Kinetic Modeling of Acetophenone Reduction Catalyzed by Alcohol Dehydrogenase from <Emphasis Type="Italic">Thermoanaerobacter</Emphasis> sp.

NADPH-dependent alcohol dehydrogenase (ADH) from Thermoanaerobacter sp. was kinetically characterized using reduction of acetophenone as a model. To achieve 98% conversion of acetophenone, cofactor regeneration by oxidation of 2-propanol with the same enzyme was used. The enzyme was stable in the batch reactor. It was enantioselective towards (S)-1-phenylethanol (ee>99.5%). Due to its high deactivation in continuously operated stirred tank reactor (k_d=0.0141 min⁻¹) there was no way to keep high conversion of acetophenone at 98%. The deactivation occurred in the repetitive batch as well. A mathematical model for the acetophenone reduction with cofactor regeneration describing the behaviour in a batch, repetitive-batch and continuously stirred tank reactor was developed.     

Power consumption and maximum energy dissipation in a milliliter‐scale bioreactor

Mean power consumption and maximum local energy dissipation were measured as function of operating conditions of a milliliter‐scale stirred tank bioreactor (V = 12 mL) with a gas‐inducing impeller. A standard laboratory‐scale stirred tank bioreactor (V = 1,200 mL) with Rushton turbines was used as reference. The measured power characteristics (Newton number as function of Reynolds number) were the same on both scales. The changeover between laminar and turbulent flow regime was observed at a Reynolds number of 3,000 with the gas‐inducing stirrer on a milliliter‐scale. The Newton number (power number) in the turbulent flow regime was 3.3 on a milliliter‐scale, which is close to values reported for six‐blade Rushton turbines of standard bioreactors. Maximum local energy dissipation (ε_max) was measured using a clay/polymer flocculation system. The maximum local energy dissipation in the milliliter‐scale stirred tank bioreactor was reduced compared with the laboratory‐scale stirred tank at the same mean power input per unit mass (ε_ø), yielding ε_max/ε_ø ≈ 10 compared with ε_max/ε_ø ≈ 16. Hence, the milliliter‐scale stirred tank reactor distributes power more uniformly in the reaction medium. These results are in good agreement with literature data, where a decreasing ε_max/ε_ø with increasing ratio of impeller diameter to reactor diameter is found (d/D = 0.7 compared with d/D = 0.4). Based on these data, impeller speeds can now be easily adjusted to achieve the same maximum local energy dissipation at different scales. This enables a more reliable and robust scale‐up of bioprocesses from milliliter‐scale to liter‐scale reactors. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2010     

Investigations of cephalosporin C production in an airlift tower loop reactor

Summary Cephalosporin C was produced by Cephalosporium acremonium in a 60 l airlift loop reactor on complex medium (with 30 kg/m³ peanut flour) in fed-batch operation. A final product concentration of 5 kg/m³ and a maximum productivity of 45 g/m³ h were attained. On-line analysis was used to determine ammonia, methionine, phosphate, reducing sugar and cephalosporin C by an autoanalyser, glucose by a flow injection analyser and cephalosporin C, penicillin N, deacetoxycephalosporin C, deacetylce-phalosporin C and methionine by HPLC. The volumetric productivity of the stirred tank reactor was higher than that of the airlift reactor because of differences in cell concentration. Specific productivities in relative to cell mass were similar in the two reactors. The substrate yield coefficient in the airlift reactor was twice that in the stirred tank reactor.Nomenclature E _o2 efficiency of oxygen transfer with regard to the specific power input - K _La volumetric mass transfer coefficient - OTR oxygen transfer rate - P power input - PR volumetric productivity of CPC - q _a volumetric aeration rate/broth volume (vvm) - SPR specific productivity with regard to RNA - V _L broth volume in reactor - z relative height of the aerated reactor     

Continuous Cellulase Production

Trichoderma viride QM 9414 growth characteristics on glucose were investigated in single stage continuous stirred tank reactor operation and growth parameters μ_max, K_s, Q_O2 identified. Multistage stirred tank fermentors in series with the first stage utilizing glucose and the subsequent stages utilizing cellulose yielded results in general agreement with theoretical predictions. Significant increase in enzyme productivity over single stage fermentation was obtained in multistage operation.     

