the particles requires perfect mixing of the particles in the reactor compartments, because particles are mainly transported from the bottom of these compartments. A large spread in the physical properties of the biocatalyst particles, especially of both size and density, may cause the particles to segregate into layers with different diameter and/or density. This affects the efficient use of the biocatalyst. The properties of the particles are dependent on the immobilization method. The suitability of different methods for possible future application in the MFBR is therefore compared. Because of segregation, successful use of a biofilm catalyst with a nonuniform thickness of the biofilm is doubtful. Experiments in a small scale reactor (+/- 0.1 m diameter) demonstrated that perfect particle mixing is possible using commercially available biocatalyst particles of uniform density. Co-immobilization of the biocatalyst with glass powder in a gel is a simple and effective method of increasing gel density. High density particles allow high liquid flow rates, and thus an improved external mass transfer can be achieved.The distributor plates, which separate the reactor compartments, must allow unhindered transport of particles. Therefore, the holes in these plates must have a diameter of at least 4.5 times that of the largest particles which are present in the particle mixture used. Furthermore, the plates must be designed such that, when scaling-up the reactor, a uniform liquid distribution over the cross-sectional area of the reactor occurs. Large-scale experiments were not carried out, but published correlations, indicate that particle mixing and a uniform liquid distribution can be accomplished in a large-scale reactor under similar flow conditions.     

Influence of the type of organisms on the biomass hold-up in a fluidized-bed reactor

Summary In the last few years, the use of fluidized-bed reactors for biological wastewater treatment has got increasing attention. In 1981, Shieh et al. proposed a model to predict the biomass concentration in a fluidized-bed reactor. From this model one can see that the biofilm density plays a very important role in determining the total biomass hold-up. In this article the influence of the type of carbon source on the biomass concentration, and as a consequence the type of organisms selected, is studied. The growth of a filamentous, budforming bacteria in a reactor treating nitrate rich surface water supplied with methanol as carbon source, results in a biomass concentration only half of the concentration which can normally be obtained in a fluidized-bed reactor treating synthetic wastewater; in this latter case rod-shaped bacteria are enriched which permit a dense packing.     

Dynamic transport and reaction model for azo dye removal in a UAFB reactor

An Upflow Anaerobic Fixed Bed (UAFB) reactor packed with activated carbon was used to remove the azo dye Reactive red 272. The biomass grown on the activated carbon surface was composed of an adapted consortium of microorganisms. Residence time distribution test indicated that the reactor was a plug flow behavior. A dynamic mathematical model is presented for dye flux along the reactor and within the bioparticles composed of two regions: activated carbon core and biofilm. The model considers that the reaction is performed in the biofilm and in the liquid phase and includes dye transport by dispersion and diffusion. The concentration profile within the bioparticles changes with reactor height and time as the equilibrium is achieved. Changes in dye concentrations affect the concentration profile in the reactor and reduce the removal efficiency. The effectiveness factor depends on the reactor height and on the dye concentration at the inlet.     

Production of penicillin in a fluidized-bed bioreactor using a carrier-supported mycelial growth

A carrier-supported mycelial growth of Penicillium chrysogenum was applied to penicillin fermentation system using celite as a support material. Hyphal growth through the pore matrices of the material showed strong anchorages and provided highly stable biofilm growth. With bioparticles developed in such a manner, both cell growth and penicillin production were observed to increase significantly compared to the conventional dispersed filamentous cultures. Maximum values of specific penicillin production rate were found to be constant regardless of the growth form. A three-phase fluidized-bed fermentor was designed and tested for penicillin production using the bioparticles. Two modes of operation, semicontinuous and repeated fed batch, of the fermentor were tried. It was noted that the overgrowth of free mycelia and the development of fluffy loose bioparticles caused poor mixing and made the fermentor operation quite difficult. Control of the bioparticle size and the extension of production phase were therefore considered important to maintain the reactor productivity at a desired level. From the results of repeated fed-batch operation it was found that the control of bioparticle size could be successfully achieved by phosphate-limiting culture condition. Penicillin production under this condition was also observed to be maintained at a high level (about 80% of the maximum) for at least 1 month.     

