Physiological state of a microbial community in a biomass recycle reactor

The transition in physiological state was investigated between a carbon-limited chemostat population and microbes growing very slowly in a biomass recycle reactor. The mixed microbial population was metabolizing a mixture of biopolymers and linear alkylbenzene sulfonate, formulated to represent the organic load in graywater. Biomass increased 30-fold during the first 14 days after a shift from chemostat to biomass recycle mode. The ratios of ATP and RNA to cell protein decreased over the first days but then remained constant. The specific rate of CO₂ production by microbes in the reactor decreased 6-fold within 24 h after the shift, and respiratory potentials declined 2–3 fold during the first 7 days. Whereas chemostat cultures used equal proportions of organic carbon substrate for catabolism and anabolism, the proportion of organic substrate oxidized to CO₂ rose from 62 to 82% over the first 8 days in a biomass recycle reactor, and eventually reached 100% as this reactor population exhibited no net growth. Biomass recycle populations removed from the system and subjected to a nutritional shift-up did not immediately initiate exponential growth. The physiological state of cells in the biomass recycle reactor may be distinct from those grown in batch or continuous culture, or from starved cells. Received 02 June 1997/ Accepted in revised form 20 February 1998     

Biodegradation of organic wastes containing surfactants in a biomass recycle reactor.

The microbial biodegradation of simulated graywater, containing 21.5 mg of linear alkylbenzene sulfonate liter-1, was investigated with a continuous-flow bioreactor with 100% biomass recycle. Low concentrations of organic matter in the ultrafiltration eluate were achieved by hydraulic residence times as short as 1.6 h and for periods of up to 74 days at a hydraulic residence time of 6 h. Upon a shift from the chemostat to the biomass recycle mode, the increase in biomass with time approximated a linear rather than an exponential function. Biomass densities as high as 6.8 g of cell protein liter-1 were reached; this was 50-fold higher than the steady-state biomass level in chemostats fed the same medium. We assessed physiological changes in the microbial community after a switch from the chemostat to the biomass recycle mode. Over 150 h, there was a two- to fourfold decrease in the respiratory potential of the microbes. After this decrease, respiratory potentials were relatively constant up to 74 days of operation. A decline in reactivity was also indicated by increasing lag periods before growth in response to organic nutrient inputs and by a decrease in the proportion of cells able to reduce tetrazolium dye. However, the bioreactor system was still capable of rapidly metabolizing inputs of organic matter, because of the very high biomass concentrations. It appears that < 10% of the organic carbon inputs accumulate as biomass.     

Effect of starvation length upon microbial activity in a biomass recycle reactor

The kinetics of substrate degradation and bacterial growth was determined in a microbial community from a biomass recycle reactor that had been deprived of substrate feed for 0–32 days. Starvation caused changes in bacterial numbers, community composition, and physiological state. Substrate starvation for less than 1 day resulted in modest (less than threefold) changes in endogenous respiration rate, ATP content, and biomass level. During a starvation period of 32 days, there were substantial changes in microbial community composition, as assessed by denaturing gradient gel electrophoresis (DGGE) fingerprinting of PCR amplicons of a portion of the 16S rDNA or by phospholipid fatty acid (PLFA) analysis. When the starved communities were stimulated with organic nutrients, the growth kinetics was a function of the length of the starvation period. For starvation periods of 2–8 days prior to nutrient addition, there was a phase of suboptimal exponential growth (S-phase) in which the exponential growth rate was about 30% of the ultimate unrestricted growth rate. S-phase lasted for 2–8 h and then unrestricted growth occurred at rates of 0.3–0.4 h⁻¹. At starvation times of 12 and 20 days, a lag phase preceded S-phase and the unrestricted growth phase. Received 04 January 2002/ Accepted in revised form 08 August 2002     

Lactic acid fermentation in a recycle batch reactor using immobilized Lactobacillus casei

Lactic acid production by recycle batch fermentation using immobilized cells of Lactobacillus casei subsp. rhamnosus was studied. The culture medium was composed of whey treated with an endoprotease, and supplemented with 2.5 g/L of yeast extract and 0.18 mM Mn(2+) ions. The fermentation set-up comprised of a column packed with polyethyleneimine-coated foam glass particles, Pora-bact A, and connected with recirculation to a stirred tank reactor vessel for pH control. The immobilization of L. casei was performed simply by circulating the culture medium inoculated with the organism over the beads. At this stage, a long lag period preceded the cell growth and lactic acid production. Subsequently, for recycle batch fermentations using the immobilized cells, the reducing sugar concentration of the medium was increased to 100 g/L by addition of glucose. The lactic acid production started immediately after onset of fermentation and the average reactor productivity during repeated cycles was about 4.3 to 4.6 g/L . h, with complete substrate utilization and more than 90% product yield. Sugar consumption and lactate yield were maintained at the same level with increase in medium volume up to at least 10 times that of the immobilized biocatalyst. The liberation of significant amounts of cells into the medium limited the number of fermentation cycles possible in a recycle batch mode. Use of lower yeast extract concentration reduced the amount of suspended biomass without significant change in productivity, thereby also increasing the number of fermentation cycles, and even maintained the D-lactate amount at low levels. The product was recovered from the clarified and decolorized broth by ion-exchange adsorption. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 55:841-853, 1997.     

