Granulation of activated sludge in a continuous flow airlift reactor by strong drag force

Most aerobic granule cultivation has been based on the sequencing batch reactor (SBR) and then the factors that affect aerobic granulations were developed in the SBR. However, little work has been done to cultivate aerobic granules in a continuous-flow bioreactor with simple structure that is realistic for engineering. This work is the first to cultivate aerobic granules in a continuous flow airlift fluidized bed reactor (CAFB) possesses a very simple structure and without settling time and starvation time controlling. The configuration of CAFB was the simplest continuous-flow aerobic granular bioreactor reported by now. The majority of granules could be formatted in the CAFB after 12 days cultivation. The effluent COD concentration maintained at 50 ± 10 mg/L for the variable COD loading rate of 3.5 g COD/L/d and 4.8 g COD/L/d, which confirmed that the CAFB performed good anti-shock abilities. CAFB performed good nitrification ability, however, little denitrification was found under the operating conditions of this study. The shear stress acting on the solid phase were hundreds of times stronger in the CAFB than in the SBR at the same aeration strength. It seems CAFB is very efficient for granulation due to the strong shear-force exertion, which is promising for continuous-flow aerobic granular bioreactor. Protein, positive to the hydrophobicity, was predominant in extracellular polymeric substances in the granules, and favored the granules formation in the CAFB combined with the polysaccharides. However, filamentous bulking always happened in 35 days operation of the CAFB, thus further study on the stability of this bioreactor is urgently necessary.     

Characterization of the two-phase systems in airlift tower-loop bioreactors during the cultivation of E. coli

During the cultivation of E. coli in an airlift tower-loop bioreactor, the following properties were measured: transverse profiles of Sauter bubble diameter, d(S); local relative gas holdup, E(G); bubble rise velocity, u(BS); local mean velocity, ū turbulence intensity, u'; macrotime scale, T(EL); dissipation time scale, tau(E); power spectrum, E(n); and energy dissipation spectrum D(n) at different distances from the aerator. The influence, distance from the aerator, absence and/or presnece of cells, and batch and/or continuous-culture operation on the behavior of the two-phase system are discussed on the basis of these properties.     

N-removal in a granular sludge sequencing batch airlift reactor

The removal of N-compounds in the sequencing batch airlift reactor (SBAR) containing granular sludge was studied under conditions of decreased dissolved oxygen (DO). A simulation model was developed to describe and evaluate the effects of several process conditions in the SBAR on N-removal performance. The model described the experimental data reasonable well. It has been shown that nitrification, denitrification, and removal of chemical oxygen demand (COD) can occur simultaneously in a granular sludge SBR. It has also been shown that the exact location of the autotrophic biomass influences the net N-removal. The distribution of the autotrophic biomass is influenced by the DO in the reactor. The optimal DO value is expected to be around 40% air saturation. It was shown that storage and subsequent degradation of poly-beta-hydroxybutyrate (PHB) benefit the denitrification. In particular, PHB is stored in bacteria situated in deeper layers of the granules below where the autotrophic activity occurs, serves as a C-source for denitrification.     

Liquid-phase dispersion in an airlift reactor with a net draft tube

Liquid-phase dispersion in an airlift reactor with a net draft tube was considered. Four net tubes with different ratios of draft tube to reactor diameters and superficial air velocities ranged from zero to 6.05 cm/s were investigated. The sparger was a porous plate. The parameter of the dispersion effect, axial dispersion coefficient, was characterized by measuring the residence time distribution in the liquid phase with single-pulse tracer input. The values of the dispersion coefficient of the proposed airlift reactor were much higher than those of the bubble column under the same operating conditions.     

Enhanced continuous production of lovastatin using pellets and siran supported growth of Aspergillus terreus in an airlift reactor

Lovastatin, a hypocholesterolemic agent, is a secondary metabolite produced by filamentous microorganism Aspergillus terreus in submerged batch cultivation. Lovastatin production by pellets and immobilized siran cells was investigated in an airlift reactor. The process was carried out by submerged cultivation in continuous mode with the objective of increasing productivity using pellet and siran supported growth of A terreus. The continuous mode of fermentation improves the rate of lovastatin production. The effect of dilution rate and aeration rate were studied in continuous culture. The optimum dilution rate for pellet was 0.02 h⁻¹ and for siran carrier was 0.025 h⁻¹. Lovastatin productivity using immobilized siran carrier (0.0255 g/L/h) was found to be greater than pellets (0.022 g/L/h). The productivity by both modes of fermentation was found higher than that of batch process which suggests that continuous cultivation is a promising strategy for lovastatin production.     

