General relationship for volumetric oxygen transfer coefficient (k L a) prediction in tower bioreactors utilizing immobilized cells

A general relationship for prediction of the volumetric oxygen transfer coefficient (k_La) in a tower bioreactor utilizing immobilized Penicillium chrysogenum as function of air superficial velocity, suspension rheological parameters and liquid physical properties is proposed in this study. The relationship was applied to three different systems and a good agreement between the calculated values and the experimental data was obtained.     

Correlation of liquid dispersion and oxygen transfer in bubble column

Summary In steady state, attained by continuous aeration after oxygen saturation of water in a bubble column, vertical composition distribution of liquid and gas phases has been determined. It has been assumed that, as a result of absorption at the bottom of the column, desorption in the upper section and vertical dispersion of dissolved oxygen flux, a closed oxygen circulation is created. Determination of the axial dispersion coefficient from hydrodynamic and oxygen transfer data verifies the mathematical model proposed. The results allow conclusions to be drawn about supersaturation and desorption and other phenomena expected in biological systems.Abbreviations C[-] Dimensionless oxygen concentration Unit=0.21 bar oxygen partial pressure or dissolved oxygen level in equilibrium with latter - E[m²/s] Axial dispersion coefficient - F[m²] Horizontal cross-section area - k _L a[s^-1] Overall oxygen transfer coefficient - u; u ₂[m/s; cm/s] Superficial velocity: related to state of bubbles leaving the sparger - x; x _atm[-] Signal registered in the experiment; signal recorded in O₂ saturated water, or water vapor saturated air stream, at temperature identical to the experiment under atmospheric pressure - y[m] Water column height - [s^-1] Dimensionless oxygen flux Indices a asorption - d desorption - g gas - l liquid - k dispersion - m measured value/in the case of hydrodynamically measured E/ Dedicated to Professor Dr. H. J. Rehm on the occasion of his 60th birthday     

Hydrodynamics and mass transfer in Aspergillus niger fermentations in bubble column and loop bioreactors

The influence of Aspergillus niger broth rheology, bioreactor geometry, and superficial gas velocity on the volumetric liquid phase oxygen transfer coefficient (k(L)a(L)), riser gas holdup (epsilon(GR)), and circulating liquid velocity (u(LR)) was studied in a bubble column (BC) and two external-circulation-loop airlift (ECLAL) bioreactors. The results are compared to those of previous studies on homogeneous fluids and in particular with a recent study on non-Newtonian carboxymethylcellulose (CMC) solutions conducted in the same contactors used for the A. niger fermentations. As expected from the CMC-based studies, in the heterogeneous broths of A. niger epsilon(GR), k(L)a(L), and u(LR) decreased with increasing broth apparent viscosity; epsilon(GR) and k(L)a(L) decreased with increasing downcomer-to-riser cross-sectional area ratio, A(d)/A(r), whereas u(LR) increased with increasing A(d)/A(r). Gas holdup data in the airlift fermentations of A. niger were well predicted by the CMC-based correlation. However, the CMC-based correlations produced conservative estimations of k(L)a(L) and overestimates of u(LR) compared to the observed values in the A. niger broths.     

Promotion of oxygen transfer in three-phase fluidized-bed bioreactors by floating bubble breakers

The objective of the present study was to investigate a method to enhance the volumetric rate of oxygen transfer in three-phase fluidized-bed bioreactors. The rates of oxygen transfer from air bubbles to viscous liquid media were promoted by floating bubble breakers in three-phase fluidized beds operated in the bubble coalescing regime. The liquid-phase volumetric oxygen transfer coefficient has been recovered by fitting the axial dispersion model to the resultant data, and its dependence on the experimental variables, such as the gas and liquid flow rates, particle size, concentration of bubble breakers, and liquid viscosity, has been examined. The results indicate that the liquid-phase volumetric oxygen transfer coefficient can be enhanced up to 20-25%. The coefficient exhibits a maximum with respect to the volume ratio of the floating bubble breakers to the fluidized solid particles; it increases with increases in the gas and liquid flow rates and size of fluidized particles, while it decreases with an increase in the liquid viscosity. An expression has been developed to correlate the liquid-phase volumetric oxygen transfer coefficient with the experimental variables.     

