Cheese whey treatment performance of an aerobic jet loop membrane bioreactor

The raw chess whey (CW) treatment capacity of a jet loop membrane bioreactor (JLMBR) was evaluated. Raw CW was first characterized for carbonaceous, nitrogenous and phosphorus compounds. The total COD range of the raw CW was between 73 and 86 kg m⁻³ and 82% of the total COD was found to be soluble. The JLMBR system, of 32 l capacity was operated continuously for 3 months with a sludge age of 1.1–2.8 days and COD loads of 3.5–33.5 kg-COD m⁻³ per day. A treatment efficiency of 97% was obtained for 1.6 days of sludge age and COD loads of 22.2 kg-COD m⁻³ per day. The sludge flocks observed in the system were highly motile, dispersed and had poor settling properties. The membrane filtration characteristics of this sludge were investigated and increasing MLSS concentration decreased membrane flux values.     

Effect of wastewater composition on treatment performance of a column bioreactor with recycle

Effect of synthetic wastewater composition on COD removal performance of a continuous column bioreactor with recycle was studied. Zooglea ramigera was used as dominant microbial culture throughout the experiments. Synthetic wastewater was composed of diluted molasses, urea, KH₂PO₄ and MgSO₄. Wastewater composition was changed by adjusting influent COD/N/P ratio between 100/7/1-100/15/1. System was operated with nitrogen and COD limitations and COD removal performances were compared. Both nitrogen and COD removal efficiencies and rates were calculated and optimum feed COD/N ratio was determined to be between 100/8-100/10.This project was supported by the Scientific and Technical Research Council of Türkiye.     

High cell density ethanol fermentation in an upflow packed-bed cell recycle bioreactor

An upflow packed-bed cell recycle bioreactor (IUPCRB) is proposed for obtaining a high cell density. The system is comprised of a stirred tank bioreactor in which cells are retained partially by a packed-bed. A 1.3 cm (ID) × 48 cm long packed-bed was installed inside a 2 L bioreactor (working volume 1 L). Continuous ethanol fermentation was carried out using a 100 g/L glucose solution containing Saccharomyces cerevisiae (ATCC 24858). Cell retention characteristics were investigated by varying the void fraction (VF) of the packed bed by packing it with particles of 0.8∼2.0 mm sized stone, cut hollow fiber pieces, ceramic, and activated carbon particles. The best results were obtained using an activated carbon bed with a VF of 30∼35%. The IUPCRB yielded a maximum cell density of 87 g/L, an ethanol concentration of 42 g/L, and a productivity of 21 g/L/h when a 0.5 h⁻¹ dilution rate was used. A natural bleeding of cells from the filter bed occurred intermittently. This cell loss consisted of an average of 5% of the cell concentration in the bioreactor when a high cell concentration (approximately 80 g/L) was being maintained.     

Production of 2,3-butanediol in a membrane bioreactor with cell recycle

Summary The production of 2,3-butanediol by Enterobacter aerogenes DSM 30053 was studied in a cell recycle system with a microfiltration module. Emphasis was put on the influence of oxygen supply, cell residence time, dilution rate, and pH. Under optimal conditions a productivity as high as 14.6 g butanediol + acetoin/l per hour was achieved with a product concentration of 54 g/l and a product yield of 88%. This productivity is three times higher than that of an ordinary continuous culture. The achievable final product concentration of a cell recycle system was limited by the accumulation of the inhibiting by-product acetic acid, which increased very rapidly at low dilution rate. To maximize product concentration a fed-batch fermentation was carried out with stepwise pH adaption at high cell density. A final product concentration of 110 g/l was obtained with a productivity of 5.4 g/l per hour and a yield of 97%.     

Modeling of local dynamic behavior of phenol degradation in an internal loop airlift bioreactor by yeast Candida tropicalis

A coupled computational fluid dynamic (CFD) model, combining hydrodynamics with biochemical reactions, was developed to simulate the local transient flow patterns and the dynamic behaviors of cell growth and phenol biodegradation by yeast Candida tropicalis in an internal loop airlift reactor (ILALR). To validate this proposed model effectively, the simulated local hydrodynamic characteristics of the gas-mineral salt medium solution (gas-liquid) two-phase system, at a phenol concentration of 1,200 mg L(-1) and no presence of cells, was experimentally investigated in the ILALR using laser Doppler anemometer (LDA) measurements and conductivity probe. Furthermore, the validation of the simulated phenol biodegradation behavior by C. tropicalis at different initial concentrations of phenol and cell was also carried out in the ILALR. The time-averaged and transient results of the model simulations illustrated a satisfactory agreement with the experimental data. Finally, the local instantaneous flow and phenol biodegradation features, including gas holdup, gas velocity, liquid velocity, cell concentration, and phenol concentration inside the ILALR were successfully predicted by the proposed model.     

