Perfluorocarbon facilitated O2 transport in a hepatic hollow fiber bioreactor

A mathematical model describing O₂ transport in a hepatic hollow fiber (HF) bioreactor supplemented with perfluorocarbons (PFCs) in the circulating cell culture media was developed to explore the potential of PFCs in properly oxygenating a bioartificial liver assist device (BLAD). The 2‐dimensional model is based on the geometry of a commercial HF bioreactor operated under steady‐state conditions. The O₂ transport model considers fluid motion of a homogeneous mixture of cell culture media and PFCs, and mass transport of dissolved O₂ in a single HF. Each HF consists of three distinct regions: (1) the lumen (conducts the homogeneous mixture of cell culture media and PFCs), (2) the membrane (physically separates the lumen from the extracapillary space (ECS), and (3) the ECS (hepatic cells reside in this compartment). In a single HF, dissolved O₂ is predominantly transported in the lumen via convection in the axial direction and via diffusion in the radial direction through the membrane and ECS. The resulting transport equations are solved using the finite element method. The calculated O₂ transfer flux showed that supplementation of the cell culture media with PFCs can significantly enhance O₂ transport to the ECS of the HF when compared with a control with no PFC supplementation. Moreover, the O₂ distribution and subsequent analysis of ECS zonation demonstrate that limited in vivo‐like O₂ gradients can be recapitulated with proper selection of the operational settings of the HF bioreactor. Taken together, this model can also be used to optimize the operating conditions for future BLAD development that aim to fully recapitulate the liver's varied functions. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2009     

Hemoglobin‐based oxygen carrier and convection enhanced oxygen transport in a hollow fiber bioreactor

A mathematical model was developed to study O₂ transport in a convection enhanced hepatic hollow fiber (HF) bioreactor, with hemoglobin‐based O₂ carriers (HBOCs) present in the flowing cell culture media stream of the HF lumen. In this study, four HBOCs were evaluated: PEG‐conjugated human hemoglobin (MP4), human hemoglobin (hHb), bovine hemoglobin (BvHb) and polymerized bovine hemoglobin (PolyBvHb). In addition, two types of convective flow in the HF extra capillary space (ECS) were considered in this study. Starling flow naturally occurs when both of the ECS ports are closed. If one of the ECS ports is open, forced convective flow through the ECS will occur due to the imposed pressure difference between the lumen and ECS. This type of flow is referred to as cross‐flow in this work, since some of the fluid entering the HF lumen will pass across the HF membrane and exit via the open ECS port. In this work, we can predict the dissolved O₂ concentration profile as well as the O₂ transport flux in an individual HF of the bioreactor by solving the coupled momentum and mass transport equations. Our results show that supplementation of the cell culture media with HBOCs can dramatically enhance O₂ transport to the ECS (containing hepatocytes) and lead to the formation of an in vivo‐like O₂ spectrum for the optimal culture of hepatocytes. However, both Starling flow and cross‐flow have a very limited effect on O₂ transport in the ECS. Taken together, this work represents a novel predictive tool that can be used to design or analyze HF bioreactors that expose cultured cells to defined overall concentrations and gradients of O₂. Biotechnol. Bioeng. 2009;102: 1603–1612. © 2008 Wiley Periodicals, Inc.     

Mixtures of hemoglobin‐based oxygen carriers and perfluorocarbons exhibit a synergistic effect in oxygenating hepatic hollow fiber bioreactors

Hepatic hollow fiber (HF) bioreactors are being developed for use as bioartificial liver assist devices (BLADs). In general, BLADs suffer from O₂ limited transport, which reduces their performance. This modeling study seeks to investigate if O₂ carrying solutions consisting of mixtures of hemoglobin‐based oxygen carriers (HBOCs) and perfluorocarbons (PFCs) can enhance O₂ transport to hepatocytes cultured in the extra capillary space (ECS) of HF bioreactors. We simulated supplementing the circulating cell culture media stream of the HF bioreactor with a mixture containing these two types of oxygen carriers (HBOCs and PFCs). A mathematical model was developed based on the dimensions and physical characteristics of a commercial HF bioreactor. The resulting set of partial differential equations, which describes fluid transport; as well as, mass transport of dissolved O₂ in the pseudo‐homogeneous PFC/water phase and oxygenated HBOC, was solved to yield the O₂ concentration field in the three HF domains (lumen, membrane and ECS). Our results show that mixtures of HBOC and PFC display a synergistic effect in oxygenating the ECS. Therefore, the presence of both HBOC and PFC in the circulating cell culture media dramatically improves transport of O₂ to cultured hepatocytes. Moreover, the in vivo O₂ spectrum in a liver sinusoid can be recapitulated by supplementing the HF bioreactor with a mixture of HBOCs and PFCs at an inlet pO₂ of 80 mmHg. Therefore, we expect that PFC‐based oxygen carriers will be more efficient at transporting O₂ at higher O₂ levels (e.g., at an inlet pO₂ of 760 mmHg, which corresponds to pure O₂ in equilibrium with aqueous cell culture media at 1 atm). Biotechnol. Bioeng. 2010; 105: 534–542. © 2009 Wiley Periodicals, Inc.     

