Design and performance characteristics of a continuous multistage tower fermentor

The design of a continuous multistage tower fermentor is described. The fermentor consists of five stages separated by perforated plates. Each stage includes mechanical mixing provided by two disc turbine impellers and has its own impeller shaft with bearing assembly and flexible coupling that enables the operation of an arbitrary number of stages. The normal operation of this system enables the co-current flow of gas and liquid, but the system can function countercurrently as well. The purpose of this study was to examine the hydrodynamic performance, i.e., the pressure gradient along the tower, the mixing time, gas holdup, the residence lime distribution of the continuous phase, the value of the backflow coefficient, and the oxygen transfer rate under conditions usually used during fermentations. From the interrelations between parameters influencing the proper performance of this system, an optimal design of plate geometry for processes requiring high oxygen transfer rate was formulated.     

Design and physical characteristics of a multistage,continuous tower fermentor

A multistage tower laboratory fermentor has been constructed consisting of eight compartments separated by sieve plates. Flow of substrate and air is concurrent from the bottom to the top of the column. It, was hoped that this system could be used to reproduce, simultaneously on a continuous basis, eight distinct phases of a batch growth curve. It was believed that the extent of batch curve simulation would depend upon the character of hydraulic mean residence time of broth in the column and in the individual compartments. The expected relationship did not occur. Rather it was found that growth in the column involved residence time characteristics not only for the fluid but also for the microorganisms, and for the growth limiting substrate. Depending upon the column operation, these could be distinct and different. The purpose of this investigation was to study the residence time distribution (RTD) of the continous (fluid) and dispersed (microorganisms) phases for model systems as well as for a yeast fermentation. Various degrees of flow nonideality, i.e., fluid blackflow and dispersed phase sedimentation, were noticed. The former seems to be due to interaction of the concurrent gas and liquid flow; it is particularly dependent upon void area of the sieve plate holes. Sedimentation is probably a function of plate design as well as cell size and density. It wa concluded that for a particular plate design the gas hold-up wass controlled by superficial air velocity and was the main parameter governing the differences between dispersed and continous phase(Rt1). This conclusion was supported by a computeraided styudy utilizing a mathematical model of fluid flow to fit the growth kinetics and cell distribution observed experimentally throughout the fermentor. Some advantages of foam control in the tower fermentor by surface active compounds are mentioned. Also, suggestions are made for carrying out fermentations that have two liquid phases, such as a hydrocarbon fermentation. The possibility of closely approximating plug-flow conditions in the multistage tower fermentor, a necessary condition for batch growth simulation, is discussed from a practical point of view.     

Effect of PO2 on growth and physiological characteristics of Candida utilis in a multistage tower fermentor

The effect of increasing the partial pressure of oxygen in the aeration gas on growth and physiological activity of the yeast Candida utilis in a multistage tower fermentor was studied. The measurements were made at steady states of continuous culture for single values of dilution rate, temperature, and pH in all stages of the fermentor and with one given ethanol concentration in the growth medium feed. The partial pressure of oxygen in the gas phase was changed in the range from 165 to 310 torr. The results revealed the existence of the upper critical value of the partial oxygen pressure in the gas phase. It was demonstrated that the upper critical value of PO ₂ influences not only the growth rate, biomass yield, and productivity but also the cell physiology resulting in changes of respiration activity and activity of alcohol and aldehyde dehydrogenases.     

Ethanol fermentation in a continuous tower fermentor

A mutant of Saccharomyces cerevisiae, which forms large, multicellular flocs in liquid culture, rapidly fermented media containing high concentrations of glucose (100-180 g/L) in a continuous nonaerated tower fermentor at 30 degrees C. The fermentor operated continuously for seven months. Batch and tower fermentor data were fitted to a kinetic model incorporating linear ethanol inhibition and Monod dependence on glucose. Conversion, ethanol yield, and ethanol productivity were related to the apparent fermentation time for initial glucose concentrations of 130 and 180 g/L. Productivities of 8-12 g ethanol/L h were achieved through the yeast bed giving conversions exceeding 90% of the theoretical yield.     