A novel split-cylinder airlift reactor for fed-batch cultures

Conventional airlift reactors are not adequate to carry out variable volume processes since it is not possible to achieve a proper liquid circulation in these reactors until the liquid height is higher than that of the downcomer. To carry out processes of variable volume, the use of a split-cylinder airlift reactor is proposed, in the interior of which two multi-perforated vertical baffles are installed in order to provide several points of communication between the reactor riser and downcomer. This improves the liquid circulation and mixing at any liquid volume. In fed-batch cultures, it is important to know how liquid height affects the hydrodynamic characteristics and the volumetric oxygen transfer coefficient since this impacts on the kinetic behavior of any fermentation. Thus, in the present work, the effect of the liquid height on the mixing time, the overall gas hold-up, and the volumetric oxygen transfer coefficient of the proposed airlift reactor were determined. The mixing time was increased and the volumetric oxygen transfer coefficient decreased due to the increase of the liquid height in the reactor in all the superficial gas velocities tested, which corresponded to a pseudohomogeneous flow regime. The experimental values of the mixing time and the mass-transfer coefficient were properly described through correlations in which the U_GR/H_L ratio was used as the independent variable. Thus, this variable might be used to describe the hydrodynamic behavior and the oxygen transfer coefficient of airlift reactors when such reactors are used in processes where the liquid volume changes with time. However, these correlations are useful for the particular device and for the particular operating conditions at which they were obtained. These empirical correlations are useful to understand some factors that influence the mixing time and volumetric oxygen transfer coefficient, but such correlations do not have a sufficient predictive potential for a satisfactory reactor design. The overall gas hold-up values were not significantly affected when the liquid height was lower than the downcomer height. However, the values decreased abruptly when the reactor was operated with liquid heights over the downcomer height, especially at high superficial gas velocities.     

Degradation of quinoline by immobilized Comamonas acidovorans in a three-phase airlift reactor

Quinolie degradation by Comamonas acidovorans was studied in a continuously operated three-phase airlift reactor. Porous glass beads were applied as support matrix for cell imobilization by colonization. Under steady-state conditions (S approximately 0), cell attachment was poor at low dilution rates but imporved considerably with increasing dilution rate. Conversion of quinoline was investigated below and above the washout for suspended culture (D(crit) = mu(max) = 0.42 h(-1)). With immobilized cells the reactor could be operated at D > mu(max), and complete conversion of quinoline was achieved as long as the specific quinoline feed rate D*S(0)/X did not exceed the maximum specific degradation rate (r(S, max)). The biofilm thickness was about 100 mum, and its efficiency was about 54% compared to suspended organisms. If quinoline overloads were supplied to the reactor, quinoline, as overloads were supplied to the reactor, quinoline, as well as its pathway intermediates, appeared in the reactor and conversion was low. Hence, the immobilized microorganisms remained viable and active. They could survive quinoline overloads. If the quinoline feed rate was reduced agains, complete conversion was reestablished. (c) 1995 John Wiley & Sons, Inc.     

A novel rectangular airlift reactor with mesh baffle-plates

An experimental rectangular airlift reactor having mesh baffle-plates has been fabricated out of Perspex and compared with conventional airlift and bubble column in terms of gas holdup, volumetric mass transfer coefficient and mixing time. Mesh baffle-plates improved mass transfer and mixing with the mass transfer coefficient of the proposed reactor being up to 12% higher than that in a conventional airlift reactor under the same operating condition. The mixing time of the proposed reactor can be 95% lower than that of the airlift reactor.     

Process development of continuous hydrogen production by Enterobacter aerogenes in a packed column reactor

Hydrogen bioproduction from agro-industrial residues by Enterobacter aerogenes in a continuous packed column has been investigated and a complete reactor characterization is presented. Experimental runs carried out at different residence time, liable of interest for industrial application, showed hydrogen yields ranging from 1.36 to 3.02 mmol_H2mmol^у_glucose or, in other words, from 37.5% to 75% of the theoretical hydrogen yield. A simple kinetic model of cell growth, validated by experimental results and allowing the prediction of biomass concentration profile along the reactor and the optimization of superficial velocity, is suggested. By applying the developed approach to the selected operative conditions, the identification of the optimum superficial velocity v_0,opt of about 2.2 cm h^у corresponding to the maximum hydrogen evolution rate H£_2g,max, was performed.     