The influence of polymeric membrane gas spargers on hydrodynamics and mass transfer in bubble column bioreactors

Gas sparging performances of a flat sheet and tubular polymeric membranes were investigated in 3.1 m bubble column bioreactor operated in a semi batch mode. Air–water and air–CMC (Carboxymethyl cellulose) solutions of 0.5, 0.75 and 1.0 % w/w were used as interacting gas–liquid mediums. CMC solutions were employed in the study to simulate rheological properties of bioreactor broth. Gas holdup, bubble size distribution, interfacial area and gas–liquid mass transfer were studied in the homogeneous bubbly flow hydrodynamic regime with superficial gas velocity (U _G) range of 0.0004–0.0025 m/s. The study indicated that the tubular membrane sparger produced the highest gas holdup and densely populated fine bubbles with narrow size distribution. An increase in liquid viscosity promoted a shift in bubble size distribution to large stable bubbles and smaller specific interfacial area. The tubular membrane sparger achieved greater interfacial area and an enhanced overall mass transfer coefficient (K _La) by a factor of 1.2–1.9 compared to the flat sheet membrane.     

Characterization of gas transfer and mixing in a bubble column equipped with a rubber membrane diffuser

Gas transfer and mixing were characterized in a 32-L bubble column reactor equipped with a commercially available rubber membrane diffuser. The performance of the membrane diffuser indicates that the slits in the membrane are best described as holes with elastic lids, acting as valves cutting off bubbles from the gas stream. The membrane diffuser thus functions as a one-way valve preventing backflow of liquid. Our design of the bottom plate of the reactor enabled us to optimize the aeration by changing the tension of the membrane. We thereby achieved mass transfer coefficients higher than those previously reported in bubble columns. A strong dependence of mass transfer on gas holdup and bubble size was indicated by estimates based on these two variables. The microalga, Rhodomonas sp. , sensitive to chemical and physical stress, was maintained for 8 months in continuous culture with a productivity identical to cultures grown in stirred tank reactors. Copyright 1998 John Wiley & Sons, Inc.     

Combined sulfite method for the measurement of the oxygen transfer coefficient k(L)a in bio-reactors

The combined sulfite method is proposed for the measurement of oxygen transfer coefficients, k_La, in bioreactors. The method consists of a steady-state and a dynamic measurement which are carried out under the same experimental conditions and thus yield data for both methods during one experiment. The applied experimental conditions are shown to avoid chemical enhancement during the steady-state measurement. Moreover, no parallel sulfite oxidation occurs during the oxygen saturation phase of the dynamic measurement. Under the applied experimental conditions, no information about the sulfite oxidation kinetics is required and possible metal ion impurities in sulfite salts do not influence the measurement. The characterization of a laboratory-scale bioreactor aerated with pure oxygen yields k_La values during the steady-state and the dynamic measurements that are in good agreement with the dynamic pressure method, the correctness of which is generally accepted. When air is used for absorption, the steady-state measurement yields k_La values that correlate to the correct variant of the standard dynamic method. The dynamic measurement with air absorption yields a k_La value which considers the influence of the non-uniform bubble size distribution present in bubble-aerated bioreactors.     

k(L)a as a predictor for successful probe-independent mammalian cell bioprocesses in orbitally shaken bioreactors

The aim of this study was to gain a better understanding of orbitally shaken bioreactors (OSRs) operated without controllers for pH and dissolved oxygen (DO) concentration. We used cylindrical OSRs with working volumes ranging from 250mL to 200L to determine that the volumetric mass transfer coefficient of oxygen (k(L)a) is a good predictor of the performance of OSRs at different scales. We showed that k(L)a values of 7-10hour(-1) were required to avoid DO limitations and to prevent conditions of low pH during the cultivation of CHO cells. Overall, cell cultures in probe-independent OSRs of different nominal volumes ranging from 250mL to 200L achieved similar cell densities, recombinant protein concentrations, and pH and DO profiles when having the same k(L)a. We conclude that k(L)a is a key parameter for probe-independent bioprocesses in OSRs and can be used as a scale-up factor for their operation.     