On-line electrocatalyzed luminol chemiluminescence determination of d-glucose and dissolved oxygen in simulated mammalian cell bioreactor perfusion fluid using solid phase reagent modules

On-line instrumentation and methods for the chemiluminescence based real-time monitoring of d-glucose and O₂ levels in mammalian cell bioreactor perfusion fluid are described. The unit processes required for the analysis include: pH adjustment using solid phase flow-through modules, immobilized enzyme catalyzed oxidation of glucose by molecular oxygen to produce hydrogen peroxide, controlled release of luminol using a solid phase flow-through module, electrocatalyzed luminescence using gold electrodes, and photodetection of chemiluminescent emissions. Calibration curves for d-glucose and dissolved O₂ in simulated bioreactor perfusion fluid have been generated using fully integrated reagentless test systems from 0–800 mg l^–1 and 0–10 mg l^–1, respectively.     

Extraction and biodegradation of a toxic volatile organic compound (1,2-dichloroethane) from waste-water in a membrane bioreactor

An extractive membrane bioreactor has been used to treat a synthetic waste-water containing a toxic volatile organic compound, 1,2-dichloroethane (DCE). Biofilms growing on the surface of the membrane tubes biodegrade DCE while avoiding direct contact between the DCE and the aerating gas. This reduces air stripping by more than an order of magnitude (from 30–35% of the DCE entering the system to less than 1%) relative to conventional aerated bioreactors. Over 99% removal of DCE from a waste-water containing 1600 mg l^–1 of DCE was achieved at waste-water residence times of 0.75 h. Biodegradation was verified as the removal mechanism through measurements of CO₂ and chloride ion evolution in the bioreactor. No DCE was detected in the biomedium over the operating period. The diffusion-reaction phenomena occurring in the biofilm have been described by a mathematical model, which provides calculated solutions that support the experimental results by predicting that all DCE is biodegraded within the biofilm. Experimentally, however, the rate of DCE degradation in the biofilm was found to be independent of O₂ concentration, while the model predictions point to O₂ being limiting.     

Azadirachtin production in stirred tank reactors by Azadirachta indica suspension culture

Successful scale-up of Azadirachta indica suspension culture for azadirachtin production was done in stirred tank bioreactor with two different impellers. The kinetics of biomass accumulation, nutrient consumption and azadirachtin production of A. indica cell suspension culture were studied in a stirred tank bioreactor equipped with centrifugal impeller and compared with similar bioreactor with a setric impeller to investigate the role of O₂ transfer efficiency of centrifugal impeller bioreactor on overall culture metabolism. The maximum cell mass for centrifugal impeller bioreactor and stirred tank bioreactor (with setric impeller) were 18.7 and 15.5 g/L (by dry cell weight) and corresponding azadirachtin concentrations were 0.071 and 0.05 g/L, respectively. Glucose and phosphate were identified as the major growth-limiting nutrients during the bioreactor cultivation. The centrifugal impeller bioreactor demonstrated less shearing and improved O₂ transfer than the stirred tank bioreactor equipped with setric impeller with respect to biomass and azadirachtin production.     

Development of a bioreactor for high density culture of hairy roots

Summary The effects of agitation and aeration on the growth of carrot hairy roots were investigated. When hydrodynamic stress index was above 0.001 cm/s, the growth rate of hairy roots decreased sharply. When volumetric O₂ transfer coefficient was high, the specific growth rate was also high. However, the specific growth rate approached the maximum value when the volumetric O₂ transfer coefficient was over 4 h^–1 . It is therefore necessary to maintain low hydrodynamic stress and high volumetric oxygen transfer for high density culture of hairy roots. By considering hydrodynamic stress and oxygen transfer, a novel bioreactor type was suggested for hairy roots cultivation.This research was supported in part by the Genetic Engineering Research Fund Korean Ministry of Education     