A continuous,multistage tower fermentor. II. Analysis of reactor performance

A method for analyzing the reactor behavior of a continuous, multistage tower fermentor is described. A model consisting of a system of interconnected, ideal subreactors is set up on the basis of the fermentor's configuration and flow pattern. The residence time distribution curve is used to test the validity of the model and the relative quantities of flow streams and regions in the model are determined. A least-square fitting procedure between measured and calculated distribution curves is used to identify the proper model. The application of this method to real cultivation conditions is also discussed. Using this approach, the multistage tower fermentor is shown to be equivalent to a cascade of four perfectly mixed tanks with a backtracking stream between stages. The extent of backflow under various conditions has also been determined.     

A continuous,multistage tower fermentor. I. Design and performance tests

The design of a continuous column fermentor with a multiple staging effect is described. The column is divided into four compartments by horizontal perforated plates and is provided with a central agitator shaft driving an impeller in each compartment. A tube at the center of each plate forms a liquid seal around the shaft and also acts as a “downcomer.” The fermentor is normally operated with counter-current flow of gas and medium. Fresh medium is added to the top stage and product is withdrawn from the bottom. The effect of plate and agitator design on fermentor performance was studied in terms of factor such as oxygen transfer rate, gas holdup, and interstage mixing. By proper choice of the design parameters, the fermentor was made to approximate a perfect four-stage cascade in terms of reactor performance. Preliminary experiments were performed with air-water systems, but a more realistic picture of fermentor performance was obtained in experience involving propagation of Escherichia coli. Data for business and substrate concentrations in each stage confirmed the staging effect of the apparatus. The fermentor operated in a stable manner for periods of more than two weeks.     

Continuous production of ethanol by yeast "immobilized" in a membrane-contained fermentor

A dialysate-feed, immobilized-cell dialysis continuous fermentation system was investigated as a method of relieving product inhibition in the conversion of glucose to ethanol by cells of Saccharomyces cerevisiae ATCC 4126. The substrate was fed into a continuous dialysate circuit and then into a batch fermentor circuit via diffusion through the microporous membranes of an intermediate dialyzer. Simultaneously, product was withdrawn from the fermentor circuit through the dialyzer membranes into the dialysate circuit and out in the effluent. Since the fermentor was operated without an effluent, the cells essentially were immobilized and converted substrate to product by maintenance metabolism. Contrary to prior results with this novel system for the continuous fermentation of lactose to lactate by lactobacillus cells, a steady state of yeast cells in the fermentor did not occur initially but was obtained by the depletion of medium nitrogen and the prevention of cell breakage, although the substrate and product concentrations then became unsteady. The inherent advantages of the system was offset in the ethanol fermentation by relatively low productivity, which appeared to be limited by membrane permeability.     

Physiological characterictics and energy balance ofKlebsiella aerogenes in a multistage tower fermentor

Biomass growth, consumption of carbon and energy source, specific rates of formation of metabolic byproducts, biomass yield referred to the C-source and to oxygen, respiration rate and the value of RQ were studied in Klebsiella aerogenes CCM 2318 (on a synthetic glucose medium) at different specific growth rates. Maintenance coefficients and the total energy balance of the cultivation process were evaluated for a multistage tower fermentor with a defined interstage mixing. The results pointed to changes in both glucose metabolism and the physiological state of the population, brought about by changes in specific growth rate. As compared with a chemostat, the culture was found to exhibit a different physiological character is stages 1 and 4 despite a considerable interstage mixing.     

Effect of oxygen supply on growth ofKlebsiella aerogenes in a multistage tower fermentor

The effect of the rate of oxygen supply on biomass growth, consumption of carbon source formation of metabolic by-products, biomass yeilds referred to C-source and oxygen, respiration rate and the respiratory quotient was studied in a multistage tower fermentor with an interstage backflow, i.e. with a continuous reinoculation of the preceding stages. Experiments were done with Klebsiella aerogenes CCM 2318 in a synthetic glucose medium with constant glucose concentration in the feed, at pH 7.0. temperature 30 degrees C, and dilution rates 0.6 and 0.178 h-1 (referred to one stage). Different behavior of the culture was found at different dilution rates both with oxygen and under oxygen limitation. As compared with the chemostat system, the regime with an interstage backflow exhibited differences in respiration rate and CO2 formation; this attests to a considerably different physiological state of the cells.     