Application of a membrane recycle bioreactor for continuous ethanol production

Summary A series of continuous fermentations were carried out with a production strain of the yeast Saccharomyces cerevisiae in a membrane bioreactor. A membrane separation module composed of ultrafiltration tubular membranes retained all biomass in a fermentation zone of the bioreactor and allowed continuous removal of fermentation products into a cell-free permeate. In a system with total (100%) cell recycle the impact of fermentation conditions [dilution rate (0.03–0.3 h^–1); substrate concentration in the feed (50–300 g·1^–1); biomass concentration (depending on the experimental conditions)] was studied on the behaviour of the immobilized cell population and on ethanol formation. Maximum ethanol productivity (15 g·1^–1·h^–1) was attained at an ethanol concentration of 81 g·1^–1. The highest demands of cells for maintenance energy were found at the maximum feed substrate concentration (300 g·1^–1) and at very low concentrations of cells in the broth.     

Lactic acid from acid whey permeate in a membrane recycle bioreactor

Whey permeate was obtained by ultrafiltration of cottage cheese whey and supplemented with yeast extract. The lactose in the permeate was converted into lactic acid by Lactobacillus bulgaricus in a high-performance membrane bioreactor configured in the cell recycle mode. At a cell concentration of 10 g l⁻¹, optimum productivity of lactic acid was 35 g l⁻¹ h⁻¹. Increasing the cell concentration to 30 g l⁻¹ enabled the use of a dilution rate of 1 h⁻¹ with complete substrate utilization. At 60 g l⁻¹, productivity was over 80 g l⁻¹ h⁻¹ with complete substrte utilization; this is vastly superior to conventional batch fermentations.     

Analysis of a fermentation recycle loop for on-line measurements

Summary Recycle lines have been widely used in on-line analysis of fermentation processes. However, like most tools, many practical considerations can remain overlooked. Upon reflecting on this technique, some of these overlooked considerations have been studied. Because of the importance of a debubbler to a recycle line, an improved design was made and tested which can produce a bubble free high flow rate stream to reduce residence times. The effect of the recycle line on the culture growth, and DO was also investigated and found to be negligible.     

Mixing time in a down-flow jet loop bioreactor

Mixing time was determined in a down-flow jet loop bioreactor with Newtonian and non-Newtonian fluids. It was observed that the mixing time decreased with an increase in linear liquid velocity, superficial gas velocity, draft tube to column diameter ratio, nozzle diameter and shear thinning of media. The optimum draft tube to column diameter ratio was found to be about 0.44. Correlations were presented for prediction of mixing time.List of Symbols A m² cross sectional area of the column - C kmol/m³ local tracer concentration - A _D m² flow area,A _D =/4 (D _Z ² -D _TO ² ) - D m column diameter - D _E m draft tube diameter - D _TO m outside diameter of the air tube - D _TFL m equivalent flow diameter,D _TFL =(D _Z ² -D _TO ² )^0.5 - D _z m nozzle diameter - g m/s² gravitational acceleration - h % inhomogeneity - H m height of the column - H _B m distance between the lower edge of the draft tube and the impact plate - H _T m distance between the upper edge of the draft tube and the liquid nozzle - K Pa.sⁿ consistency index in power-law model - L _E m length of the draft tube - n flow index in the power-law model - Re _j jet Reynolds number,Re _j =(D _TFL×w₁×_L)/ _eff - t _M s mixing time - t _sg m/s superficial gas velocity based onA - W _l m/s linear liquid velocity based onD _D Greek Letters N/m² shear stress - s shear rate - kg/m³ density of liquid - N/m surface tension of the liquid - Pa.sⁿ viscosity of liquid Indices X concentration at infinite time maximum value of tracer concentration - eff effective - L Liquid - obs observed - pred Predicted     

Very high ethanol productivity in an innovative continuous two-stage bioreactor with cell recycle

The performance of an innovative two-stage continuous bioreactor with cell recycle—potentially capable of giving very high ethanol productivity—was investigated. The first stage was dedicated to cell growth, whereas the second stage was dedicated to ethanol production. A high cell density was obtained by an ultrafiltration module coupled to the outlet of the second reactor. A recycle loop from the second stage to the first one was tested to improve cell viability and activity. Cultivations of Saccharomyces cerevisiae in mineral medium on glucose were performed at 30°C and pH 4. At steady state, total biomass concentrations of 59 and 157 gDCW l⁻¹ and ethanol concentrations of 31 and 65 g l⁻¹ were obtained in the first and second stage, respectively. The residual glucose concentration was 73 g l⁻¹ in the first stage and close to zero in the second stage. The present study shows that a very high ethanol productivity (up to 41 g l⁻¹ h⁻¹) can indeed be obtained with complete conversion of the glucose and with a high ethanol titre (8.3°GL) in the two-stage system.     

