Extractive fermentation for lactic acid production

Lactic acid extractive fermentation was demonstrated using Alamine 336 in oleyl alcohol at acidic pH. The use of an efficient extraction system was possible through employment of the cell immobilization procedure. Process modeling was performed to relate the various process parameters such as flow rate, concentration, and pH. In experiments with 15% Alamine 336/oleyl alcohol, the bioreactor operation resulted in a higher productivity (12 g/L gel h) compared to that of a control fermentation (7 g/L gel h). Strategies for optimizing the extractive fermentation process were proposed considering both productivity and product recovery.     

Optimization of an industrial microalgae fermentation

Optimization of cellular productivity of an industrial microalgae fermentation was investigated. The fermentation was carried out at Coors Biotech Products Company, Fort Collins, Colorado. A mathematical model was developed based on the data collected from pilot plant test runs at different operating conditions. Pontryagin's maximum principle was used for determining the optimal feed policy. A feedback control algorithm was also studied for maximizing the cellular productivity. During continuous operation, the optimum dilution rate was determined by an adaptive optimization scheme based on the steepest descent technique and a recursive least squares estimation of model parameters. A direct search algorithm was also applied to determine the optimum feed rate. Comparison of the theoretical results of the different optimization schemes revealed that the direct search algorithm was preferable because of its simplicity. The experimental results of real time application of the feedback algorithm agreed fairly well with those of the theoretical analyses. (c) 1994 John Wiley & Sons, Inc.     

On-line adaptive control of a fed-batch fermentation of Saccharomyces cerevisiae

The feasibility of applying an adaptive control technique to a fermentation process is investigated. The nonlinear, time-variant parameters of a fermentation process were estimated on-line as a series of linearized describing matrices. The matrices were used to update a suboptimal feedback law which controlled the process in real time over the linear region. Experiments were performed on a small-scale fully instrumented fermenter with the online, real-time adaptive control package. Results are presented for both single- and multivariable control, and indicate successful control of yeast cell growth.     

Optimal process/solvent design for ethanol extractive fermentation with cell recycling

In this study, the computer-aided process/solvent design is introduced to find an optimal biocompatible solvent and to maximize the ethanol production rate simultaneously for the single- or double-stage extractive fermentation process with cell recycling. Such a process/solvent design problem is formulated as a mixed-integer nonlinear programming problem that is solved by mixed-integer hybrid differential evolution in order to obtain a global design. The double-stage process can use a smaller amount of fresh solvent to increase ethanol productivity compared with that of the single-stage process, but it will also decrease overall conversion. Comparing the case studies, the simultaneous process/solvent design could yield higher overall ethanol productivity than that of the process design. The maximum ethanol production rate for the double-stage extractive fermentation with cell recycling was about 10-fold higher than that of continuous fermentation and about twofold higher than that of continuous fermentation with cell recycling.     

Fed-batch versus batch fermentation

This article concerns the comparison between batch and fed-batch fermentation based on productivity and including the analysis of the implications on product manufacturing cost. The calculation method of productivity is based on the assumption that batch production rate data are applicable to fed-batch fermentation and that, within a certain range of concentrations, the percent rate of change of batch production rate with respect to time is proportional to the difference of product concentration at maximum production rate minus instant concentration. General correlations are developed and plotted in diagrams for easy practical application of the proposed method of calculation. Correlations so established may find application to design and to planning and control of operating conditions of fermentation plants. Example calculations refer to penicillin G production.     

Ethanol from whey: Continuous fermentation with cell recycle

The production of ethanol from cheese whey lactose has been demonstrated using a single-stage continuous culture fermentation with 100% cell recycle. In a two-step process, an aerobic fed batch operation was used initially to allow biomass buildup in the absence of inhibitory ethanol concentrations. In the anaerobic ethanol-producing second step, a strain of Kluyveromyces fragilis selected on the basis of batch fermentation data had a maximum productivity of 7.1 g ethanol/L/h at a dilution rate of 0.15 h(-1), while achieving the goal of zero residual sugar concentration. The fermentation productivity diminished when the feed sugar concentation exceeded 120 g/L despite the inclusion of a lipid mixture previous shown to enhance batch fermentation productivities.     

