Contribution of aerial hyphae of Aspergillus oryzae to respiration in a model solid-state fermentation system

Oxygen transfer is for two reasons a major concern in scale-up and process control in industrial application of aerobic fungal solid-state fermentation (SSF): 1) heat production is proportional to oxygen uptake and it is well known that heat removal is one of the main problems in scaled-up fermenters, and 2) oxygen supply to the mycelium on the surface of or inside the substrate particles may be hampered by diffusion limitation. This article gives the first experimental evidence that aerial hyphae are important for fungal respiration in SSF. In cultures of A. oryzae on a wheat-flour model substrate, aerial hyphae contributed up to 75% of the oxygen uptake rate by the fungus. This is due to the fact that A. oryzae forms very abundant aerial mycelium and diffusion of oxygen in the gas-filled pores of the aerial hyphae layer is rapid. It means that diffusion limitation in the densely packed mycelium layer that is formed closer to the substrate surface and that has liquid-filled pores is much less important for A. oryzae than was previously reported for R. oligosporus and C. minitans. It also means that the overall oxygen uptake rate for A. oryzae is much higher than the oxygen uptake rate that can be predicted in the densely packed mycelium layer for R. oligosporus and C. minitans. This would imply that cooling problems become more pronounced. Therefore, it is very important to clarify the physiological role of aerial hyphae in SSF.     

Three-dimensional simulation of grain mixing in three different rotating drum designs for solid-state fermentation

A previously published two-dimensional discrete particle simulation model for radial mixing behavior of various slowly rotating drums for solid-state fermentation (SSF) has been extended to a three-dimensional model that also predicts axial mixing. Radial and axial mixing characteristics were predicted for three different drum designs: (1) without baffles; (2) with straight baffles; and (3) with curved baffles. The axial mixing behavior was studied experimentally with video- and image-analysis techniques. In the drum without baffles and with curved baffles the predicted mixing behavior matched the observed behavior adequately. The predicted axial mixing behavior in the drum with straight baffles was predicted less accurately, and it appeared to be strongly dependent on particle rotation, which was in contrast to the other drum designs. In the drum with curved baffles complete mixing in the radial and axial direction was achieved much faster than in the other designs; that is, it was already achieved after three to four rotations. This drum design may therefore be very well suited to SSF. It is concluded that discrete particle simulations provide valuable detailed knowledge about particle transport processes, and this may help to understand and optimize related heat and mass transfer processes in SSF.     

Numerical simulation and PEPT measurements of a 3D conical helical-blade mixer: a high potential solids mixer for solid-state fermentation

Helical-blade solids mixers have a large potential as bioreactors for solid-state fermentation (SSF). Fundamental knowledge of the flow and mixing behavior is required for robust operation of these mixers. In this study predictions of a discrete particle model were compared to experiments with colored wheat grain particles and positron emission particle tracking (PEPT) measurements. In the discrete particle model individual movements of particles were calculated from interaction forces. It was concluded that the predicted overall flow behavior matched well with the PEPT measurements. Differences between the model predictions and the experiments with wheat grains were found to be due to the assumption that substrate particles were spherical, which was in the model. Model simulations and experiments with spherical green peas confirmed this. The mixing in the helical-blade mixer could be attributed to (1) the transport of particles up and down in the interior of the mixer, and (2) dispersion or micro-mixing of particles in the top region of the mixer. It appeared that the mixing rate scaled linearly with the rotation rate of the blade, although the average particle velocity did not scale proportionally. It may be that the flow behavior changes as a function of the rotation rate (e.g., changing thickness of the top region); further study is required to confirm this. To increase the mixing performance of the mixer, a larger blade or a change in the shape of the mixer (larger top surface/volume ratio) is recommended.     

Water and glucose gradients in the substrate measured with NMR imaging during solid-state fermentation with Aspergillus oryzae

Gradients inside substrate particles cannot be prevented in solid-state fermentation. These gradients can have a strong effect on the physiology of the microorganisms but have hitherto received little attention in experimental studies. We report gradients in moisture and glucose content during cultivation of Aspergillus oryzae on membrane-covered wheat-dough slices that were calculated from (1)H-NMR images. We found that moisture gradients in the solid substrate remain small when evaporation is minimized. This is corroborated by predictions of a diffusion model. In contrast, strong glucose gradients developed. Glucose concentrations just below the fungal mat remained low due to high glucose uptake rates, but deeper in the matrix glucose accumulated to very high levels. Integration of the glucose profile gave an average concentration close to the measured average content. On the basis of published data, we expect that the glucose levels in the matrix cause a strong decrease in water activity. The results demonstrate that NMR can play an important role in quantitative analysis of water and glucose gradients at the particle level during solid-state fermentation, which is needed to improve our understanding of the response of fungi to this nonconventional fermentation environment.     