Cybernetic model predictive control of a continuous bioreactor with cell recycle

The control of poly-beta-hydroxybutyrate (PHB) productivity in a continuous bioreactor with cell recycle is studied by simulation. A cybernetic model of PHB synthesis in Alcaligenes eutrophus is developed. Model parameters are identified using experimental data, and simulation results are presented. The model is interfaced to a multirate model predictive control (MPC) algorithm. PHB productivity and concentration are controlled by manipulating dilution rate and recycle ratio. Unmeasured time varying disturbances are imposed to study regulatory control performance, including unreachable setpoints. With proper controller tuning, the nonlinear MPC algorithm can track productivity and concentration setpoints despite a change in the sign of PHB productivity gain with respect to dilution rate. It is shown that the nonlinear MPC algorithm is able to track the maximum achievable productivity for unreachable setpoints under significant process/model mismatch. The impact of model uncertainty upon controller performance is explored. The multirate MPC algorithm is tested using three controllers employing models that vary in complexity of regulation. It is shown that controller performance deteriorates as a function of decreasing biological complexity.     

Ethanol from hydrolyzed whey permeate using Saccharomyces cerevisiae in a membrane recycle bioreactor

A diauxic fermentation was observed during batch fermentation of enzyme-hydrolyzed whey permeate to ethanol by Saccharomyces cerevisiae. Glucose was consumed before and much faster than galactose. In the continuous membrane recycle bioreactor (MRB), sugar utilization was a function of dilution rate and concentration of sugars. At a cell concentration of 160 kg/m³, optimum productivity was 31 kg/(m³ · h) at ethanol concentration of 65 kg/m³. Low levels of acetate (0.05–0.1 M) reduced cell growth during continuous fermentation, but also reduced galactose utilization.     

Simulated scale-up of a yeast fermentation using a loop bioreactor

A tubular loop reactor was used to carry out the simulated scale-up of aSaccharomyces cerevisiae fermentation. Performance of the microorganism was assessed in terms of biomass, ethanol concentration respiratory quotient and yield. The behaviour of the culture was shown to be similar in loop reactor (t_c, 10s) and STR.     

Utilization of an external loop bioreactor for the isolation of a flocculating strain ofKluyveromyces marxianus

A continuous open loop bioreactor was used to induce flocculation in an originally nonflocculent strain ofKluyveromyces marxianus. The sedimentation capacity of the isolated strain was of such a magnitude that the cell concentration inside the fermentor was 50 times larger than in the effluent. Also, a batch system was used with the same objective, but no flocculation was obtained.The kinetic parameters of the flocculent strain were compared with those of the mother strain. It was shown that both maximum specific growth rate and maximum specific ethanol production rate were lower in the flocculent strain. Ethanol had a larger inhibitory effect on the kinetic parameters of the isolated strain. Also, the batch fermentations with this strain presented a larger final biomass concentration and a reduced ethanol yield.     

Operational patterns affecting lactic acid production in ultrafiltration cell recycle bioreactor

Lactic acid production with cell recycling on an ultrafiltration tubular membrane reactor was studied; higher lactic acid concentrations as well as productivities were obtained under long-term fermentations compared with other high cell density systems. Different operational conditions, namely dilution rates and start-up modes, were assessed. Performances were very different at the three different dilution rates tested (D = 0.20 h(-1), D = 0.40 h(-1), or D = 0.58 h(-1)). The different behaviours are discussed and factors responsible for them are presented. The best way to operate for lactic acid production is chosen, the dilution rate of D = 0.40 h(-1) being the one providing the best overall performance. On the other hand, results show that of the two start-up modes tested, continuous start (membrane open) permits higher permeabilities throughout the operational runs than batch start (membrane closed). Operational stability was found to be directly associated with membranes that work at "steady state," the membrane permeability being kept around 15 L/m(2) h. Optimized cell bleed can improve time of operation if such membrane permeability can be maintained for a longer time. A comparison of results with those obtained in other lactic acid production systems is presented; such comparison shows that this tubular ultrafiltration membrane cell recycle reactor presents three important advantages: (1) concomitant lactic acid concentrations and productivities; (2) long periods of operation at reasonable permeabilities; and (3) good mechanical stability permitting the use of steam sterilization. (c) 1995 John Wiley & Sons, Inc.     