添加表面活性剂改善丁醇萃取发酵性能

研究了各种表面活性剂对丁醇萃取发酵的影响。丁醇发酵中有大量H2、CO2气体生成,生成的气泡携带发酵溶剂产物（丁醇、丙酮）进入萃取液相,促进了水相中发酵毒性产物向萃取液相的移动。研究发现,表面活性剂可以降低气-液膜的表面张力,促使大气泡破碎,从而使发酵产气以较小气泡的形式穿过萃取液相。添加表面活性剂可以强化发酵溶剂产物从水相到萃取相的移除速度,缩短发酵产物在油水两相中达到平衡的时间。有利于提高发酵生产强度。以地沟生物柴油为萃取剂,吐温-80的添加量为质量分数0．140％时,与对照相比（无表面活性剂的萃取发酵）,相同发酵时间内萃取相中丁醇体积分数提高了21．2％．总溶剂生产强唐也提高了16．5％．     

In situ extractive fermentation of acetone and butanol

The productivity of the acetone-butanol fermentation was increased by continuously removing acetone and butanol from the fermentation broth during fed-batch culture. Whole broth containing viable cells of Clostridium acetobutylicum was cycled to a Karr reciprocating plate extraction column in which acetone and butanol were extracted into oleyl alcohol flowing counter-currently through the column. By continuously removing these toxic metabolites from the broth, end product inhibition was reduced, and a concentrated feed solution containing 300 g/L glucose was fermented at an overall butanol productivity of 1.0 g/L h, 70% higher than the productivity of normal batch fermentation. The continuous extraction process provides flexible operation and lends itself to process scale-up.     

Application of balancing methods in modeling the penicillin fermentation

This paper shows the application of elementary balancing methods in combination with simple kinetic equations in the formulation of an unstructured model for the fed-batch process for the production of penicillin. The rate of substrate uptake is modeled with a Monod-type relationship. The specific penicillin production rate is assumed to be a function of growth rate. Hydrolysis of penicillin to penicilloic acid is assumed to be first order in penicillin. In simulations with the present model it is shown that the model, although assuming a strict relationship between specific growth rate and penicillin productivity, allows for the commonly observed lag phase in the penicillin concentration curve and the apparent separation between growth and production phase (idiophase-trophophase concept). Furthermore it is shown that the feed rate profile during fermentation is of vital importance in the realization of a high production rate throughout the duration of the fermentation. It is emphasized that the method of modeling presented may also prove rewarding for an analysis of fermentation processes other than the penicillin fermentation.     

Fed-batch sorbose fermentation using pulse and multiple feeding strategies for productivity improvement

Microbial oxidation of D-sorbitol tol-sorbose byAcetobacter suboxydans is of commercial importance since it is the only biochemical process in vitamin C synthesis. The main bottleneck in the batch oxidation of sorbitol to sorbose is that the process is severely inhibited by sorbitol. Suitable fed-batch fermentation designs can eliminate the inherent substrate inhibition and improve sorbose productivity. Fed-batch sorbose fermentations were conducted by using two nutrient feeding strategies. For fed-batch fermentation with pulse feeding highly concentrated sorbitol (600 g/L) along with other nutrients were fed intermittently in four pulses of 0.5 liter in response to the increased DO signal. The fed-batch fermentation was over in 24 h with a sorbose productivity of 13.40 g/L/h and a final sorbose concentration of 320.48 g/L. On the other hand, in fed-batch fermentation with multiple feeds, two pulse feeds of 0.5 liter nutrient medium containing 600 g/L sorbitol was followed by the addition of 1.5 liter nutrient medium containing 600 g/L sorbitol at a constant feed rate of 0.36 L/h till the full working capacity of the reactor. The fermentation was completed in 24 h with an enhanced sorbose productivity of 15.09 g/L/h and a sorbose concentration of 332.60 g/L. The sorbose concentration and productivity obtained by multiple feeding of nutrients was found to be higher than that obtained by pulse feeding and was therefore a better strategy for fed-batch sorbose fermentation.     

Real-time optimisation of a fermentation process

An adaptive on-line sub-optimal control system for yeast fermentation was developed. The control package is described with a brief history of progress. Results show the effect of the control package on process variables, and indicate present limitations and future development.     

