Vacuum fermentation for ethanol production using strains of Zymomonas mobilis

Summary Using strains of Z.mobilis, a vacuum fermentation system has been evaluated. The system was designed with the fermentor at atmospheric pressure and an external vacuum vessel (50 mm Hg). Sequential operation of the vacuum vessel was under microprocessor control. The use of Z.mobilis together with the two-stage design of the vacuum system has been found to overcome the problems of oxygen addition and the possibility of contamination reported previously for vacuum fermentations with yeasts. The productivity of 85 g/1/h found in the continuous cell recycle experiments was similar to that reported previously for a strain of S.cerevisiae.     

Ethanol production by Zymomonas mobilis CP4 from sugar cane chips

Summary The fermentation of large sugar cane chips (1.0–1.5 in) to ethanol by Zymomonas mobilis CP4 (Z. mobilis) was studied in two glass fermentors operating with culture circulation for agitation (the EX-FERM type): a. A laboratory scale(2.5 liter) cylindrical vessel; b. A bench scale (8 liter) wide vessel. Z. mobilis cultures consumed 89–96% of the cane sucrose, converting it to ethanol by 90–97% of the theoretical yield in the laboratory scale fermentor and by 83–90% in the bench scale fermentor culture. Comparative Saccharomyces spp. cultures in laboratory fermentor consumed 96–98% of the cane sucrose, with ethanol conversion of only 75–79% of the theoretical yield.These preliminary results indicated that sucrose in agricultural size sugar cane chips was ethanol fermentable as compared to small size sugar cane chips or to sugar cane juice. Z. mobilis CP4 cultures converted sucrose more efficiently to ethanol than Saccharomyces spp. as shown in the laboratory scale fermentor studies.The ethanol yields in a wide bench scale fermentor cultures were slightly lower than in a laboratory fermentor.     

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.     

Continuous production of ethanol from a glucose,xylose and arabinose mixture by a flocculent strain ofPichia stipitis

Summary Enhanced rates of continuous ethanol production by a flocculent strain ofPichia stipitis from a sugar mixture (xylose 75%, glucose 20%, arabinose 5%) were attained using a single-stage gas lift tower fermentor. With a substrate feed of 50g/l, the biomass accumulated at a level near 50g/l, showed a maximum and stable ethanol productivity of 10.7 g/l.h, with a substrate conversion of 80%; the ethanol yield reached 0.41g/g. In these operating conditions, similar performances were obtained when D.xylose alone was supplied.     

Continuous high rate production of ethanol by Zymomonas mobilis in an attached film expanded bed fermentor

Summary Experiments were conducted with Zymomonas mobilis in an attached film expanded bed (AFEB) fermentor at different dilution rates, using a feed glucose concentration of 100 gm/l. Vermiculite was used as the bed material for attachment of the bacterial film. Ethanol volumetric productivities were maximum at a dilution rate of 3.6hr^-1. The productivities were 105 gm/l-hr and 210 gm/l-hr based on total fermentor volume and bed volume, respectively.     

Ethanol production from fructose in continuous culture by free and flocculent cells of Zymomonas mobilis

Summary Zymomonas mobilis strain ZM4 was used for ethanol production from fructose (100 g/l) in continuous culture with a mineral (containing Ca pantothenate) or a rich (containing yeast extract) mediium. With both media high conversion yields were observed but the ethanol productivity was limited by the low biomass content of the fermentor. A new flocculent strain of Z.mobilis (ZM4F) was cultivated in a CSTR with an internal settler and showed a maximal productivity of 93 g/l.h (fructose conversion of 80%). When the fructose conversion was 96% an ethanol productivity of 85.6 g/l.h with an ethanol yield of 0.49 g/g (96% of theoretical) was observed.     

Growth and cell wall composition of glucose-limited bean cells (Phaseolus vulgaris L.)

Glucose-limited bean cells (Phaseolus vulgaris L.) were grown in a modified bacterial fermentor at a constant pH of 4.8. The cultures were kept in steady state at different specific growth rates varying from 0.00216 h^–1 to 0.0106 h^–1. Culture conditions are described that are needed to start a continuous culture. First, it was essential to use log-phase cells as starting material. Second, it was important to increase the dilution rate gradually, otherwise cells in the culture aggregated. Cells grown at the highest dilution rate employed contained twice as much protein per gram dry weight as cells grown at the lowest dilution rate. The composition of the cell walls also varied with the dilution rate in contrast to their relatively constant composition when grown in batch culture.     

