Bacterial adsorption to smooth surfaces: Rate, extent, and spatial pattern

The influence of bulk-water bacterial cell concentration and specific growth rate history on bacterial adsorption rates to surfaces was investigated using response surface analysis. A pure culture of Pseudomonas sp. 224S was grown in a chemostat and pumped into a continuous flow reactor where the bacteria were exposed to clean, glass surfaces under turbulent flow conditions for a period of six hours. Adsorption rate decreased approximately linearly with increasing specific growth rate history. Glass surfaces became saturated with 224S at ca. 0.1% coverage and the resulting spatial pattern of the adsorbed cells deviated from random in the direction of uniformity.     

Domestic wastewater treatment using multi-electrode continuous flow MFCs with a separator electrode assembly design

Treatment of domestic wastewater using microbial fuel cells (MFCs) will require reactors with multiple electrodes, but this presents unique challenges under continuous flow conditions due to large changes in the chemical oxygen demand (COD) concentration within the reactor. Domestic wastewater treatment was examined using a single-chamber MFC (130 mL) with multiple graphite fiber brush anodes wired together and a single air cathode (cathode specific area of 27 m²/m³). In fed-batch operation, where the COD concentration was spatially uniform in the reactor but changed over time, the maximum current density was 148?±?8 mA/m² (1,000 Ω), the maximum power density was 120 mW/m², and the overall COD removal was >90 %. However, in continuous flow operation (8 h hydraulic retention time, HRT), there was a 57 % change in the COD concentration across the reactor (influent versus effluent) and the current density was only 20?±?13 mA/m². Two approaches were used to increase performance under continuous flow conditions. First, the anodes were separately wired to the cathode, which increased the current density to 55?±?15 mA/m². Second, two MFCs were hydraulically connected in series (each with half the original HRT) to avoid large changes in COD among the anodes in the same reactor. The second approach improved current density to 73?±?13 mA/m². These results show that current generation from wastewaters in MFCs with multiple anodes, under continuous flow conditions, can be improved using multiple reactors in series, as this minimizes changes in COD in each reactor.     

Biodiesel production by enzymatic process using Jatropha oil and waste soybean oil

In this study, non-edible Jatropha oil and postcooking waste soybean oil were utilized for enzymatic biodiesel production. The process was optimized by using a statistical method. In addition, a novel continuous process using co-immobilized Rhizopus oryzae and Candida rugosa lipases was developed. The optimum conditions for the batch process were determined to be a reaction temperature of 45oC, an agitation speed of 250 rpm, 10 wt% of water, and 20% of immobilized lipases. A conversion of about 98% at 4 h could be achieved for biodiesel production using Jatropha oil, while a conversion of about 97% at 4 h was achieved from waste soybean oil. A packed bed reactor charged with co-immobilized lipases was employed for continuous biodiesel production from Jatropha and waste soybean oil. The reactor consisted of a jacketed glass column (ID 25 mm × 130 mm), in which a temperature of 45°C was maintained by water circulation. A maximum conversion of about 80% in 24 h at a flow rate of 0.8 mL/ min was achieved with the continuous process, whereas in the two-stage continuous process, a conversion of about 90% in 72 h was attained at a flow rate of 0.1 mL/min.     

Design of a biomedical reactor for plasma low-density lipoprotein removal

The purpose of this study was to design a biomedical reactor that reduces plasma cholesterol when incorporated in an in vivo extracorporeal system. Phospholipase A(2), immobilized onto Agarose beads and housed inside the bioreactor, modifies plasma low density lipoprotein (LDL) into a form that is rapidly removed from circulation. In a packed bed reactor, the enzymatic conversion of LDL to the modified form (with plasma taken from hypercholesterolemic New Zealand white rabbits) was relatively low, 25% +/- 6 for a single pass of plasma through the reactor. An extended bed reactor, a hybrid of fluidized and packed bed reactors, was then developed to increase the conversion. This reactor displays a single pass conversion of 60% +/- 5 under optimal flow conditions. An evaluation of the flow rate through the reactor indicates that the system is limited by external mass transfer when employed under in vivo conditions. In addition, this system requires blood separation before the enzyme modification, which complicates the circuit control. Therefore, a new system was designed for in vivo use with rabbits. The resulting design, called the plasma separator reactor (PSR), combines plasma separation and enzymatic conversion in a single chamber. The PSR has three advantages over other studied systems: improved external mass transfer conditions, easy controlability, and simple set-up procedures. Single pass conversion reached 52% +/- 12 in suboptimal flow under simulated in vivo conditions. This reactor was also tested in vivo with hypercholesterolemic New Zealand white rabbits. A continuous conversion of up to 80% +/- 6 of rabbit plasma phospholipids was observed during 90 min of blood circulation (5 mL/min). The decrease in total plasma cholesterol reached a level of 60% of the initial value and was observed to be a function of the bioreactor enzyme activity. (c) 1993 John Wiley & Sons, Inc.     