Studies of insufficient mixing in bioreactors: Effects of limiting oxygen concentrations and short term oxygen starvation on Penicillium chrysogenum

The effect of oxygen limitation on the respiration rate of Penicillium chrysogenum was studied. The results show that measurements of critical oxygen tensions within a process that on morphological or on physical grounds exhibits an inhomogenous structure are not likely to resemble the Monod model.In order to study the effects of short term oxygen starvation on the respiratory capacity of Penicillium chrysogenum, a two compartment fermenter was constructed. This fermenter consists of one well mixed aerobic part (CSTR) and one minor anaerobic part (CPFR). In the latter the circulation time as well as the volume can be varied. After passage of the whole cell culture volume through the anaerobic part, irreversible inhibition of the respiration was observed. This was caused by a circulation time of 5 and 10 min in the plug flow reactor and with a volume of 6% of the stirred tank reactor volume. However, circulation times of 1 and 2 min with an anaerobic zone of 1% of the stirred tank reactor volume did not give any irreversible effects on the respiratory capacity.This was compared with the results of the previously established model ln(1 — I _OUR//100)^–1 = kt [1]. The I _OUR is the percentage irreversible inhibition of the respiration, t is the anaerobic circulation time and k is a constant. The two compartment fermenter results agree with the earlier model at circulation times of 5 and 10 min, but not with the shorter times, and this suggests that a lag phase exists in the inactivation kinetics.     

Jet aeration as alternative to overcome mass transfer limitation of stirred bioreactors

In industrial biotechnology increasing reactor volumes have the potential to reduce production costs. Whenever the achievable space time yield is determined by the mass transfer performance of the reactor, energy efficiency plays an important role to meet the requirements regarding low investment and operating costs. Based on theoretical calculations, compared to bubble column, airlift reactor, and aerated stirred tank, the jet loop reactor shows the potential for an enhanced energetic efficiency at high mass transfer rates. Interestingly, its technical application in standard biotechnological production processes has not yet been realized. Compared to a stirred tank reactor powered by Rushton turbines, maximum oxygen transfer rates about 200% higher were achieved in a jet loop reactor at identical power input in a fed batch fermentation process. Moreover, a model‐based analysis of yield coefficients and growth kinetics showed that E. coli can be cultivated in jet loop reactors without significant differences in biomass growth. Based on an aerobic fermentation process, the assessment of energetic oxygen transfer efficiency [kgO₂ kW^?1 h^?1] for a jet loop reactor yielded an improvement of almost 100%. The jet loop reactor could be operated at mass transfer rates 67% higher compared to a stirred tank. Thus, an increase of 40% in maximum space time yield [kg m^?3 h^?1] could be observed.     