A shaking bioreactor equipped with twin ceramic membranes for acetic acid production using Acetobacter pasteurianus

A shaking bioreactor system with twin internal ceramic membranes was developed for effective perfusion culture and applied to the continuous production of acetic acid using Acetobacter pasteurianus. The system makes it possible to carry out the back-washing of the membrane without stopping the continuous operation because one membrane can be washed by medium feed flow while another membrane provides filtration of the broth by the simple switching of the medium and the broth flow direction. The medium flow through the membrane could successfully wash the surface of the membrane thereby effectively maintaining the filtration ability. By using the system, continuous operation of more than 800 h was achieved and the maximum acetic acid productivity reached 13.4 g l^–1 h^–1 using air enriched with 40% O₂.     

Growth characteristics of Sanguinaria canadensis L. Cell suspensions and immobilized cultures for production of benzophenanthridine alkaloids

Summary Sanguinaria canadensis L. plants were harvested from a local forest and calli were initiated from leaf explants. The production of benzophenanthridine alkaloids (i.e. sanguinarine, sanguilutine, sanguirubine, chelerythrine, chelilutine and chelirubine) by S. canadensis cell grown in modified B5 and IM2 media was compared to the alkaloid content of rhizomes. Sanguinarine accounted for approximately 80% of the total alkaloid content of cultured cells (1.3%,g g^–1) while sanguinarine and sanguirubine accounted for 70% of rhizome alkaloids (9.0%, g g^–1). Sanguinarine, chelirubine and chererythrine were the only known alkaloids detected in cultured S. canadensis cells. Maximum alkaloid production of cultures performed using B5 medium, containing half the original nitrate concentration, was observed following extracellular nitrate and sugar depletion. The scale-up of this culture was successfully performed in a 2-1 immobilization bioreactor. The consumption of sugar and nitrate as well as the oxygen (OTR) and carbon dioxide (CTR) transfer rates of the immobilized cell culture were monitored for 15 days. The maximum sugar and nitrate consumption rates were 1.8 g l^–1 per day and 2.3 mm per day respectively. The maximum OTR and CTR of the immobilized cell culture were 0.8 mmol O₂ l^–1 h^–1 and 0.95 mmol CO₂ l^–1 h^–1 respectively. The sanguinarine yield of this culture reached 1.0% based on biomass dry weight (g g^–1 dw) by day 15.     

Design of a bubble-swawm bioreactor for animal cell culture

A stationary bubble-swarm has been used to aerate a mammalian cell culture bioreactor with an extremely low gas flow rate. Prolonging the residence time of the gas bubbles within the medium improved the efficiency of the gas transfer into the liquid phase and suppressed foam formation. An appropriate field of speed gradients prevented the bubbles from rising to the surface. This aeration method achieves an almost 90% transfer of oxygen supplied by the bubbles. Consequently, it is able to supply cells with oxygen even at high cell densities, while sparging with a gas flow of only 0.22·10^–3–1.45·10^–3 vvm (30–200 ml/h).The reactor design, the oxygen transfer rates and the high efficiency of the system are presented. Two repeated batch cultures of a rat-mouse hybridoma cell line are compared with a surface-aerated spinner culture. The used cell culture medium was serum-free, either with or without BSA and did not contain surfactants or other cell protecting agents. One batch is discussed in detail for oxygen supply, amino acid consumption and specific antibody production.     

CO2 and O2 gas exchange in outdoor thin-layer high density microalgal cultures

Two thin layer culture units operated as batch cultures with the algaChlorella kessleri were used in gas exchange experiments. The mass transfer coefficient K_g [g m^–2 h^–1 kPa^–1] of O₂ and CO₂ desorption from culture surface decreased with increasing culture temperature. Between 60–70% of supplied CO₂ was used for algal growth. It was estimated that the length of growth surface may be extended to about 50 m, without additional saturation by CO₂. On average 1.35 g CO₂ was consumed by the alga per 1 g of produced O₂. Net CO₂ consumption (R_CO2) and O₂ production (R_O2) were not inhibited by irradiance. R_O2 did not decrease (in some cases it even increased) along the culture surface, despite increased accumulation of O₂. Measurement of pO₂ where the culture leaves the reactor before being pumped back onto the illuminated surface, correlated with O₂ production and CO₂ consumption and may be used to monitor the reactors growth performance.     