Performance of a perforated plate column as a multistage continuous fermentor

Microorganisms were continuously cultivated in multistage column consisting of ten perforated plate sections to which medium and air were supplied concurrently from the bottom. At steady state the cell concentration in the various stages was gradationally differentiated from the bottom to the top in the direction of medium flow. RNA content per unit cell concentration at each sage was determined. The cells in the lower stages were higher in RNA content than those from the upper stages. Wash out was observed to occur in the column at dilution rates which do not result in wash out in a single stage chemostat system. A study of the flow characteristics revealed that the overall performance of the plate column was equivalent to that of a multistage system, when hole diameter and hole area to column cross sectional area ratio were properly selected. This was true even in highly aerated conditions. These results indicated that the perforated plates in the column hindred intermixing through the plates, and that each stage functioned as an independent stirred vessel. Industrial and research application of this type fermentor was discussed.     

Film fermentor for ethanol production by yeast immobilized on cotton cloth

Summary Saccharomyces cerevisiae cells were immobilized on cotton cloth. The resulting yeast films were placed in parallel in a rectangular fermentor which was designed for scale-up. Ethanol production from sugars in the hydrolysate of Jerusalem artichoke tubers was studied in three modes of operation: batch, circulated batch and continuous flow. Circulated batch fermentation gave the shortest time of fermentation and accordingly the highest average ethanol productivity.     

Growth characteristics of Candida utilis on volatile substrate in a multistage tower fermentor.

The influence of increasing ethanol concentration in the feed on growth and physiological activity of the yeast Candida utlis was studied. The measurements were made at steady states of continuous culture under constant values of dilution rate, temperature, and pH in all stages of the fermentor; Synthetic ethanol was used as the sole source of carbon and energy in the concentration range 10-100 g/liter. The maximum biomass concentration in the effluent and maximum productivity was achieved at 75 g ethanol/liter in the feed. In respect to ethanol losses in the outlet and biomass yield, the optimum ethanol concentration in the input of the growth medium was found to be about 50 g/liter using a four-stage system.     

A Mathematical model for ethanol production by extractive fermentation in a continuous stirred tank fermentor

Extractive fermentation is a technique that can be used to reduce the effect of end product inhibition through the use of a water-immiscible phase that removes fermentation products in situ. This has the beneficial effect of not only removing inhibitory products as they are formed (thus keeping reaction rates high) but also has the potential for reducing product recovery costs. We have chosen to examine the ethanol fermentation as a model system for end product inhibition and extractive fermentation and have developed a computer model predicting the productivity enhancement possible with this technique together with other key parameters such as extraction efficiency and residual glucose concentration. The model accommodates variable liquid flowrates entering and leaving the system, since it was found that the aqueous outlet flowrate could be up to 35% lower than the inlet flowrate during extractive fermentation of concentrated glucose feeds due to the continuous removal of ethanol from the fermentation broth by solvent extraction. The model predicts a total ethanol productivity of 82.6 g/L h if a glucose feed of 750 g/L is fermented with a solvent having a distribution coefficient of 0.5 at a solvent dilution rate of 5.0 h(-1). This is more than 10 times higher than for a conventional chemostat fermentation of a 250 g/L glucose feed. The model has furthermore illustrated the possible trade-offs that exist between obtaining a high extraction efficiency and a low residual glucose concentration.     

Batch and multistage continuous ethanol fermentation of cellulose hydrolysate and optimum design of fermentor by graphical analysis

Batch and single-flow four-stage continuous ethanol fermentations of bagasse hydrolysate have been investigated at pH 4.0 and 30°C with a strain of the yeast Saccharomyces cerevisiae. The studies were carried out in the laboratory four-stage cascade continuous stirred-tank fermentors at varying feed glucose concentrations (10, 14, 18, and 22%). The range of dilution rates employed varied from 0.05 to 0.2 hr^?1. The hydrolysate was supplemented with a cheap nitrogen source (CNS), CaCl₂·H₂O and MgSO₄·7H₂O. A 2% (v/v) CNS concentration was found to be sufficient to avoid growth limitation at a glucose concentration of 116 g/liter. The conditions of continuous culture in a multistage system are predicted by a graphical method based on batch-culture data. The results thus obtained are compared with those predicted by kinetic models and with the experimental results. The variations between the results obtained experimentally and those computed either by a kinetic model or by graphical analyses were found to be within the limits of experimental error. The solutions based on the concept of minimum residence time necessary to achieve the desired biomass or product concentrations are also discussed.     