Bioprocess engineering characteristics of the horizontal stirred tank

Bioreactor performance studies of the recently developed horizontal stirred tank with a volume of 421 have been carried out for fermentation with Trichosporon cutaneum. Quantification on the basis of measured oxygen transfer capacity and power consumption is presented and compared with data for a conventional vertical tank bioreactor.During the experiments it has been observed that two different forms of morphology of Trichosporon, i.e. the normal yeast-form (Y) with single cells and a mycelium-form (M) with filamentous cells, are present in the horizontal stirred tank when working with the original strain (DSM 70698). After separation both forms were characterized and later on used for bioreactor performance studies in the horizontal and vertical stirred tank. Results of oxygen efficiency show the drastic effect of the morphology change on bioreactor performance. Finally different bioreactors are quantitatively compared on the basis of oxygen transfer, power consumption and productivity using the reference fermentation system Trichosporon cutaneum.List of Symbols F m³/h flow rate (volumetric) - k _La1/h volumetric transfer coefficient of OTR - M Nm torque - n 1/s rotational speed - P Nm/s power - V m³ volume - V _G1/min gas flow rate - x kg/m³ biomass concentration - ^* morphology index - ^* engineering (specific) viscosity - _app Ns/m² apparent viscosity - ₀ N/m² yield stress (Casson law) - t _1/e h measured time acc. to momentum method [17] - tEh characteristic time of electrode response - t _Gh mean residence time of gas phase Abbreviations CFR completely filled reactor - CRR cyclic ring reactor (torus) - JLR jet loop reactor - HSTR horizontal stirred tank reactor - M mycelium-form of Trichosporon cutaneum - O₂-eff O₂-efficiency - OUR O₂-uptake rate - OTR O₂-transfer rate - STR stirred tank reactor - ThLR thin layer reactor - VSTR vertical stirred tank reactor - Y yeast-form of Trichosporon cutaneum The work presented in this paper was supported by an Austrian Research Grant (FFWF, Project no. 4496)     

Continuous production of α-amylase byBacillus amyloliquefaciens in a two-stage fermentor

Summary The production of a secondary metabolite (-amylase) by a highly aerobic bacterium (Bacillus amyloliquefaciens) was examined in batch, single-stage chemostat, two-stage stirred tank, and two-stage stirred tank/tubular reactor configurations. The relative performance of these reactor systems as measured by product concentration and volumetric productivity was compared, and the effect of aeration rate on the extent of plug flow in the tubular reactor was examined.     

Process of penicillin G hydrolysis catalyzed by penicillin acylase immobilized on acylic carrier

The usefulness of penicillin acylase immobilized onto butyl acrylate — ethyl glycol dimethacrylate (called in this paper acrylic carrier) in penicillin G hydrolysis performed in a stirred tank reactor is shown. The enzyme-acrylic carrier preparation does not deteriorate its own properties in the mixing condition of slurry reactor. The experiments were carried out in a batch and a continuous stirred tank reactor as well as continuous stirred tank reactors in series. It was found to be a satisfactory agreement between experimental and predicted results. It also indicated the optimal substrate concentration range which provides the most effective enzyme operation. A superiority of the three reactors in series over the batch reactor is shown.List of Symbols C_E g/m³ equivalent enzyme concentration - C_SO mol/m³ initial penicillin G concentration - K_A mol/m³ substrate affinity constant - K_iS mol/m³ substrate inhibitory constant - K_iP mol/m³ PhAA inhibitory constant - K_iQ mol/m³ 6-APA inhibitory constant - k₃ mol/g min constant rate of dissotiation of the active complex - r mol/m³ rate of reaction - t min. reaction time - t_j min. maintenance time - degree of conversion - _B, _F dimensionless time - min. residence time - PA penicillin acylase - PG penicillin G - PhAA phenylacetic acid - 6-APA 6-aminopenicillanic acid     

Polysialic acid production using Escherichia coli K1 in a disposable bag reactor

Polysialic acid (polySia), consisting of α‐(2,8)‐linked N‐acetylneuraminic acid monomers plays a crucial role in many biological processes. This study presents a novel process for the production of endogenous polySia using Escherichia coli K1 in a disposable bag reactor with wave‐induced mixing. Disposable bag reactors provide easy and fast production in terms of regulatory requirements as GMP, flexibility, and can easily be adjusted to larger production capacities not only by scale up but also by parallelization. Due to the poor oxygen transfer rate compared to a stirred tank reactor, pure oxygen was added during the cultivation to avoid oxygen limitation. During the exponential growth phase the growth rate was 0.61 h^?1. Investigation of stress‐related product release from the cell surface showed no significant differences between the disposable bag reactor with wave‐induced mixing and the stirred tank reactor. After batch cultivation a cell dry weight of 6.8 g L^?1 and a polySia concentration of 245 mg L^?1 were reached. The total protein concentration in the supernatant was 132 mg L^?1. After efficient and time‐saving downstream processing characterization of the final product showed a protein content of below 0.04 mg_protein/g_polySia and a maximal chain length of ～90 degree of polymerization.     