Influence of growth manner on nitrifying bacterial communities and nitrification kinetics in three lab-scale bioreactors

The effects of growth type, including attached growth, suspended growth, and combined growth, on the characteristics of communities of ammonia-oxidizing bacteria (AOB) and nitrite-oxidizing bacteria (NOB) were studied in three lab-scale Anaerobic/Anoxic_m-Oxic_n (AmOn) systems. These systems amplified activated sludge, biofilms, and a mixture of activated sludge and biofilm (AS-BF). Identical inocula were adopted to analyze the selective effects of mixed growth patterns on nitrifying bacteria. Fluctuations in the concentration of nitrifying bacteria over the 120 days of system operation were analyzed, as was the composition of nitrifying bacterial community in the stabilized stage. Analysis was conducted using polymerase chain reaction-denaturing gradient gel electrophoresis (PCR-DGGE) and real-time PCR. According to the DGGE patterns, the primary AOB lineages were Nitrosomonas europaea (six sequences), Nitrosomonas oligotropha (two sequences), and Nitrosospira (one sequence). The primary subclass of NOB community was Nitrospira, in which all identified sequences belonged to Nitrospira moscoviensis (14 sequences). Nitrobacter consisted of two lineages, namely Nitrobacter vulgaris (three sequences) and Nitrobacter alkalicus (two sequences). Under identical operating conditions, the composition of nitrifying bacterial communities in the AS-BF system demonstrated significant differences from those in the activated sludge system and those in the biofilm system. Major varieties included several new, dominant bacterial sequences in the AS-BF system, such as N. europaea and Nitrosospira and a higher concentration of AOB relative to the activated sludge system. However, no similar differences were discovered for the concentration of the NOB population. A kinetic study of nitrification demonstrated a higher maximum specific growth rate of mixed sludge and a lower half-saturation constant of mixed biofilm, indicating that the AS-BF system maintained relatively good nitrifying ability.     

The effects of cells on oxygen transfer in bioreactors

Cells may affect oxygen transfer rates by three mechanisms: respiration of cells accumulated at the gas/liquid interface, physical presence of cells as solid particles, and modification of the medium by cells. These effects were studied experimentally in bubble-aerated bioreactors using baker's yeast at different cell concentrations, agitation speeds, aeration rates, and specific oxygen uptake rates. The overall effect of cells was to enhance oxygen transfer rates. The physical presence of cells as solid particles was found to retard oxygen transfer, presumably due to the lower oxygen permeability in the cell layer accumulated near the bubble surfaces. Cell respiration and medium modification, on the other hand, enhanced oxygen transfer rates. The retardation by nonrespiring cells and the enhancement due to cell respiration were found stronger at higher agitation speeds and lower aeration rates employed. This was attributed to the higher interfacial cell accumulation associated with the smaller bubbles produced under these conditions in the systems studied.     

Production of a microbial lipase by Staphylococcus carnosus (pLipMut2) in a bubble column reactor and a centrifugal field bioreactor

Extracellular lipase production by the recombinant strain Staphylococcus carnosus (pLipMut2) has been studied. First substrate optimization was carried out in shaken cultures. As a result, the best substrate yield of 20 units/g (peptone + yeast extract) and maximum lipase activity in the culture supernatant of 1.7 units/cm³ could be obtained by a nutrient rich complex medium consisting of 75 kg/m³ yeast extract, 15 kg/m³ tryptone, 5 kg/m³ glucose and 0.5 kg/m³ K₂HPO₄. Higher initial substrate concentration caused inhibition of growth. Antifoam agent at higher levels than 1 cm³/ dm³ resulted in a negative influence on lipase yield. Comparative fermentation studies have been carried out in a bubble column reactor and in a centrifugal field bioreactor. Direct proportionality between growth, lipase production and oxygen consumption was observed. In the bubble column reactor usual superficial air velocities (4 cm/s) caused intensive foam generation, thus fermentation was only possible after installation of a broader column head to allow coalescence. In the centrifugal field bioreactor higher productivities were obtained without foam problems at superficial gas velocities which were one order of magnitude lower than in the bubble column. Fermentations have been performed batchwise and without holding pH constant. Neither pH control nor glucose feeding could improve the substrate yield further. Compared to former fermentation studies with the strain S. carnosus (pLipPS1) lipase yield (lipase activity/cell density) could be improved by 300% and substrate yield (lipase activity/substrate concentration) by 600%.     