Improvement of the yield of physiologically active oligosaccharides in continuous hydrolysis of chitosan using immobilized chitosanases

The continuous production of chitosan oligosaccharides using a packed-bed enzyme reactor was investigated as to the effects of the operation conditions on the yield of pentamers and hexamers of chitosan oligosaccharides. A column reactor packed with immobilized chitosanases prepared by the multipoint attachment method was used for continuous hydrolysis of chitosan. In this reactor, the decrease of the yield of the target intermediate oligosaccharides due to axial mixing was negligible. The surface enzyme density of the support and flow rate of the substrate solution significantly affected the maximum yield of pentamers and hexamers. These effects were summarized as a correlation with the Damk?hler number (Da), defined as the ratio of the maximum reaction rate to the maximum mass transfer rate. The optimum condition was determined based on Da. Under the optimized condition (Da = 0.12), pentamers and hexamers could be produced continuously for a month with a yield of over 35% (7 kg/m(3) in concentration).     

An evaluation of a ceramic monolith as an enzyme support material

Catalase was immobilized on commercially available monolithic catalyst supports and also on participate support obtained by crushing the monolith. The kinetics of the monolith- and particulate-supported enzymes were analyzed in a continuous tubular reactor system and pressure drop was also monitored. Analysis of the results indicates that the monolith-supported system presents very little resistance to flow which results in a considerably smaller pressure drop than is obtained in flow through particulate-supported systems under comparable conversion conditions. Ceramic monoliths thus appear to be very suitable for use as enzyme supports in continuous tubular reactor applications, particularly where high pressure drops might be expected.     

Effect of mixing on the washout and steady-state performance of continuous cultures

The effects of mixing on the critical mean holding time for washout and the steady state performance of growth processes in continuous flow reactors are investigated. Macromixing, micromixing, and cell recycle arc considered. The tanks-in-series model composed of N completely mixed flow reactors, the dispersion model, the plug flow model, and a combined model composed of a plug flow reactor and a continuous stirred tank flow reactor connected in series arc used to represent the macro-mixing or residence time distribution. The extreme cases of micromixing, namely, complete segregation and maximum mixedness, as well as intermediate states of micromixing are investigated to determine their effects on washout and the occurence of multiple steady states. A technique for predicting the maximum mixedness washout condition from a knowledge of the residence time distribution is presented and used to determine the washout condition for the dispersion model under maximum mixedness conditions.     

Effect of wall growth on the kinetic modeling of nitrite oxidation in a CSTR

A simple kinetic model was developed for describing nitrite oxidation by autotrophic aerobic nitrifiers in a continuous stirred tank reactor (CSTR), in which mixed (suspended and attached) growth conditions prevail. The CSTR system was operated under conditions of constant nitrite feed concentration and varying volumetric flow rates. Experimental data from steady-state conditions in the CSTR system and from batch experiments were used for the determination of the model's kinetic parameters. Model predictions were verified against experimental data obtained under transient operating conditions, when volumetric flow rate and nitrite feed concentration disturbances were imposed on the CSTR. The presented kinetic modeling procedure is quite simple and general and therefore can also be applied to other mixed growth biological systems.     

Ethanol production in horizontal bioreactor

Summary The rate of continuous alcohol fermentation by a mixture of free and immobilized yeast cells was found to be higher in a horizontal flow channel reactor than in a vertical column reactor under the same operational conditions. This higher fermentation rate in the horizontal reactor was attributed to accumulation of yeast cells in the reactor by free sedimentation and incomplete mixing in the direction of liquid flow. It was estimated that most of the ethanol in the horizontal bioreactor was produced by free cells in suspended or settled states. The relatively low ethanol production by the immobilized yeast cells on the ethanol production was considered due to higher product inhibition of fermentation rate within the support.     