Hollow-fibre fermenter using ultrafiltration

Summary A novel bioreactor with hollow fibres was developed to facilitate substrate transfer across membrane walls as well as to retain a continuous cell growth in the shell side. Ultrafiltration was induced through membrane by pressurizing feed solution to the inside of a hollow fibre with inlet and outlet pumps. The ultrafiltrate accumulated outside the hollow fibres was recirculated through a reservoir where a part of solution containing cells and substrate was removed to keep the level of reservoir solution constant. Ethanol production by Saccharomyces cerevisiae was carried out to test the feasibility of this reactor. The productivity of this reactor was compared with that of a continuous stirred tank reactor (CSTR).     

Production of optically pure L-alanine in batch and continuous stirred tank reactors using immobilized Pseudomonas sp.

A process to obtain optically pure l-alanine has been developed using batch and continuous stirred tank reactors with a new l-aminoacylase-producing bacterium Pseudomonas sp. BA2 immobilized in calcium alginate beads coated with glutaraldehyde. The maximum production of l-alanine in a continuous stirred tank reactor was 11.26 g after 2 days of operation which is higher than that previously reported.     

Impact of nozzle operation on mass transfer in jet aerated loop reactors. Characterization and comparison to an aerated stirred tank reactor

The impact of mass transfer on productivity can become a crucial aspect in the fermentative production of bulk chemicals. For highly aerobic bioprocesses the oxygen transfer rate (OTR) and productivity are coupled. The achievable space time yields can often be correlated to the mass transfer performance of the respective bioreactor. The oxygen mass transfer capability of a jet aerated loop reactor is discussed in terms of the volumetric oxygen mass transfer coefficient k_La [h^?1] and the energetic oxygen transfer efficiency E [kgO₂ kW^?1 h^?1]. The jet aerated loop reactor (JLR) is compared to the frequently deployed aerated stirred tank reactor. In jet aerated reactors high local power densities in the mixing zone allow higher mass transfer rates, compared to aerated stirred tank reactors. When both reactors are operated at identical volumetric power input and aeration rates, local k_La values up to 1.5 times higher are possible with the JLR. High dispersion efficiencies in the JLR can be maintained even if the nozzle is supplied with pressurized gas. For increased oxygen demands (above 120 mmol L^?1 h^?1) improved energetic oxygen transfer efficiencies of up to 100 % were found for a JLR compared to an aerated stirred tank reactor operating with Rushton turbines.     

New milliliter‐scale stirred tank bioreactors for the cultivation of mycelium forming microorganisms

A novel milliliter‐scale stirred tank bioreactor was developed for the cultivation of mycelium forming microorganisms on a 10 milliliter‐scale. A newly designed one‐sided paddle impeller is driven magnetically and rotates freely on an axis in an unbaffled reaction vessel made of polystyrene. A rotating lamella is formed which spreads out along the reactor wall. Thus an enhanced surface‐to‐volume ratio of the liquid phase is generated where oxygen is introduced via surface aeration. Volumetric oxygen transfer coefficients (k_La) > 0.15 s^?1 were measured. The fast moving liquid lamella efficiently prevents wall growth and foaming. Mean power consumption and maximum local energy dissipation were measured as function of operating conditions in the milliliter‐scale stirred tank bioreactor (V = 10 mL) and compared to a standard laboratory‐scale stirred tank bioreactor with six‐bladed Rushton turbines (V = 2,000 mL). Mean power consumption increases with increasing impeller speed and shows the same characteristics and values on both scales. The maximum local energy dissipation of the milliliter‐scale stirred tank bioreactor was reduced compared to the laboratory‐scale at the same mean volumetric power input. Hence the milliliter impeller distributes power more uniformly in the reaction medium. Based on these data a reliable and robust scale‐up of fermentation processes is possible. This was demonstrated with the cultivation of the actinomycete Streptomyces tendae on both scales. It was shown that the process performances were equivalent with regard to biomass concentration, mannitol consumption and production of the pharmaceutical relevant fungicide nikkomycin Z up to a process time of 120 h. A high parallel reproducibility was observed on the milliliter‐scale (standard deviation < 8%) with up to 48 stirred tank bioreactors operated in a magnetic inductive drive. Rheological behavior of the culture broth was measured and showed a highly viscous shear‐thinning non‐Newtonian behavior. The newly developed one‐sided paddle impellers operated in unbaffled reactors on a 10 milliliter‐scale with a magnetic inductive drive for up to 48 parallel bioreactors allows for the first time the parallel bioprocess development with mycelium forming microorganisms. This is especially important since these kinds of cultivations normally exhibit process times of 100 h and more. Thus the operation of parallel stirred tank reactors will have the potential to reduce process development times drastically. Biotechnol. Bioeng. 2010; 106: 443–451. © 2010 Wiley Periodicals, Inc.     