Fungal bioremediation of phenolic wastewaters in an airlift reactor

Of the various types of industry-generated effluents, those containing organic pollutants such as phenols are generally difficult to remediate. There is a need to develop new technologies that emphasize the destruction of these pollutants rather than their disposal. In this work the white rot fungus, Trametes pubescens, was demonstrated to be an effective bioremediation agent for the treatment of phenolic wastewaters. An airlift loop reactor was optimized, in terms of volumetric oxygen transfer rate (K(L)a = 0.45 s(-1)), to provide an environment suited to rapid growth of T.pubescens (mu = 0.25 day(-1)) and a particularly efficient growth yield on glucose of 0.87 g biomass.g glucose(-1). The phenolic effluent was shown to be a paramorphogen, influencing fungal pellet morphology in the reactor, as well as increasing laccase enzyme activity by a factor of 5 over the control, to a maximum of 11.8 U.mL(-1). This increased activity was aided by the feeding of nonrepressing amounts (0.5 g.L(-1)) of glucose to the reactor culture. To our knowledge the degradation results represent the highest rate of removal (0.033 g phenol.g biomass(-1).day(-1)) of phenolic compounds from water reported for white rot fungi.     

Hydrodynamic characteristics and gas-liquid mass transfer in a biofilm airlift suspension reactor

The hydrodynamics and mass transfer, specifically the effects of gas velocity and the presence and type of solids on the gas hold-up and volumetric mass transfer coefficient, were studied on a lab-scale airlift reactor with internal draft tube. Basalt particles and biofilm-coated particles were used as solid phase. Three distinct flow regimes were observed with increasing gas flow rate. The influence of the solid phase on the hydrodynamics was a peculiar characteristic of the regimes. The volumetric mass transfer coefficient was found to decrease with increasing solid loading and particle size. This could be predominantly related to the influence that the solid has on gas hold-up. The ratio between gas hold-up and volumetric mass transfer coefficient was found to be independent of solid loading, size, or density, and it was proven that the presence of solids in airlift reactors lowers the number of gas bubbles without changing their size. To evaluate scale effects, experimental results were compared with theoretical and empirical models proposed for similar systems.     

Mass transfer in an airlift reactor with a net draft tube.

Gas-liquid mass transfer in an airlift reactor with net draft tube is investigated. The effects of both the ratio of draft tube to reactor diameter and the reactor pressure on oxygen transfer are considered. The value of the volumetric mass transfer coefficient, kLa, increases with a decreasing diameter ratio at higher air flow rates. The correlation of volumetric mass transfer coefficient with respect to the true superficial air velocity under different reactor pressures is determined. The kLa value decreases with increasing reactor pressure.     

Dynamic modeling and simulation of continuous airlift bioreactors

For dynamic behaviors of continuous airlift bioreactors, a mathematical model based on a tanks-in-series model with backflow has been developed. The equations describing the dynamics of airlift bioreactors are material balances for micro-organism, substrate, dissolved oxygen and oxygen in gas-phase and heat balances. Non-ideal mixing of liquid and gas phases is taken into account using a tanks-in-series model with backflow. The batch operation, startup operation and the consequence of plant failure were simulated and the effects of design and operating parameters for an airlift bioreactor on its dynamic behaviors were discussed. The concentration profiles of micro-organism, substrate, dissolved oxygen and oxygen in gas-phase and the temperature profile in an airlift bioreactors and their dynamics were obtained. The computational results indicate that the transients of a chemostat in the case of bubble column bioreactor are slower compared with those in the case of airlift bioreactor. The proposed simulator is more precise as compared with models published previously in the literature and therefore provides more reliable and rational examination of continuous airlift bioreactor performance.     

Production of thuringiensin from Bacillus thuringiensis using a net-draft-tube,modified airlift reactor

A net-draft-tube, modified airlift reactor and a stirred-tank reactor were used for thuringiensin production by Bacillus thuringiensis subsp. darmstadiensis growing with various concentrations of molasses. The optimum concentration of molasses for thuringiensin production in both reactors was 15 g/l. There was a 6 h delay in sporulation in the modified airlift reactor compared with that in the stirred-tank reactor. Thuringiensin yield in the modified airlift reactor (2.2 g/l) was consequently higher than that in the stirred-tank reactor (1.1 g/l).     