High performance bacterial fermentation process with two gaseous substrates

Two methane utilizing bacteria strains, GB 21 and WSB 874, were cultivated with methane as sole carbon and energy source in a submerged continuous fermentation process. The aim of the investigations was to reach high biomass concentrations (>25 g BDM ·kg^?1 medium) and high productivities (>3 g BDM · kg^?1 · h^?1). A precondition for the high-performance fermentation process was to ensure a transfer rate of methane and oxygen in quantities required by the microorganisms. For this purposes a high performance stirred pressure fermenter was used. The fermentation process is characterized by the transfer of two gaseous substrates. In order to develop a technical process it was necessary to investigate both the correlations between the two gases and the productivity of the fermentation process and the influence of system pressure on the microorganisms. Within a pressure range of up to 0.7 MPa a biomass concentration of up to 50 g BDM · kg^?1 medium and a productivity of up to 9 g BDM · kg^?1 · h^?1 was reached in a continuously running fermentation process under nonsterile conditions. Under these fermentation conditions the microbial population consisted of a dominating main culture GB 21 or WSB 874, respectively, and an accompanying flora (type II). The microbial population was very stable in its composition during the fermentation process running continuously for weeks and months.     

A membrane-integrated fermentation reactor system: its effects in reducing the amount of sub-raw materials for D-lactic acid continuous fermentation by Sporolactobacillus laevolacticus

Continuous fermentation by retaining cells with a membrane-integrated fermentation reactor (MFR) system was found to reduce the amount of supplied sub-raw material. If the amount of sub-raw material can be reduced, continuous fermentation with the MFR system should become a more attractive process for industrialization, due to decreased material costs and loads during the refinement process. Our findings indicate that the production rate decreased when the amount of the sub-raw material was reduced in batch fermentation, but did not decrease during continuous fermentation with Sporolactobacillus laevolacticus. Moreover, continuous fermentation with a reduced amount of sub-raw material resulted in a productivity of 11.2 g/L/h over 800 h. In addition, the index of industrial process applicability used in the MFR system increased by 6.3-fold as compared with the conventional membrane-based fermentation reactor previously reported, suggesting a potential for the industrialization of this D-lactic acid continuous fermentation process.     

Modeling and advanced control of recombinant Zymomonas mobilis fed-batch fermentation

This work presents the development of an unstructured kinetic model incorporating the differing degrees of product, substrate, and pH inhibition on the kinetic rates of ethanol fermentation by recombinant Zymomonas mobilis CP4:pZB5 for growth on two substrates. Product inhibition was observed to start affecting the specific growth rate at an ethanol concentration of 20 g/L and the specific productivity at about 35-40 g/L. Specific growth rate was also shown to be more sensitive to inhibition by lowered pH as well. A model for the inhibition of two competing substrates' cellular uptake via membrane transport is proposed. Inhibition functions and model parameters were determined by fitting experimental data to the model. The model was utilized in a nonlinear model predictive control (NMPC) algorithm to control the product concentration during fed-batch fermentation to offset the inhibitory effects of product inhibition. Using the optimal feeding policy determined online, the volumetric productivity of ethanol was improved 16.6% relative to the equivalent batch operation when the final ethanol concentration was reached.     

Seed stage development for improved fermentation performance: Increased milbemycin production byStreptomyces hygroscopicus

Fermentation development for improved culture productivity can be achieved in a number of ways. Conventional approaches usually concentrate initially on optimisation of the final stage fermentation. However an understanding of the seed stage and its further development can lead to an improvement in final stage productivity. A significant increase in the production of milbemycin VM44866 byStreptomyces hygroscopicus was achieved by manipulation of several factors associated with the seed stage fermentation. Juvenile seeds and seed media containing reduced levels of carbohydrates overcame the detrimental effects of passaging and seed age associated with the standard (control) process. The effect of final stage inoculum level was seed medium-dependent and seed fermentation incubation temperature also affected subsequent milbemycin VM44866 production. These findings were extended to a second milbemycin-producing strain and these results have demonstrated the potential benefits of seed stage optimisation for improved final stage production.     

通气对乳酸发酵过程的影响

对拟干酪乳杆菌发酵产乳酸的过程进行研究,通过改变不同的通气量(不通气、0.1vvm、0.2 vvm、0.5 vvm)确定0.1vvm的通气量最有利于产生乳酸;再通过优化通气策略,在发酵0～15 h不通空气,15～50 h通0.1 vvm空气使得乳酸的产量比全程通0.1 vvm空气又提高了11.7%,同时乳酸产率也提高了16.2%。最后通过对胞内NAD~+、NADH、乳酸脱氢酶和NADH氧化酶活性、以及发酵过程氧化还原电位(Oxidation-reduction potential,ORP)变化进行分析,阐述了通气影响乳酸发酵过程的机理。     