Citric acid production and morphology of Aspergillus niger as functions of the mixing intensity in a stirred tank and a tubular loop bioreactor

The relationship between Aspergillus niger morphology and citric acid production was investigated in two reactor systems with different configurations, a tubular loop and a stirred tank bioreactor, with operating volumes of 6 and 8 dm³, respectively. Morphology was quantified by image analysis. In each system, morphology, characterized by the parameter P (mean convex perimeter of clumps), and citric acid production, were agitation-dependent and closely linked. Increased agitation caused a reduction of clump sizes and results when both reactors demonstrate that the parameter P should not exceed a threshold value in order to achieve increased productivities. The results obtained from the two reactors were in agreement, both qualitatively and quantitatively. Reducing the fundamentally different mixing conditions of the two bioreactors to the order of the dimensionless mixing parameter relative mixing time (τ_m), results showed that the loop simulated the stirred tank. Also, relationships valid for one system accurately described the results obtained from the other system, demonstrating the validity of the relationship between morphology and productivity for the particular fermentation, regardless of the reactor type. Previous attempts to evaluate the use of loop configurations as scale-up tools and their performance as bioreactors, neglected the morphology of the producer micro-organisms. This study demonstrated the close link between morphology and productivity for citric acid production by A. niger, and identified a morphology parameter that was used successfully to characterize the process performance.     

Production of fructooligosaccharides in high yield using a mixed enzyme system of β-fructofuranosidase and glucose oxidase

A mixed enzyme system, with -fructofuranosidase (obtained from Aspergillus japonicus) and commercial glucose oxidase (Gluzyme, Novo Nordisk), produced fructooligosaccharides (FOS) in high yield from sucrose. The reaction was performed in an aerated stirred tank reactor controlled at pH 5.5 by a slurry of CaCO₃. Glucose, an inhibitor of -fructofuranosidase, produced in the reaction was converted by glucose oxidase to gluconic acid, which was then precipitated to calcium gluconate in solution. The system produced more than 90% (w/w) FOS on a dry weight basis, the remainder was glucose, sucrose and a small amount of calcium gluconate. Most of the FOS and sucrose was hydrolyzed to fructose in the mixed enzyme system with glucose oxidase and -fructofuranosidase from Asp. niger.     

Casein hydrolysis in stirred tank reactors using chymotrypsin immobilized on magnetic supports

Nickel-NiO-BSA-chymotrypsin has been used to hydrolyze casein in both batch and continuous stirred tank reactors. The kinetics of hydrolysis in both types of reactor were considered. Some operational problems encountered using fine powder catalysts in batch stirred tank reactors are discussed. High gradient magnetic separation was found to be a powerful catalysts retention method for magnetic support particles, particularly when using a ferromagnetic collection matrix. Nickel particles of diameter 3–7 μm were easily separated from water at a processing velocity of 39 mm/sec. Nickel powder and precipitated Fe₃O₄ were also separated satisfactorily using a rotating drum magnetic separator.     