Region-dependent oxygen transfer rate in the rectangular airlift reactor

Gas hold-up and the oxygen transfer in the zones of the internal loop airlift reactor with rectangular cross-section was studied. It was found, that the downcomer to the riser gas hold-up ratio depends on the gas flow rate, the physicochemical properties of the system and on the reactor height. The ratio of the downcomer mass transfer coefficient to the global mass transfer coefficient was less than 6%. The ratio of the downcomer to the global mass transfer coefficient slightly increased with increase of the gas flow rate and decreased with increase of the liquid viscosity. The proposed correlation for the global overall mass transfer coefficient predicts the experimental data well within 16.6% deviation. It was confirmed that the reactor height is the important parameter for a design and a scale-up of the airlift reactors.     

Hydrodynamic study of an internal airlift reactor for microalgae culture

Internal airlift reactors are closed systems considered today for microalgae cultivation. Several works have studied their hydrodynamics but based on important solid concentrations, not with biomass concentrations usually found in microalgae cultures. In this study, an internal airlift reactor has been built and tested in order to clarify the hydrodynamics of this system, based on microalgae typical concentrations. A model is proposed taking into account the variation of air bubble velocity according to volumetric air flow rate injected into the system. A relationship between riser and downcomer gas holdups is established, which varied slightly with solids concentrations. The repartition of solids along the reactor resulted to be homogenous for the range of concentrations and volumetric air flow rate studied here. Liquid velocities increase with volumetric air flow rate, and they vary slightly when solids are added to the system. Finally, liquid circulation time found in each section of the reactor is in concordance with those employed in microalgae culture.     

Bacterial cellulose production by Acetobacter xylinum in a 50-L internal-loop airlift reactor

Bacterial cellulose (BC) production was realized in a batch cultivation of Acetobacter xylinum subsp. sucrofermentans BPR2001 in a 50-L internal-loop airlift reactor. When the bacterium was cultivated with air supply, 3.8 g/L of BC was produced after 67 hours. When oxygen-enriched gas was supplied, the concentration of BC was doubled and the production rate of BC was 0.116 g/L. h, which was two times higher than that of air-supplied culture and comparable to that in a mechanically agitated stirred-tank fermentor. Bacterial cellulose produced by the airlift reactor formed a unique ellipse pellet (BC pellet), different from the fibrous form which was produced in an agitated stirred-tank fermentor. The BC-pellet suspension was demonstrated to have a higher volumetric oxygen transfer coefficient than the fibrous BC suspension in a 50-L internal-loop airlift reactor. The mixing time of BC-pellet suspension in the airlift reactor was also shorter than that in water.     

Gluconic acid production from sucrose in an airlift reactor using a multi-enzyme system

Sucrose from sugarcane is produced in abundance in Brazil, which provides an opportunity to manufacture other high-value products. Gluconic acid (GA) can be produced by multi-enzyme conversion of sucrose using the enzymes invertase, glucose oxidase, and catalase. In this process, one of the byproducts is fructose, which has many commercial applications. This work concerns the batch mode production of GA in an airlift reactor fed with sucrose as substrate. Evaluation was made of the influence of temperature and pH, as well as the thermal stability of the enzymes. Operational conditions of 40 °C and pH 6.0 were selected, based on the enzymatic activity profiles and the thermal stabilities. Under these conditions, the experimental data could be accurately described by kinetic models. The maximum yield of GA was achieved within 3.8 h, with total conversion of sucrose and glucose and a volumetric productivity of around 7.0 g L^?1 h^?1.     

Process engineering and optimization of glycerol separation in a packed-bed reactor for enzymatic biodiesel production

A process model for efficient glycerol separation during methanolysis in an enzymatic packed-bed reactor (PBR) was developed. A theoretical glycerol removal efficiency from the reaction mixture containing over 30% methyl esters was achieved at a high flow rate of 540 ml/h. To facilitate a stable operation of the PBR system, a batch reaction prior to continuous methanolysis was conducted using oils with different acid values and immobilized lipases pretreated with methyl esters. The reaction system successfully attained the methyl ester content of over 30% along with reduced viscosity and water content. Furthermore, to obtain a high methyl ester content above 96% continuously, long-term lipase stability was confirmed by operating a bench-scale PBR system for 550 h, in which the intermediates containing methyl esters and residual glycerides were fed into the enzyme-packed columns connected in series. Therefore, the developed process model is considered useful for industrial biodiesel production.