Development of an ultrahigh-temperature process for the enzymatic hydrolysis of lactose. IV. Immobilization of two thermostable beta-glycosidases and optimization of a packed-bed reactor for lactose conversion.

Recombinant hyperthermostable beta-glycosidases from the archaea Sulfolobus solfataricus (Ss beta Gly) and Pyrococcus furiosus (CelB) were covalently attached onto the insoluble carriers chitosan, controlled pore glass (CPG), and Eupergit C. For each enzyme/carrier pair, the protein-binding capacity, the immobilization yield, the pH profiles for activity and stability, the activity/temperature profile, and the kinetic constants for lactose hydrolysis at 70 degrees C were determined. Eupergit C was best among the carriers in regard to retention of native-like activity and stability of Ss beta Gly and CelB over the pH range 3.0-7.5. Its protein binding capacity of approximately 0.003 (on a mass basis) was one-third times that of CPG, while immobilization yields were typically 80% in each case. Activation energies for lactose conversion by the immobilized enzymes at pH 5.5 were in the range 50-60 kJ/mol. This is compared to values of approximately 75 kJ/mol for the free enzymes. Immobilization expands the useful pH range for CelB and Ss beta Gly by approximately 1.5 pH units toward pH 3.5 and pH 4.5, respectively. A packed-bed enzyme reactor was developed for the continuous conversion of lactose in different media, including whey and milk, and operated over extended reaction times of up to 14 days. The productivities of the Eupergit C-immobilized enzyme reactor were determined at dilution rates between 1 and 12 h(-1), and using 45 and 170 g/L initial lactose. Results of kinetic modeling for the same reactor, assuming plug flow and steady state, suggest the presence of mass-transfer limitation of the reaction rate under the conditions used. Formation of galacto-oligosaccharides in the continuous packed-bed reactor and in the batch reactor using free enzyme was closely similar in regard to yield and individual saccharide components produced.     

Development of a stable continuous flow immobilized enzyme reactor for the hydrolysis of inulin

A 23.5-fold purified exoinulinase with a specific activity of 413 IU/mg and covalently immobilized on Duolite A568 has been used for the development of a continuous flow immobilized enzyme reactor for the hydrolysis of inulin. In a packed bed reactor containing 72 IU of exoinulinase from Kluyveromyces marxianus YS-1, inulin solution (5%, pH 5.5) with a flow rate of 4 mL/h was completely hydrolyzed at 55 degrees C. The reactor was run continuously for 75 days and its experimental half-life was 72 days under the optimized operational conditions. The volumetric productivity and fructose yield of the reactor were 44.5 g reducing sugars/L/h and 53.3 g/L, respectively. The hydrolyzed product was a mixture of fructose (95.8%) and glucose (4.2%) having an average fructose/glucose ratio of 24. An attempt has also been made to substitute pure inulin with raw Asparagus racemosus inulin to determine the operational stability of the developed reactor. The system remained operational only for 11 days, where 85.9% hydrolysis of raw inulin was achieved.     

Continuous hybridoma suspension cultures with and without cell retention: kinetics of growth, metabolism and product formation.

A laboratory scale bioreactor was constructed from glass and polycarbonate materials whereby a track-etch membrane (3 microns pore diameter) was integrated into its two-part bottom flange. The reactor performance was evaluated for continuous hybridoma suspension cultures under various conditions of cell retention. A total retention experiment demonstrated that this type of stirred tank reactor cannot be operated at near zero growth rate conditions. Instead, at steady viable cell concentrations of congruent to 3 x 10(6) cells per ml, specific growth and death rates were estimated at 0.60 +/- 0.06 d-1. Specific substrate (glucose, glutamine, O2, amino acids) consumption, by-product (ammonia, alanine, amino acids) and product (antibody) production rates as well as various apparent molar yield coefficients were obtained and are compared to metabolic quotients and yield coefficients previously calculated from standard continuous culture experiments, i.e., without cell retention, at specific growth rates of 0.63 and 1.24 d-1. Furthermore, steady-state data on viable cell and antibody concentrations, spec. mAb productivities, and space-time yields determined before and after a step change (2.5-fold increase) in dilution rate at identical specific growth rates mu are presented.     