Denitrification Performance of Pseudomonas denitrificans in a Fluidized‐Bed Biofilm Reactor and in a Stirred Tank Reactor

Denitrification of a synthetic wastewater containing nitrates and methanol as carbon source was carried out in two systems – a fluidized‐bed biofilm reactor (FBBR) and a stirred tank reactor (STR) – using Pseudomonas denitrificans over a period of five months. Nitrogen loading was varied during operation of both reactors to assess differences in the response to transient conditions. Experimental data were analyzed to obtain a comparison of denitrification kinetics in biofilm and suspended growth reactors. The comparison showed that the volumetric degradation capacity in the FBBR (5.36 kg _N · m^–3 · d^–1) was higher than in the STR, due to higher biomass concentration (10 kg _BM · m^–3 vs 1.2 kg _BM m^–3).     

Flow dynamics of immobilized enzyme reactors

Summary Enzymic conversion of glucose to fructose was carried out in a packed bed and in a fluidized bed reactor. The flow dynamics of these two flow systems, loaded with two different types of immobilized loaded with two different types of immobilized glucose isomerase particles, were studied. The theoretical RTD curve calculated from the axial dispersed plug flow model equation was matched to the experimental RTD curve by an optimization technique. The effect of fluid velocity on the extent of liquid dispersion was established. Theoretical predictions on the conversion of glucose to fructose were calculated using three mathematical models, namely, a plug flow model, a continuous stirred tank reactor (CSTR) model and an axial dispersed plug flow model. The experimental results showed that the axial dispersed plug flow model was superior in predicting the performance of both the packed bed and fluidized bed reactor.Abbreviations C Dimensionless concentration - D Dispersion coefficient [cm²/sec] - d _p Mean particle diameter [cm] - E Enzyme concentration [mol/gm] - F Fructose concentration [mol/cm³] - F _e Equilibrium fructose concentration [mol/cm³] - G Glucose concentration [mol/cm³] - G _e Equílibrium glucose concentration [mol/cm³] - G _o Initial glucose concentration [mol/cm³] - Reduced glucose concentration [mol/cm³] - K Equilibrium constant - K _mf Forward reaction rate constant [mol/cm³] - K _mr Reserve reaction rate constant [mol/cm³] - K _m Rate constant [mol/cm³] - L Total length of the reactor bed [cm] - l Length [cm] - Q Flow rate [cm³/s] - r Rate of reaction based on volume of substrate - u Superficial liquid velocity [cm/s] - v Interstitial liquid velocity [cm/s] - V Reactor bed volume [cm³] - V _mf Forward reaction rate constant [mol/s·g enzyme] - V _mr Reserve reaction rate constant [mol/s·g enzyme] - z Dimensionless distance along the reactor - Density [g/cm²]     

Hydrolysis of triglyceride by solid phase lipolytic enzymes of Rhizopus arrhizus in continuous reactor systems

Continuous hydrolysis of triglyceride in organic solvent systems using Rhizopus arrhizus mycelia as a source of insolubilized lipase has been studied in packed-bed and stirred-tank reactors. Typically a packed bed reactor containing 1 g of mycelia fed at 1 mL/min with a solution of 2.5% (w/v) olive oil in di-isopropyl ether gave a fatty acid yield of 45% at 30°C. The optimum water concentration was found to be 0.17% (w/v) except under conditions of high oil feed concentration and high yield where no optimum was established. No temperature optimum was observed over the range 20–55°C. Calculated activation energies of 13–20 kJ/mol, depending on temperature, were lower, while K_m(app) values of 0.1–0.3M were higher than those for hydrolysis in conventional aqueous emulsion systems. No evidence of any significant diffusional limitation, which could account for these values, was obtained. The mycelia showed a loss of activity of 0.6–1.0%h at 30°C. The packed bed proved markedly superior to the stirred tank for this system.