The potential for establishment of axial temperature profiles during solid-state fermentation in rotating drum bioreactors

The mixing and heat transfer phenomena within rotating drum bioreactors (RDBs) used for solid-state fermentation processes are poorly studied. The potential for the establishment of axial temperature gradients within the substrate bed was explored using a heat transfer model. For growth of Aspergillus oryzae on wheat bran within a 24 L RDB with air at a superficial velocity of 0.0023 m s(-1) and 15% relative humidity, the model predicts an axial gradient between the air inlet and outlet of 2 degrees C during rapid growth, compared to experimental axial temperature gradients of between 1 and 4 degrees C. Undesirably high temperatures occur throughout the bed under these operating conditions, but the model predicts that good temperature control can be achieved using humid air (90% relative humidity) at superficial velocities of 1 m s(-1) for a 204 L RDB. For a 2200 L RDB, good temperature control is predicted with superficial velocities as low as 0.4 m s(-1) with the airflow being switched from 90% to 15% relative humidity whenever the temperature at the outlet end of the drum exceeds the optimal temperature for growth. This work suggests that significant axial temperature gradients can arise in those RDBs that lack provision for axial mixing. It is therefore advisable to use angled lifters within RDBs to promote axial mixing.     

Discrete particle simulations predicting mixing behavior of solid substrate particles in a rotating drum fermenter.

A soft-sphere discrete particle model was used to simulate mixing behavior of solid substrate particles in a slow rotating drum for solid-state fermentation. In this approach, forces acting on and subsequent motion of individual particles can be predicted. The (2D) simulations were qualitatively and quantitatively validated by mixing experiments using video and image analysis techniques. It was found that the simulations successfully predicted the mixing progress as a function of the degree of filling and size of the drum. It is shown that only relatively large, straight baffles perpendicular to the drum wall (67% of the drum radius) increase the mixing performance of the rotating drum. Considering the different aspects of mixing dealt with in this work, it is concluded that the soft sphere discrete particle model can serve as a valuable tool for investigating mixing of solid substrate particles. Finally, it is expected that this model may evolve into a potential tool for design and scale-up of mixed solid-state fermenters.     

Heat and water transfer in a rotating drum containing solid substrate particles

In previous work we reported on the simulation of mixing behavior of a slowly rotating drum for solid-state fermentation (SSF) using a discrete particle model. In this investigation the discrete particle model is extended with heat and moisture transfer. Heat transfer is implemented in the model via interparticle contacts and the interparticle heat transfer coefficient is determined experimentally. The model is shown to accurately predict heat transfer and resulting temperature gradients in a mixed wheat grain bed. In addition to heat transfer, the addition and subsequent distribution of water in the substrate bed is also studied. The water is added to the bed via spray nozzles to overcome desiccation of the bed during evaporative cooling. The development of moisture profiles in the bed during spraying and mixing are studied experimentally with a water-soluble fluorescent tracer. Two processes that affect the water distribution are considered in the model: the intraparticle absorption process, and the interparticle transfer of free water. It is found that optimum distribution can be achieved when the free water present at the surface of the grains is quickly distributed in the bed, for example, by fast mixing. Alternatively, a short spraying period, followed by a period of mixing without water addition, can be applied. The discrete particle model developed is used successfully to examine the influence of process operation on the moisture distribution (e.g., fill level and rotation rate). It is concluded that the extended discrete particle model can be used as a powerful predictive tool to derive operating strategies and criteria for design and scale-up for mixed SSF and other processes with granular media.     

A two-phase model for water and heat transfer within an intermittently-mixed solid-state fermentation bioreactor with forced aeration

A two-phase dynamic model is developed that describes heat and mass transfer in intermittently-mixed solid-state fermentation bioreactors. The model predicts that in the regions of the bed near the air inlet there can be significant differences in the air and solid temperatures, while in the remainder of the bed the gas and solid phases are much closer to equilibrium, although there can be differences in water activity of around 0.05. The increase in the temperature of the gas as it flows through the bed means that it is impossible to prevent the bed from drying out, even if saturated air is used at the air inlet. The substrate can dry to water activities that severely limit growth, unless the bed is intermittently mixed, with the addition of water to bring the water activity back to the desired value. Under the conditions assumed for the simulation, which was designed to mimic the growth of Aspergillus niger on corn, two mixing events were necessary, one at 17.4 and the other at 27.9 h. Even though such a strategy can minimize the restriction of growth by water-limitation, temperature-limitation remains a problem due to the rapid heating dynamics. The model is obviously a useful tool that can be used to guide scale-up and to test control strategies. Such a model, describing the non-equilibrium situation between the gas and solid phases, has not previously been proposed for solid-state fermentation bioreactors. Models in the literature that assume gas-solid temperature and moisture equilibrium cannot describe the large temperature differences between the gas and solid phase which occur within the bed near the air inlet.     

Use of confocal scanning laser microscopy to measure the concentrations of aerial and penetrative hyphae during growth of Rhizopus oligosporus on a solid surface

In order to develop a method for use in investigations of spatial biomass distribution in solid-state fermentation systems, confocal scanning laser microscopy was used to determine the concentrations of aerial and penetrative biomass against height and depth above and below the substrate surface, during growth of Rhizopus oligosporus on potato dextrose agar. Penetrative hyphae had penetrated to a depth of 0.445 cm by 64 h and showed rhizoid morphology, in which the maximum biomass concentration, of 4.45 mg dry wt cm(-3), occurred at a depth of 0.075 cm. For aerial biomass the maximum density of 39.54 mg dry wt (-3) occurred at the substrate surface. For both aerial and penetrative biomass, there were two distinct regions in which the biomass concentration decayed exponentially with distance from the surface. For aerial biomass, the first exponential decay region was up to 0.1 cm height. The second region above the height of 0.1 cm corresponded to that in which sporangiophores dominated. This work lays the foundation for deeper studies into what controls the growth of fungal hyphae above and below the surfaces of solid substrates.