Enhancing gas-liquid mass transfer rates in non-newtonian fermentations by confining mycelial growth to microbeads in a bubble column

The performance of a penicillin fermentation was assessed in a laboratory-scale bubble column fermentor, with mycelial growth confined to the pore matrix of celite beads. Final cell densities of 29 g/L and penicillin titres of 5.5 g/L were obtained in the confined cell cultures. In comparison, cultures of free mycelial cells grown in the absence of beads experienced dissolved oxygen limitations in the bubble column, giving only 17 g/L final cell concentrations with equally low penicillin titres of 2 g/L. The better performance of the confined cell cultures was attributed to enhanced gas liquid mass transfer rates, with mass transfer coefficients (k(L)a) two to three times higher than those determined in the free cell cultures. Furthermore, the confined cell cultures showed more efficient utilization of power input for mass transfer, providing up to 50% reduction in energy requirements for aeration.     

Determination of power consumption and volumetric oxygen transfer coefficient in bioreactors

A torque meter has been developed for determining the power consumption in a bench stirred tank. The device has been bonded in the stirrer shaft inside a commercial bench fermentor, in order to avoid frictional losses in the mechanical seal. Power consumption measurements in ungassed and gassed systems were obtained at different agitation and aeration conditions, for Newtonian and non-Newtonian fluids. Also, a simple modified sulfite method for volumetric oxygen transfer coefficient (k_La) determination was developed and the experimental data were correlated with the gassed power (P_g) by using well-known correlations presented in the literature.     

Methanethiol degradation in anaerobic bioreactors at elevated pH (8): reactor performance and microbial community analysis

The degradation of methanethiol (MT) at 30 degrees C under saline-alkaline (pH 8-10, 0.5M Na(+)) conditions was studied in a lab-scale Upflow Anaerobic Sludge Blanket (UASB) reactor inoculated with estuarine sediment from the Wadden Sea (The Netherlands). At a sodium concentration of 0.5M and a pH between 8 and 9 complete MT degradation to sulfide, methane and carbon dioxide was possible at a maximum loading rate of 22mmolMTL(-1)day(-1) and a hydraulic retention time of 6h. The presence of yeast extract (100mg/L) in the medium was essential for complete MT degradation. 16S rRNA based DGGE and sequence analysis revealed that species related to the genera Methanolobus and Methanosarcina dominated the archaeal community in the reactor sludge. Their relative abundance fluctuated in time, possibly as a result of the changing operational conditions in the reactor. The most dominant MT-degrading archaeon was enriched from the reactor and obtained in pure culture. This strain WR1, which was most closely related to Methanolobus taylorii, degraded MT, dimethyl sulfide (DMS), methanol and trimethylamine. Its optimal growth conditions were 0.2M NaCl, 30 degrees C and pH 8.4. In batch and reactor experiments operated at pH 10, MT was not degraded.     

Oxygen mass transfer and gas holdup in a bubble column bioreactor with biosynthesis liquids

The influence of the rheology of some antibiotic biosynthesis liquids produced by Streptomyces aureofaciens, Nocardia mediterranei and Penicillium chrysogenum on the volumetric liquid phase oxygen transfer coefficient, k_La, and gas holdup, ε_G, together with the influence of superficial gas velocity, were studied in a bubble column bioreactor, using samples of fermentation liquids taken from industrial stirred tank fermenters, at 30-hour intervals during fermentation batch. The results were compared to those of previous studies from literature on non-Newtonian homogeneous fluids, such as CMC-Na, xanthan and starch solutions, respectively. In the heterogeneous broths, ε_G and k_La decreased with increasing apparent viscosity of the broth and increased with increasing superficial velocity. The experimental data were correlated using non-linear regression with correlation coefficients above 0.85.     