Continuous production of extracellular protease by Bacillus subtilis in a two-stage fermentor

Growth and protease production of Bacillus subtilis in semisynthetic and synthetic media were studied in batch culture and in a two-stage, laboratory scale, continuous fermentor. The amount, of extracellular protease production was measured under specific growth conditions in both stages of the ferment or. At the dilution rates employed, the cells in the first stage of the ferment or produced negligible quantities of protease, and the culture primarily functioned as a continuous inoculum for the second stage of the fermentor. The culture effluent from the second stage of the fermentor contained extracellular protease, on the average, equal to 60 per cent, of the activity that had been found in the supernatant of a 48-hr batch culture grown in a medium having the same composition as that in the continuous fermentor. Extracellular protease was produced in semisynthetic medium by B. subtilis in the two-stage fermentor for as long as 20 days without culture degeneration. Additional studies indicated that continuous protease production could also be achieved in a synthetic medium. The RNA/ protein ratios of cells grown in semisynthetic medium in batch culture and in each stage of the two-stage fermentor were examined. There was a positive correlation between the amount of protease produced by the cells and their RNA/ protein ratio. Techniques employed for continuous production of protease by B. subtilis and the potential use of the method for investigating the control of secondary metabolite synthesis are discussed.     

Production of mold lactase

A process for production of mold lactase was developed. Tests were carried out in pilot and industrial scale with an Aspergillus niger strain selected after screening a number of molds.A computer coupled autoanalyzer system was used for monitoring enzyme formation in the pilot fermentor. Lactase production was investigated using different pH- and temperature-profiles. A. niger lactase has an acid pH optimum, a high temperature optimum and good stability. It does not require any metal ions. It is suitable for immobilization for hydrolysis of lactose in acid whey.Three-fold enhancement of lactase production was obtained by mutagenizing A. niger using NTG as mutagenic agent.The lactases produced by the mutants have the same pH and temperature optima and stability but the growth properties of the mutants were different from those of the original strain.Sufficient specific activity of the enzyme preparation for immobilization was obtained by purifying the enzyme by selective adsorption on Na-Ca-silicate.     

12β-Hydroxylation of digitoxin by Digitalis lanata cells. Production of deacetyllanatoside C in a 20-litre airlift bioreactor

Digitalis lanata cell lines obtained via cell aggregate cloning have been characterized with regard to their growth and ability to form deacetyllanatoside C from digitoxin. Cell line W.1.4 achieved 12-hydroxylation rates as high as 200 mg/L d. It was thus used in biotransformation experiments on a 20-litre scale. Six fermentor runs were performed, the best of which yielded 13.2 g deacetyllanatoside C.     

Production of acetone - butanol from acid whey

Summary Clostridium acetobutylicum ATCC 824 was used to produce butanol and acetone by fermenting acid whey. Results showed that both autoclaving and agitation played roles in solvent production. Maximum production was obtained in 120 h using autoclaved, pH adjusted (6.0) acid whey at 37 °C in a fermentor that was not agitated.     

An experimental study of acid production rate controlled operations of a continuous fermentor

The efficacy of acid production rate (APR) controlled operations of a continuous fermentor supporting the growth of a methylotroph, L3, was experimentally examined. Direct digital control of pH at a constant value allowed for on-line estimation of APR during the fermentation. Two types of APR controlled operations were studied. In the first type of operation, the APR was controlled at a constant value according to a predetermined program by manipulating the feed flow rate to the fermentor. Such an operation effectively stabilized the cell mass productivity of a continuous fermentor subjected to disturbances in the feed nutrient concentration. It resulted in a near complete conversion of methanol to yield a cell mass product with very low amounts of unutilized methanol at both steady state and transient fermentation situations. In the second type of operation, the feed flow rate was manipulated to optimize the steady state value of APR during the fermentation. This method shows promise for on-line steady state optimization of cell mass productivity in a continuous fermentor.     

Robust pole placement control of a fermentor

This paper deals with robust pole placement control of a continuous flow alcoholic fermention process. The strain used for experiments is Saccharomyces cerevisae UG5. The fermentor is subject to changs in pH, temperature, mixing, etc. The regularized pole placement adaptive control algorithm is used for regulation and tracking purposes. The substrate concentration and the dilution rate have been respectively selected as controlled and control variables. The eliminant matrix associated to the pole placement problem is non-singular if the identified input-output model has common poles and zeros. Two solutions have been adopted to deal with this ill-conditioning problem. The first solution consists of monitoring the determinant of the eliminant matrix and the second consists of adding a correction term to the highest degree coefficient of either the numerator or denominator of the process transfer function. A robust recursive identification scheme is used for parameters estimation. The fermentor was interfaced with PC computer using a multitasking operating system. Experiments carried out with the fermentor, illustrate the use of the regularized pole placement adaptive control algorithm.     