Mathematical model for a three-phase fluidized bed biofilm reactor in wastewater treatment

A mathematical model for a three phase fluidized bed bioreactor (TFBBR) was proposed to describe oxygen utilization rate, biomass concentration and the removal efficiency of Chemical Oxygen Demand (COD) in wastewater treatment. The model consisted of the biofilm model to describe the oxygen uptake rate and the hydraulic model to describe flow characteristics to cause the oxygen distribution in the reactor. The biofilm model represented the oxygen uptake rate by individual bioparticle and the hydrodynamics of fluids presented an axial dispersion flow with back mixing in the liquid phase and a plug flow in the gas phase. The difference of settling velocity along the column height due to the distributions of size and number of bioparticle was considered. The proposed model was able to predict the biomass concentration and the dissolved oxygen concentration along the column height. The removal efficiency of COD was calculated based on the oxygen consumption amounts that were obtained from the dissolved oxygen concentration. The predicted oxygen concentration by the proposed model agreed reasonably well with experimental measurement in a TFBBR. The effects of various operating parameters on the oxygen concentration were simulated based on the proposed model. The media size and media density affected the performance of a TFBBR. The dissolved oxygen concentration was significantly affected by the superficial liquid velocity but the removal efficiency of COD was significantly affected by the superficial gas velocity. An erratum to this article can be found online at .     

Hydrogen production with immobilized sewage sludge in three-phase fluidized-bed bioreactors

Municipal sewage sludge was immobilized with a modified alginate gel entrapment method, and the immobilized cells were used to produce hydrogen gas in a three-phase fluidized bed. The hydrogen-producing fluidized beds were operated at different liquid velocity (U(0)) and hydraulic retention time (HRT). The results show that in response to operating liquid velocities, the fluidized-bed system had three flow regimes, namely, plug flow, slug flow, and free bubbling. Pressure fluctuation analysis was used to analyze the hydrodynamic properties in this three-phase fluidized bed when it was under a steady-state production of biogas. With a steady-state biogas production rate (U(g)) of 0.196 mL/s/L, a transition state occurred at a liquid velocity (U(0)) of 0.85 cm/s. As U(0) < 0.85 cm/s, the system was basically a nonhomogeneous fluidized bed, whereas the bed became homogeneous when U(0) was higher than 0.85 cm/s. The fluidized bed can be stably carried out at high loading rates (HRT as low as 2 h). Hydrogen fermentation results show that the maximal hydrogen production rate was 0.93 L/h/L and the best yield (Y(H)2(/sucrose)) was 2.67 mol H(2)/mol sucrose.     

Simultaneous nitrification and denitrification by controlling vertical and horizontal microenvironment in a membrane-aerated biofilm reactor

Nitrogen and carbon components in domestic modified wastewater were completely removed by simultaneous nitrification and denitrification using a membrane-aerated biofilm reactor where biofilm was fixed on a hollow-fiber membrane. To measure the spatial distribution of pH, ammonium and nitrate ions and to observe microbes inside the biofilm fixed on the membrane, microelectrodes and the fluorescence in situ hybridization (FISH) method were applied. Due to plug flow in the vertical direction (from the bottom to the top of the reactor), ammonium nitrogen was gradually removed and negligible nitrate nitrogen was detected throughout the reactor. FISH revealed that ammonia-oxidizing bacteria were mainly distributed inside the biofilm and other bacteria, which included denitrifying bacteria, were mainly distributed outside the biofilm and over the suspended sludge. In order to characterize bacterial activity in the vertical direction of the reactor, nitrification rates at lower, central and upper points were calculated using microelectrode data. The nitrification rate at the lower point was 7 and 125 times higher than those at the central and upper points, respectively. These results show that the removal of carbon and nitrogen compounds was accomplished efficiently by using various kinds of bacteria distributed vertically and horizontally in a single reactor.     

Countercurrent multistage fluidized bed reactor for immobilized biocatalysts: II. Operation of a laboratory-scale reactor

In Part I of this series,(1) we derived a model and made simulations for a multistage fluidized bed reactor (MFBR). It was concluded that the MFBR can be an attractive alternative for a fixed bed reactor when operated with a deactivating biocatalyst. In Part II of this series, the design of a laboratory-scale MFBR and its evaluation to investigate the practical feasibility of this reactor type, will be described. Experiments with a duration as long as 10 days were carried out successfully using immobilized glucose isomerase as a model reaction system. The results predicted by the model are in good agreement with the measured glucose concentration and biocatalyst activity gradients, indicating perfect mixing of the particles in the reactor compartments.The diameters of the biocatalyst particles used in the experiments showed a large spread, with the largest being 1.7 times the smallest. Therefore, an additional check was carried out, to make sure that the particles were not segregating according to size. Particles withdrawn from the reactor compartments were investigated using an image analyzer. Histograms of particle size distribution do not indicate segregation and it is concluded that the particles used have been mixed completely within the compartments. As a result, transport of biocatalyst is nearly plug flow.