Flow regimes in a two phase reversed flow jet loop bioreactor

Reversed flow jet loop bioreactors (RFJLB) have been used extensively for 2 or 3 phase biochemical reactions. From visual observations and gas holdup data, 3 distinct flow regimes are identified in RFJLB, namely: (1) Bubble free regime (BFR), where bubbles are observed in the draft tube only; (2) Transition regime (TR), where bubbles are observed in both the draft tube and the annulus, but without circulation; and (3) Complete bubble circulation regime (CBCR), where bubbles circulate in both the draft tube and annulus. CBCR is the most desirable regime, since the reactor operation in this regime gives a higher gas holdup and mass transfer rate than in the other two regimes. In the present study, the hydrodynamic behavior of RFJLB was investigated under various operational and geometrical conditions, such as gas and liquid velocity and nozzle configuration. Factors affecting the critical liquid circulation velocity (CLCV) above which the CBCR is established were identified and evaluated quantitatively.     

Hydrodynamic performance of a three-phase airlift bioreactor with an enlarged degassing zone

The hydrodynamics of biotechnological processes is complex. So far, few studies were made with bioreactors of the airlift type with an enlarged degassing zone.In this work, the influence of solids loading, solids specific gravity and draught tube dimensions on mixing and circulation times and critical air flow rate for an internal loop airlift bioreactor with an enlarged sedimentation/degassing zone is studied.The results indicate that the critical air flow rate as well as the mixing time increase with an increase in solids loading in the bioreactor. Circulation time presents a maximum for a solids load between 5 and 10% (v/v). It is also shown that small variations in solids specific gravity, for values close to that of the liquid, have a significant influence on the critical air flow rate and on the mixing time.An optimal (minimal) value for the circulation time and for the critical air flow rate was obtained for a riser to down comer diameter ratio of 0.46. The minimum mixing time was obtained for a riser to down comer height ratio of 0.80.This work was supported by J.N.I.C.T. (Junta Nacional de Investigação Cientifica e Tecnológica).     

Biodegradation of paint stripper solvents in a modified gas lift loop bioreactor

Paint stripping wastes generated during the decontamination and decommissioning of former nuclear facilities contain paint stripping organics (dichloromethane, 2-propanol, and methanol) and bulk materials containing paint pigments. It is desirable to degrade the organic residues as part of an integrated chemical-biological treatment system. We have developed a modified gas lift loop bioreactor employing a defined consortium of Rhodococcus rhodochrous strain OFS and Hyphomicrobium sp. DM-2 that degrades paint stripper organics. Mass transfer coefficients and kinetic constants for biodegradation in the system were determined. It was found that transfer of organic substrates from surrogate waste into the air and further into the liquid medium in the bioreactor were rapid processes, occurring within minutes. Monod kinetics was employed to model the biodegradation of paint stripping organics. Analysis of the bioreactor process was accomplished with BIOLAB, a mathematical code that simulates coupled mass transfer and biodegradation processes. This code was used to fit experimental data to Monod kinetics and to determine kinetic parameters. The BIOLAB code was also employed to compare activities in the bioreactor of individual microbial cultures to the activities of combined cultures in the bioreactor. This code is of benefit for further optimization and scale-up of the bioreactor for treatment of paint stripping and other volatile organic wastes in bulk materials. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 55: 163-169, 1997.     

N-removal performance and underlying bacterial taxa of upflow filter bioreactor system under different dissolved oxygen and internal recycle conditions

Biological N-removal treatment of piggery wastewater in the upflow anaerobic–anoxic–aerobic floating filter (UA³FF) bioreactor based on the concept of nitritation–denitritation was studied along with the changes in internal recycle ratio and dissolved oxygen concentration (DO). Consecutive changes in the recirculation ratio between the anoxic and aerobic reactors has resulted in abundance and composition shifts of N-cycling bacteria as well as other bacterial groups, reflecting different survival strategies across (bio/physico)chemical milieu. The DO concentration was optimized to achieve nitritation in the aerobic reactor and denitritation in the anoxic reactor. Optimal nitritation–denitritation (270 and 130 g NO₂ ⁻–N produced or reduced/m³ filter media/day) was obtained at DO of 1.0–1.5 mg/l, inter-reactor recirculation ratio of 1:1–2:1, HRT of 24 h, pH of 7.6 ± 0.3, and temperature of 28 ± 4 °C. Since only well known nitrifying and denitrifying taxa were found, nitritation–denitritation was likely carried out by these bacteria rather than the yet unidentified novel taxa. Archaeal nitrifiers recently discovered to be important in the global N-cycle were not detected.     

Stirred tank bioreactor with a recirculation loop for improved L-lysine production

Summary A bioreactor equipped with a recirculation loop was used to investigate the fermentation for L-lysine production. The broth was pumped from the bottom of the fermenter and fed back to the top. With the recirculation stream, antifoam was not required as the fermentation proceeded and the proposed system significantly improved the productivity for L-lysine fermentation.