Productivity enhancement in l-sorbose fermentation using oxygen vector

Sorbose, an intermediate of Vitamin-C is produced by biological oxidation of sorbitol by Acetobacter suboxydans. The utility of oxygen vector (N-hexadecane) in enhancing the sorbose accumulation and its productivity was examined for sorbitol to sorbose bioconversion process. Shake flask fermentations were conducted using 1% to 6% (v/v) N-hexadecane. Higher sorbose production was observed in shake flask containing 1-4% N-hexadecane as compared to shake flasks without N-hexadecane. A maximum of 82.12 kgm(-)(3) sorbose accumulated in 24 h by the addition of 4% N-hexadecane as against 64.83 kgm(-)(3) sorbose without the addition of N-hexadecane. However, the concentration of sorbose produced in the same time decreased when 5% and 6% N-hexadecane were used. Batch sorbose fermentation conducted using 4% N-hexadecane demonstrated decrease in the process time from 14 h to 12 h. The productivity increased from 14.3 kgm(-)(3) h(-)(1) to 16.7 kgm(-)(3) h(-)(1) when 4% N-hexadecane was used. Fed-batch fermentation using 4% N-hexadecane was over in 20 h with a productivity of 15.9 kgm(-)(3) h(-)(1), and a sorbose accumulation of 311.68 kgm(-)(3) was obtained. The same fed-batch fermentation finished in 25 h when no N-hexadecane was used. A productivity of 12.6 kgm(-)(3) h(-)(1) and a final sorbose accumulation of 316 kgm(-)(3) were obtained. The increase in productivity and lower process time were achieved by the addition of N-hexadecane to the fermentation medium.     

Porous alumina beads for immobilization of lactic acid bacteria and its application for repeated-batch fermentation in soy sauce production

Porous alumina beads with controlled pores were prepared for the immobilization of lactic acid bacteria to improve soy sauce productivity, and the alumina support with the highest lactic acid productivity was used for repeated-batch fermentation. Immobilized lactic acid bacteria could be used 5 times in repeated-batch fermentation, where higher productivities were obtained than that in conventional fermentation. The lactic acid fermentation process was mathematically modeled from the material balance and the rate equation. The simulated results agreed with the experimental ones.     

On-line estimation of sugar concentration for control of fed-batch fermentation of lignocellulosic hydrolyzates by Saccharomyces cerevisiae

A feed control strategy, based on estimated sugar concentrations, was developed with the purpose of avoiding severe inhibition of the yeast Saccharomyces cerevisiae during fermentation of spruce hydrolyzate. The sum of the fermentable hexose sugars, glucose and mannose, was estimated from on-line measurements of carbon dioxide evolution rate and biomass concentration by use of a simple stoichiometric model. The feed rate of the hydrolyzate was controlled to maintain constant sugar concentration during fed-batch fermentation, and the effect of different set-point concentrations was investigated using both untreated and detoxified hydrolyzates. The fed-batch cultivations were evaluated with respect to cellular physiology in terms of the specific ethanol productivities, ethanol yields, and viability of the yeast. The simple stoichiometric model used resulted in a good agreement between estimated sugar concentrations and off-line determinations of sugar concentrations. Furthermore, the control strategy used made it possible to maintain a constant sugar concentration without major oscillations in the feed rate or the sugar concentration. For untreated hydrolyzates the average ethanol productivity could be increased by more than 130% compared to batch fermentation. The average ethanol productivity was increased from 0.12 to 0.28 g/g h. The productivity also increased for detoxified hydrolyzates, where an increase of 16% was found (from 0.50 to 0.58 g/g h).     

Applied in situ product recovery in ABE fermentation

The production of biobutanol is hindered by the product's toxicity to the bacteria, which limits the productivity of the process. In situ product recovery of butanol can improve the productivity by removing the source of inhibition. This paper reviews in situ product recovery techniques applied to the acetone butanol ethanol fermentation in a stirred tank reactor. Methods of in situ recovery include gas stripping, vacuum fermentation, pervaporation, liquid–liquid extraction, perstraction, and adsorption, all of which have been investigated for the acetone, butanol, and ethanol fermentation. All techniques have shown an improvement in substrate utilization, yield, productivity or both. Different fermentation modes favored different techniques. For batch processing gas stripping and pervaporation were most favorable, but in fed‐batch fermentations gas stripping and adsorption were most promising. During continuous processing perstraction appeared to offer the best improvement. The use of hybrid techniques can increase the final product concentration beyond that of single‐stage techniques. Therefore, the selection of an in situ product recovery technique would require comparable information on the energy demand and economics of the process. © 2017 American Institute of Chemical Engineers Biotechnol. Prog., 33:563–579, 2017