Distillery waste recycle through membrane filtration in batch alcohol fermentation

A ceramic ultrafiltration membrane was used to recycle distillery wastes in a batch ethanol fermentation process. By reusing the membrane permeate in the saccharification step, almost the same ethanol yield was obtained up to eight recycles and a slight increase in the fermentation by-products was observed. As the number of recycles increased, organic compounds and salts accumulated up to the third recycle but leveled off afterward.     

Systematic simulation of a tubular recycle reactor on the basis of pilot plant experiments

Systematic simulation may decisively help in development and optimization of bioprocesses. By applying simulation techniques, optimal use can be made of experimental data, decreasing development costs and increasing the accuracy in predicting the behavior of an industrial scale plant.The procedure of the dialogue between simulation and experimental efforts will be exemplified in a case study. Alcoholic fermentation of glucose by zymomonas mobilis bacteria in a gasified tubular recycle reactor was studied first by systematic simulation, using a computer model based solely on literature data. On the base of the results of this simulation, a 0.013 m³ pilot plant reactor was constructed. The pilot plant experiments, too, were based on the results of the systematic simulation.Simulated and experimental data were well in agreement. The pilot plant experiments reiterated the trends and limits of the process as shown by the simulation results. Data from the pilot plant runs were then used to improve the simulation model. This improved model was subsequently used to simulate the performances of an industrial scale plant. The results of this simulation are presented. They show that the alcohol fermentation in a tubular recycle reactor is potentially advantageous to other reactor configurations, especially to continuous stirred tanks.List of Symbols CPFR Continous plug flow reactor - CST R Continous stirred tank reactor - CTR Continous tubular reactor - FMC Fermentation micro computer - P kg/m³ Product concentration - S kg/m³ Glucose concentration - S _o kg/m³ Glucose concentration in the feed - X kg/m³ Biomass concentration - z Cell damage     

Broth recycle in a yeast fermentation

Fermentation is a water-intensive process requiring treatment of large amounts of effluent broth. It is desirable to increase the ratio of product produced to the volume of effluent by minimizing the discharge of effluent from the fermentation process. A study of recycling spent fermentation process. A study of recycling spent fermentation broth for the subsequent fermentation was carried out with Apiotrichum curvatum an oleaginous yeast, as the working culture. Spent broth from a defined medium was recycled t replace as much as 75% of the water and salts for subsequent batches and this was repeated for seven sequential batches without affecting cell mass and lipid production. A 64% vlume reduction of wastewater was achieved in this manner. However, when using whey permeate as the medium, lipid production dropped after three consecutive recycle operations at 50% recycle, and after two consecutive recycle operations at 75% and 100% recycle. Accumulation of ions in the broth appeared to be responsible for the inhibition. An ion exchange step was able to eliminate the ion buildup and restore fermentation performance. (c) 1994 John Wiley & Sons, Inc.     

Kinetics of yeast alcohol dehydrogenase and its coenzyme coimmobilized in a tubular flow reactor

Yeast alcohol dehydrogenase and nicotinamide adenine dinucleotide (NAD) were coimmobilized, with covalent attachment, to the interior surface of a nylon tube. The NAD was attahed at the N(6) group of the adenine moiety; an NAD derivative was prepared and attached to free carboxyl groups at a partially hydrolyzed nylon surface. The enzyme was attached, through glutaraldehyde residues, to free amino groups on the surface. Kinetic studies were carried out in which the reduced NAD was recycled by means of phenazine ethosulfate and 2,6-dichlorophenol indophenol. The reaction was studied over a range of flow rates and ethanol concentrations. The variation of rate with flow rate suggested that there was little diffusion control with respect to ethanol and that there was no observable inhibition by the reaction products. These conclusions were confirmed by evidence based on dimensionless parameters for the reaction and by direct inhibition experiments. The apparent Michaelis constant was lower than when only the enzyme was immobilized, suggesting that the immobilized enzyme-coenzyme system is of high efficiency. Overall rates of reaction were lower than when there was saturation with NAD. The tube showed no measurable loss of catalytic activity over a period of one month.     