Biological ferrous sulfate oxidation by A. ferrooxidans immobilized on chitosan beads

The immobilization of Acidithiobacillus ferrooxidans cells on chitosan and cross-linked chitosan beads and the biooxidation of ferrous iron to ferric iron in a packed-bed bioreactor were studied. The biofilm formation was carried out by using a glass column reactor loaded with chitosan or cross-linked chitosan beads and 9 K medium previously inoculated with A. ferrooxidans cells. The immobilization cycles on the carrier matrix with the bioreactor operating in batch mode were compared. Then, the reactor was operated using a continuous flow of 9 K medium at different dilution rates. The results indicate that the packed-bed reactor allowed increasing the flow rate of medium approximately two fold (chitosan) and eight fold (chitosan cross-linked) without cells washout, compared to a free cell suspension reactor used as control, and to reach ferric iron productivities as high as 1100 and 1500 mg l(-1) h(-1) respectively. Scanning electron microscopy micrographs of the beads, infrared spectroscopy and the X-ray diffraction patterns of precipitates on the chitosan beads were also investigated.     

Study of gaseous substrate fermentations: carbon monoxide conversion to acetate. 2. Continuous culture

The fermentation of gaseous substrates such as CO, H(2), and CO(2) may be performed in a continuous stirred tank reactor, as well as the traditional batch reactor. In this article, the conversion of carbon monoxide by Peptostreptococcus productus is demonstrated in a stirred tank reactor under both mass transfer-controlled and nonmass transfer-controlled conditions. Utilizing a non-steady-state procedure, intrinsic rates are evaluated under non-mass transfer-controlled conditions in a time period of only 5-6 hours. A steady-state procedure was used to evaluate CSTR performance under mass transfer-controlled conditions. The mass transfer coefficient was calculated, followed by the development of a model to predict CSTR behavior for this gas phase substrate.     

Modeling biofilm accumulation and mass transport in a porous medium under high substrate loading

A packed bed biofilm reactor inoculated with pure culture Pseudomonas aeruginosa was run under high substrate loading and constant flow rate conditions. The 3.1-cm-diameter cylindrical reactor was 5 cm in length and packed with 1-mm glass beads. Daily observations of biofilm thickness, influent and effluent glucose substrate concentration, and effluent dissolved and total organic carbon were made during the 13-day experiment. Biofilm thickness appeared to rech quasi-steady-state condition after 10 days. A published biofilm process simulation program (AQUASIM) was used to analyze experimental data. Comparison of observed and simulated variables revealed three distinct phases of biofilm accumulation during the experiment: an initial phase, a growth phase, and a mature biofilm phase. Different combinations of biofilm and mass transport process variables were found to be important during each phase. Biofilm detachment was highly correlated with shear at the biofilm surface during all three phases of biofilm development. (c) 1995 John Wiley & Sons, Inc.     

Highly enantioselective esterification of racemic ibuprofen in a packed bed reactor using immobilised Rhizomucor miehei lipase

A systematic study of the enantioselective resolution of ibuprofen by commercial Rhizomucor miehei lipase (Lipozyme(R) IM20) has been carried out using isooctane as solvent and butanol as esterificating agent. The main variables controlling the process (temperature, ibuprofen concentration, ratio butanol:ibuprofen) have been studied using an orthogonal full factorial experimental design, in which the selected objective function was enantioselectivity. This strategy has resulted in a polynomial function that describes the process. By optimizing this function, optimal conditions for carrying out the esterification of racemic ibuprofen have been determined. Under these conditions, enantiomeric excess and total conversion values were 93.8% and 49.9%, respectively, and the enantioselectivity was 113 after 112 h of reaction. These conditions have been considered in the design of a continuous reactor to scale up the process. The esterification of ibuprofen was properly described by pseudo first-order kinetics. Thus, a packed bed reactor operating as a plug-flow reactor (PFR) is the most appropriate in terms of minimizing the residence time compared with a continuous stirred tank reactor (CSTR) to achieve the same final conversion. This reactor shows a similar behavior in terms of enantioselectivity, enantiomeric excess, and conversion when compared with batch reactors. A residence-time distribution (RTD) shows that the flow model is essentially a plug flow with a slight nonsymmetrical axial dispersion (Peclet number = 43), which was also corroborated by the model of CSTR in series. The stability of the system (up to 100 h) and the possibility of reutilization of the enzyme (up to four times) lead to consider this reactor as a suitable configuration for scale up of the process.     