Bacillus sphaericus V-penicillin acylase I. Fermentation

Summary In an aerobic fermentor with a fermentation medium based on 4% corn steep liquor and salts, Bacillus sphaericus, strain NCTC 10338, produces an intracellular V-penicillin acylase, when pH is in the narrow interval 7.5–8.0. The strain grows well outside this pH range, but the growth is not associated with acylase activity in the cells. The enzyme was not induced by phenoxy acetic acid and was not repressed by glucose.     

Immobilization and culture of coffee (Coffea arabica L.) cells on novel culture systems using a basket-shaped unit, “EGSTAR”

Summary A simple and new basket-shaped unit for agitation made of stainless steel (EGSTAR), in which immobilized coffee cells in Ca-alginate gel beads were packed, was placed in a jar fermentor (System-1). This system allowed the plant cells to grow submersed in the unit even at high agitation speed (650 rpm). Only a small amount of cells existed out of the EGSTAR. Most of the purine alkaloids produced were released into the medium. Suspended coffee cells in the jar fermentor were also possibly immobilized onto a polyurethane foam sheet fixed inside the net of the EGSTAR (System-2). The total cells in System-2 biotransformed theobromine to caffeine (77.9%). Other plant cell suspensions were also immobilized as efficiently as were the coffee cells in this system. Thus, System-2 is a simple and convenient system for immobilization of plant cells to produce secondary metabolites. This paper is Part 79 in the series of “Studies on Plant Tissue Cultures”. For Part 78, see Orihara, Y., Furuya, T., Hashimoto, N., Deguchi, Y., Tokoro, K., and Kanisawa, T., (1992)Phytochemistry 31: 827–831.     

Evaluation of semiconductor gas sensor system for on-line ethanol estimation

Summary On-line estimation of ethanol concentration during a fermentation was carried out with a semiconductor gas sensor system using a semipermeable membrane to separate a gas stream from the fermentor broth. The system has the advantages of low-cost, in-situ steam sterilization and a relatively fast response time (1 min.). Good agreement was found between on-line and off-line measurements with fermentation of 25% glucose media using S.uvarum and Z.mobilis. However, significant deviations occurred with the fermentation of sugar-cane juice, grape-juice and molasses.     

Continuous hydrocarbon fermentation with colloidal emulsion feed. A kinetic model for two-liquid phase culture

Candida tropicalis was cultured in a chemostat-type fermentor with n-hexadecane, dispersed in water as submicron droplets, as the only carbon substrate. The emulsion as well as the aqueous medium were fed continuously into the fermentor. A Monod-type equation can correlate the specific group rate in the continuous fermentor with the concentration of submicron droplets. The same equation can also be fitted to the data for the conventional-type batch culture in the same fermentor in which an oil phase as well as an aqueous phase existed, if the hydrocarbon concentration in the aqueous phase excluding oil drops is employed as the substrate concentration. This demonstrates that Candida tropicalis takes up only submicron droplets of n-hexadecane as the carbon substrate.     

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.     

High-productivity fermentation process for cultivating industrial microorganisms

Summary High-productivity continuous fermentation processes have been developed for the production of important industrial microorganisms in specially designed fermentors.Saccharomyces cerevisiae, Pichia pastoris, Kluyveromyces fragilis, andCandida utilis yeasts have been grown in bench-scale fermentors at cell densities of over 120 g/l, whileEscherichia coli, Bacillus megaterium, Methylomonas sp. andPseudomonas putida bacteria have been cultivated to cell densities of more than 110 g/l. Productivities (g cells per 1 per h) greater than 25 have been achieved in both bench-scale and 1500-liter fermentors with yeasts, and values as high as 55 have been achieved with bacteria in the bench-scale fermentor. The microorganisms were grown on defined media using ammonia for pH control and as nitrogen source. The fermentor, capable of high oxygen and heat transfer rates, was operated at constant volume with continuous feed and product discharge. The high-productivity process reduces fermentor size, media sterilization requirements, and may under some circumstances eliminate waste and recycle streams. It can also be applied to a variety of biological products.     

Phenolic 9,10-secosteroids as products of the catabolism of bile acids by a Pseudomonas sp.

The obligate aerobe, Pseudomonas putida ATCC 31752, efficiently utilises bile acids as a source of carbon and energy for growth and maintenance. When aeration is considerably restricted, a consequence to the catabolism of the bile acids in a fermentor is an accumulation of certain steroidal catabolites. Evidence is presented to show that among these are hydroxy-9,10-seco-1,3,5(10)-androstratriene-9,17-diones and those from four of the common bile acids, cholic, chenodeoxycholic, hyodeoxycholic and deoxycholic acids have been isolated and their structures determined. The product of catabolism of hyodeoxycholic acid appears to exist in a hemi-acetal form which readily forms an acetal during isolation procedures. All but one of these are described for the first time.