High density cell culture of Panax notoginseng for production of ginseng saponin and polysaccharide in an airlift bioreactor

High cell density of Panax notoginseng in a 17 l airlift bioreactor was achieved in batch cultivation using a modified MS medium. The dry cell weight, ginseng saponin and polysaccharide reached 24, 1.7 and 2.8 g l^–1, respectively, after 15 d. A strategy of sucrose feeding based on changes in the specific O₂ uptake rate was applied to the cell cultures, which increased these respective yields to 30, 2.3 and 3.2 g l^–1.     

Effect of oxygen supply on berberine production in cell suspension cultures and immobilized cells ofThalictrum minus

The ample supply of O₂ proved to be of great importance for berberine production in cell suspension culture ofThalictrum minus, as the specific O₂ consumption rate of berberine-producing cells was twice as high as that of non-producing cells. Furthermore, berberine yield increased with increases in the volumetric O₂ transfer coefficient (K_La). Estimation of the optimum conditions of oxygen supply in suspension cultures and immobilized cells according to a known theoretical model assuming O₂ uptake by cells to be a zero-order reaction was in good agreement with the experimental data. The O₂ supply to immobilized cells could be improved by reducing the cell density and radius of the bead.     

Evaluation of the environmental conditions for the continuous production of lignin peroxidase by Phanerochaete Chrysosporium in fixed-bed bioreactors

A new system to produce lignin peroxidase (LiP) continuously by Phanerochaete chrysosporium is described. A fixed-bed bioreactor with a pulsing device was used as the optimal bioreactor configuration. Addition of veratryl alcohol (1 mM), tryptophan (1 mM), no Mn²⁺ addition, low glucose addition rate (60–70 mg l^–1 h) and an atmosphere of O₂ gave maximum LiP activities of 700 U l^–1, which are higher than those previously reported.     

High density cultivation of Anchusa officinalis in a stirred-tank bioreactor with in situ filtration

Previously, Su et al. [Biotechnol Bioeng 42: 884–890 (1993)] reported improved production of rosmarinic acid by Anchusa officinalis in shake-flask cultures using a cultivation strategy that involved intermittent medium exchange. Implementation of this cultivation strategy in 2.5-1 stirred-tank bioreactor cultures is investigated in the present study. Intermittent cell/medium separation in the bioreactor was accomplished by means of automated in situ culture filtration. In the bioreactor culture, rosmarinic acid production was found very sensitive to agitation and aeration conditions as well as dissolved oxygen concentration. A maximum cell density of 35 g dry weight/l and a rosmarinic acid concentration of 3.7 g/l were obtained by maintaining the dissolved oxygen concentration above 30% air saturation, gradually raising the impeller tip speed from 34 cm/s to 72 cm/s, and keeping the aeration rate at 0.44 vvm while increasing the O₂: air ratio in the gas feed stream to 4:1. This result is comparable with the data obtained from shake-flask cultures using the same culture strategy.     

A novel membrane bioreactor for microbial growth

A novel membrane bioreactor, previously assessed for its gas transfer characteristics, was used in various size and membrane configurations for the growth of the strictly aerobic bacterium Pseudomonas aeruginosa. The bioreactor was found to readily support growth, and the initial growth rates showed the previously demonstrated enhanced effect in gas O₂ mass transfer of the dimpled membrane bioreactor over flat membrane bioreactors. The production of a secondary metabolite by a Pseudomonas sp. following growth was demonstrated, as was the biotransformation of a nitrile by Nocardia rhodochrous with the removal of the biotransformation products across a membrane. The potential of the bioreactor, in terms of other applications in the field of biotechnology, is disscussed. Correspondence to: A. M. Nicholson     

Cell growth and oxygen transfer in Methylosinus trichosporium OB3b cultures

Summary The steady-state concentration of M. trichosporium OB3b increased about two-fold in the continuous culture when the feeding medium was supplemented by ferrous sulphate (50mg/L) and citric acid (100mg/L) at a steady state. In batch and continuous cultures, the cell growth was significantly inhibited by excess N-sources (NH₄OH, NH₄Cl, NH₄NO₃, HNO₃, and NaNO₃) and ammonium N-sources were more inhibitory. Both volumetric O₂ transfer coefficient and specific O₂ uptake rate increased monotonously in an extensive range of air flow rate (0.1–7 vvm) and the methane interfered with the O₂ transfer even at very low flow rates (0.01–0.1 vvm).     