Comments on the communication: on the calculation of shear rate and apparent viscosity in airlift and bubble column bioreactors

The determination of the shear rate in bubble column and airlift bioreactors is an important question from both the perspective of cell damage and the correlation of hydrodynamic parameters in non-Newtonian fluids in these contractors. In the context of correlating hydrodynamic parameters in non-Newtonian fluids, a common approach involves assuming that there exists an average shear rate in the column that is proportional to the superficial gas velocity. This average shear rate is then used to evaluate an effective viscosity of the non-Newtonian fluid that is subsequently used to quantify the fluid's rheological behavior in correlation. Contrary to a recent communication, this report illustrates that this approach, which has mainly been applied to bubble columns, can also be applied to external loop airlift contractors, replacing the superficial gas velocity by the superficial gas velocity by the superficial gas velocity supplied to the riser of the contractor. This extension is based upon consideration of the relevant characteristic velocity in the active zone (i.e., the riser section) of the reactor.     

Homogenisation and oxygen transfer rates in large agitated and sparged animal cell bioreactors: Some implications for growth and production

Because of concern for cell damage, very low agitation energy inputs have been used in industrial animal cell bioreactors, typical values being two orders of magnitude less than those found in bacterial fermentations. Aeration rates are also very small. As a result, such bioreactors might be both poorly mixed and also unable to provide the higher oxygen up-take rates demanded by more intensive operation. This paper reports experimental studies both of K _L a and of mixing (via pH measurements) in bioreactors up to 8 m³ at Wellcome and of scaled down models of such reactors at Birmingham. Alongside these physical measurements, sensitivity of certain cell lines to continuously controlled dO₂ has been studied and the oxygen up-take rates measured in representative growth conditions. An analysis of characteristic times and mixing theory, together with other recent work showing that more vigorous agitation and aeration can be used especially in the presence of Pluronic F-68, indicates ways of improving their performance. pH gradients offer a special challenge.     

Tobermolite effects on methane removal activity and microbial community of a lab-scale soil biocover

Three identical lab-scale biocovers were packed with an engineered soil (BC 1), tobermolite only (BC 2), and a mixture of the soil and tobermolite (BC 3), and were operated at an inlet load of 338–400 g-CH₄ m^?2 d^?1 and a space velocity of 0.12 h^?1. The methane removal capacity was 293 ± 47 g-CH₄ m^?2 d^?1 in steady state in the BC 3, which was significantly higher than those in the BC 1 and BC 2 (106 ± 24 and 114 ± 48 g-CH₄ m^?2 d^?1, respectively). Quantitative PCR indicated that bacterial and methanotrophic densities (6.62–6.78 × 10⁷ 16S rDNA gene copy number g-dry sample^?1 and 1.37–2.23 × 10⁷ pmoA gene copy number g-dry sample^?1 in the BC 1 and BC 3, respectively) were significantly higher than those in the BC 2. Ribosomal tag pyrosequencing showed that methanotrophs comprised approximately 60 % of the bacterial community in the BC 2 and BC 3, while they only comprised 43 % in the BC 1. The engineered soil favored the growth of total bacteria including methanotrophs, while the presence of tobermolite enhanced the relative abundance of methanotrophs, resulting in an improved habitat for methanotrophs as well as greater methane mitigation performance in the mixture. Moreover, a batch experiment indicated that the soil and tobermolite mixture could display a stable methane oxidation level over wide temperature (20–40 °C, at least 38 μmol g-dry sample^?1 h^?1) and pH (5–8, at least 61 μmol g-dry sample^?1 h^?1) ranges. In conclusion, the soil and tobermolite mixture is promising for methane mitigation.