Kinetics of ethanol production by yeast in continuous culture

Summary The rate of fermentation of glucose by Saccharomyces uvarum in steadystate continuous culture in excess of substrates showed non-competitive inhibition kinetics with respect to ethanol. A model is presented which predicts that growth stops at a finite ethanol concentration, which was calculated to be 95 gl^-1 for the system used here. The observed maximum ethanol concentration in a single stage continuous culture was 92 gl^-1.     

Comparative study of ethanol production by an immobilized yeast in a tubular reactor and in a multistage reactor

Summary The productivity of continuous ethanol fermentation has been increased using fixed bed reactors where a high density of yeast cells was maintained on a packing of wood chips. Two different systems have been used: 1. A tubular reactor which produced alcohol solutions containing up to 13.5% (V/V) ethanol. High CO₂ retention and a poor mass transfer between bulk medium and immobilized biomass prevented production rates higher than 2.2 g/l·h. 2. A multistage reactor where a better utilisation of the reactor volume led to improved performances. Solutions containing 132 g/l of ethanol (16.5% V/V) were produced with a productivity increased up to 4.8 g/l·h. A better distribution of the active biomass and a lower gradient of alcohol concentration between support and bulk medium are possible reasons for this improvement.     

Improvements in ethanol concentration and fermentor ethanol productivity in yeast fermentations using whole soy flour in batch,and continuous recycle systems

Summary Ethanol concentrations and fermentor productivities were increased 20.2 and 15.5% at 90 and 95% recycle, respectively, when whole soy flour was added to the feed (2 g/ at 90% recycle, and 1 g/ at 95% recycle) of a continuous yeast fermentation system with recycle of cells and soy flour (soy flour concentrations were 2% at steady state in the fermentor) by UF membranes as compared to controls. The improvements were primarily due to increases in cell concentrations. Similar results were obtained for batch cultures.     

Ethanol production in a microporous hollow-fiber-based extractive fermentor with immobilized yeast

Microporous-membrane-based extractive product recovery in product-inhibited fermentations allows in situ recovery of inhibitory products in a nondispersive fashion. A tubular bioreactor with continuous strands of hydrophobic microporous hollow fibers having extracting solvent flowing in fiber lumen was utilized for yeast fermentation of glucose to ethanol. Yeast was effectively immobilized on the shell side in small lengths of chopped microporous hyrophilic hollow fibers. The beneficial effects of in situ dispersion-free solvent ex (oleyl alcohol and dibutyl phthalate) were demonstrated for a 300 g/L glucose substrate feed. Outlet glucose concentration dropped drastically from 123 to 41 g/L as solvent/ substrate flow ratio was increased from 0 to 3 at 9 mL/h of substrate flow rate with oleyl alcohol as extracting solvent. The significant productivity increase with in situ solvent extraction became more evident as solvent/ substrate flow ratio increased. A model of the locally integrated extractive bioreactor describes the observed fermentor performance quite well.     

Oxygen transfer and mixing in a tower cycling fermentor

Tower cycling fermentors for the production of single-cell protein from volatile substrates were studied. The mass transfer, mixing and circulation patterns, and residence time distribution (RTD) curves were investigated in these vessels. This study suggests that the tower cycling fermentors for volatile substrates fermentation may improve product yields and at the same time reduce the power consumption, thereby resulting in a significant increase in operating cost savings and capital profits. The results of this research further indicate a future potential for commercial scale tower cycling fermentors.     

Continuous ethanol production in the gas-lift tower fermenter

Summary A highly flocculent strain of Saccharomyces uvarum was used to convert glucose to ethanol and CO₂ in a single stage, continuous, gas-lift tower fermenter. Satisfactory operation was maintained in prolonged runs with yeast concentrations in excess of 100 g/L (d.w.) and hydraulic retention times less than 0.4 h. Maximum ethanol concentration and productivity were 88 g/L and 44.5 g/Lh respectively. Conversion efficiency was between 80 and 95% of theoretical.