A Novel Oscillating Bioreactor BelloCell: Implications for Insect Cell Culture and Recombinant Protein Production

BelloCell is a novel packed bed bioreactor that allows alternating nutrient and gas transfer to a culture. Spodoptera frugiperda Sf-9 grown in the BelloCell (300 ml culture) reached 1.3–1.5×10⁷ cells ml⁻¹ in 7–8 days and the total baculovirus-expressed protein yield was 2.3-times that in a stirred tank bioreactor (600 ml culture). The superior cell and protein yields underline the potential of BelloCell for cell culture and recombinant protein production.     

CO2 in large-scale and high-density CHO cell perfusion culture

Productivity in a CHO perfusion culture reactor was maximized when pCO₂ was maintained in the range of 30–76 mm Hg. Higher levels of pCO₂ (> 150 mm Hg) resulted in CHO cell growth inhibition and dramatic reduction in productivity. We measured the oxygen utilization and CO₂ production rates for CHO cells in perfusion culture at 5.55×10^-17 mol cell^-1 sec^-1 and 5.36×10^-17 mol cell^-1 sec^-1 respectively. A simple method to directly measure the mass transfer coefficients for oxygen and carbon dioxide was also developed. For a 500 L bioreactor using pure oxygen sparge at 0.002 VVM from a microporous frit sparger, the overall apparent transfer rates (k_La+k_AA) for oxygen and carbon dioxide were 0.07264 min^-1 and 0.002962 min^-1 respectively. Thus, while a very low flow rate of pure oxygen microbubbles would be adequate to meet oxygen supply requirements for up to 2.1×10⁷ cells/mL, the low CO₂ removal efficiency would limit culture density to only 2.4×10⁶ cells/mL. An additional model was developed to predict the effect of bubble size on oxygen and CO₂ transfer rates. If pure oxygen is used in both the headspace and sparge, then the sparging rate can be minimized by the use of bubbles in the size range of 2–3 mm. For bubbles in this size range, the ratio of oxygen supply to carbon dioxide removal rates is matched to the ratio of metabolic oxygen utilization and carbon dioxide generation rates. Using this strategy in the 500 L reactor, we predict that dissolved oxygen and CO₂ levels can be maintained in the range to support maximum productivity (40% DO, 76 mm Hg pCO₂) for a culture at 10⁷ cells/mL, and with a minimum sparge rate of 0.006 vessel volumes per minute.A = volumetric agitated gas-liquid interfacial area at the top of the liquid, 1/mB = cell broth bleeding rate from the vessel, L/minCER = carbon dioxide evolution rate in the bioreactor, mol/min[CO₂] = dissolved CO₂ concentration in liquid, M[CO₂]^* = CO₂ concentration in equilibrium with sparger gas, M[CO₂]^** = CO₂ concentration in equilibrium with headspace gas, MCO₂(1) = dissolved carbon dioxide molecule in water[C_T] = total carbonic species concentration in bioreactor medium, M[C_T]_F = total carbonic species concentration in feed medium, MD = bioreactor diameter, mD_I = impeller diameter, mD_b = the initial delivered bubble diameter, mF = fresh medium feeding rate, L/minH_L = liquid height in the vessel, mk_A = carbon dioxide transfer coefficient at liquid surface, m/mink _infA ^supO = oxygen transfer coefficient at liquid surface, m/minNomenclature     

Kinetic Characterization of Extracellular Catalases fromPenicillium piceum F-648 and Its Hydrogen Peroxide-Adapted Variants

A comparative kinetic study of extracellular catalases produced by Penicillium piceum F-648 and their variants adapted to H₂O₂ was performed in culture liquid filtrates. The specific activity of catalase, the maximum rate of catalase-induced H₂O₂ degradation (V _max), V _max/K _M ratio, and the catalase inactivation rate constant in the enzymatic reaction (k _in, s^–1) were estimated in phosphate buffer (pH 7.4) at 30°C. The effective constant representing the rate of catalase thermal inactivation (k _in ^*, s^–1) was determined at 45°C. In all samples, the specific activity and K _M for catalase were maximum at a protein concentration in culture liquid filtrates of (2.5–3.5) × 10^–4 mg/ml. The effective constants describing the rate of H₂O₂ degradation (k, s^–1) were similar to that observed in the initial culture. These values reflected a twofold decrease in catalase activity in culture liquid filtrates. We hypothesized that culture liquid filtrates contain two isoforms of extracellular catalase characterized by different activities and affinities for H₂O₂. Catalases from variants 5 and 3 with high and low affinities for H₂O₂, respectively, had a greater operational stability than the enzyme from the initial culture. The method of adaptive selection for H₂O₂ can be used to obtain fungal variants producing extracellular catalases with improved properties.