Glycosynthase reaction meets the flow: Continuous synthesis of lacto-N-triose II by engineered β-hexosaminidase immobilized on solid support

The D746E variant of Bifidobacterium bifidum β-N-acetyl-hexosaminidase is a promising glycosynthase (engineered glycosidase deficient in hydrolase activity) for the synthesis of lacto-N-triose II (LNT II), a core structural unit of human milk oligosaccharides. Here, we develop a flow process for the glycosynthase reaction, which is the regioselective β-1,3-glycosylation of lactose from a d -glucosamine 1,2-oxazoline donor. Using the glycosynthase immobilized on agarose beads (∼30 mg/g) packed into a fixed bed (1 ml), we show stable continuous production of LNT II (145–200 mM) at quantitative yield from the donor substrate. The wild-type β-N-acetyl-hexosaminidase used under exactly comparable conditions gives primarily (∼85%) the hydrolysis product d -glucosamine. By enabling short residence times (2 min) that are challenging for mixed-vessel types of reactor to establish, the glycosynthase flow reactor succeeds in an effective uncoupling of the LNT II formation (∼80–100 mM/min) from the slower side reactions (decomposition of donor substrate, enzymatic hydrolysis of LNT II) to obtain optimum synthetic efficiency. Our study thus provides a strong case for the application of flow chemistry principles to glycosynthase reactions and by that, it reveals the important synergy between enzyme and reaction engineering for biocatalytic synthesis of oligosaccharides.     

Continuous ethanol production by Zymomonas mobilis in a fluidized bed reactor. Part II: Process development for the fermentation of hydrolysed B-starch without sterilization

A continuous fluidized bed reactor operation system has been developed for ethanol production by Zymomonas mobilis using hydrolysed B-starch without sterilization. The operation system consists of two phases. In the first phase macroporous glass carriers in a totally mixed fluidized bed reactor were filled up totally with a monoculture of Z. mobilis by fast computer-controlled colonization, so that in the subsequent production phase no contaminants, especially lactic-acid bacteria, could penetrate into the carrier beads. In the production phase the high concentration of immobilized Z. mobilis cells in the fluidized bed reactor permits unsterile fermentation of hydrolysed B-starch to ethanol at short residence times. This results in wash-out conditions for contaminants from the substrate. Long-term experimental studies (more than 120 days) of unsterile fermentation of hydrolysed B-starch in the laboratory fluidized bed reactor (2.2 l) demonstrated stable operation up to residence times of 5 h. A semi-technical fluidized bed reactor plant (cascade of two fluidized bed reactors, each 55 l) was operated stably at a mean residence time of 4.25 h. Glucose conversion of 99% of the unsterile hydrolysed B-starch was achieved at 120 g glucose/l^–1 in the substrate, resulting in an ethanol concentration of 50 g·l^–1 and an ethanol space-time yield of 13 g·l^–1·h^–1. This is a factor of three compared to ethanol fermentation of hydrolysed B-starch with Z. mobilis in a continuous stirred tank reactor, which can only be operated stably under sterile conditions. Correspondence to: D. Weuster-Botz     

Immobilization of urease within a thin channel ultrafiltration cell

Urease [urea amidohydrolase, EC 3.5.1.5] has been immobilized within a thin channel ultrafiltration cell. Loss of enzymic activity as a result of concentration polarization and other causes was minimized. The flow characteristics of the reactor were fully characterized by analysis of the distribution of residence times (using F diagrams) and kinetic data were also obtained for the immobilized enzyme. These data show that under certain conditions the thin channel ultrafiltration reactor can be considered to be an ideally mixed vessel. After almost 8 days of continuous operation it was found that 15% of the original enzyme activity remained.     

Stability of the biocatalysts of L-aspartic acid synthesis based on immobilized Escherichia coli cells

Experiments were carried out to investigate the process of a continuous enzymatic synthesis of L-aspartic acid from ammonium fumarate in uniform filling flow reactors. Escherichia coli (Soviet strain 85) cells immobilized in polyacrylamide gel granules reinforced by a solid carrier were used as biocatalysts. The conditions, under which a high aspartase activity of the biocatalyst and a stable hydrodynamic performance of the reactor were maintained, were determined. The main kinetic characteristics of a continuous performance of the reactor for 150 days were obtained.