Continuous alcohol fermentation in an immobilized cell rotating disk reactor

The increasing interest in alcohol fermentation over these last years because of the energy crisis has been demonstrated by an increase in scientific research. After a brief analysis of the main results of the literature in the field of alcohol fermentation reactors, the use of a new type of immobilized cell reactor [the rotating biological surface (RBS) reactor] was studied. As is well known, the RBS reactor is a form of fixed-film reactor and can be described as a dynamic trickling filter. Our experimental apparatus employed a spongy material to trap the yeast cells on the disks. The results of fermentations carried out in the RBS reactor working in batch, in continuous with cell support, and in continuous without cell support have been presented in order to compare the different productivities and to assess the performance of the RBS immobilized cell reactor. An ethanol productivity of 7.1 g/L h was achieved in the RBS-ICR at a dilution rate of 0.3 h(-1), 2.5 times higher than the maximum productivity obtained in the RBS reactor without support at a lower dilution rate. The adoption of a spongy material as a cell immobilizer, combined with the use of the RBS reactor, enhances the particular advantages of both systems.     

Water recycle in biomass production processes

Various aspects of process water recycle in a continuous flow fermentation process are analyzed. Simple mass balance equations in terms of product and feed components for a single-stage reactor producing biomass are developed. Constraints on the recycle ratio, imposed by the efficiency of the dewatering stage, are examined. The recycle analysis is extended using a kinetic growth model incorporating water soluble product formation and growth inhibition. The potential effect of recycle on substrate conversion and product accumulation is also examined and the concept of a critical recycle ratio in fermentation processes is developed.     

Ethanol-type fermentation from carbohydrate in high rate acidogenic reactor

It has been found, in this study, that a new ethanol-type fermentation can be obtained in a continuous flow, high-rate acidogenic reactor receiving molasses as the feed. The operating pH must be maintained at about 4.5 to avoid onset of propionic fermentation. The acidogenic reactor had a VSS level of 20 g/L and its organic loading was as high as 80 to 90 kg COD/m(3) d. The operating ORP was around -250 mV. The ethanol-type fermentation was characterized by a simultaneous production of acetic acid and ethanol, while the yield of propionic was minimal even at a high organic loading rate of 80 to 90 kg COD/m(3) d, and also, the hydrogen partial pressure was as high as 50 kPa. Thus, this study has shown that the production of propionic acid is not always related to high hydrogen partial pressure. When the operating pH was increased to 5.5, the yield of propionic acid became significant. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 54: 428-433, 1997.     

Competitive yeast fermentation with selective flocculation and recycle

Continuous fermentations were carried out involving competition between two strains of Saccharomyces cerevisiae. One of the strains has a lower specific growth rate and is very flocculent, whereas the fastergrowing strain is nonflocculent. The product stream from the chemostat was fed into an inclined settler where the flocculent strain was partially separated from the nonflocculent strain as a result of the higher sedimentation rate of the flocculent cells. The underflow from the inclined settler, which was concentrated and enriched with flocculent cells, was recycled to the chemostat. When no recycle was used, the fastergrowing, nonflocculent yeast rapidly overtook the culture. With selective recycle, however, the experiments demonstrated that the slower-growing flocculent yeast could be maintained as the dominant species. A theoretical development is also presented in order to describe the competition between two strains in the bioreactor-settler system. The concept of selective recycle via selective flocculation and sedimentation offers a possible means of maintaining unstable recombinant microorganisms in continuous 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.     

Lipase-catalysed esterification reaction in a tubular reactor

Summary Lipozyme catalysed esterification of oleic acid with lauryl alcohol was studied in a tubular recycle reactor. Water formed during the reaction was removed by adsorption, either by passing the product mixture through another column packed with molecular sieve, or by packing the reactor partially with silica gel.     

Continuous ethanol fermentation in a tower reactor with flocculating yeast recycle: scale-up effects on process performance, kinetic parameters and model predictions

An unsegregated and unstructured model developed for a small-scale process of ethanol production in a tower reactor with cell recycle was applied to describe the experimental data obtained in a large-scale process. The model was developed considering the following points: reactor hydrodynamic behavior analogous to that of ideal CSTR, substrate limitation, inhibition phenomena linked both to ethanol and to biomass, absence of fermentation in the settler, and no loss of cell viability. The scale-up criterion consisted in maintaining an identical relation settler volume/fermentor volume on the two scales. All large-scale experiments were carried out using a flocculating yeast strain IR-2, isolated from fermented food, and identified as Saccharomyces cerevisiae. Sugarcane juice was used as the substrate source with sugar concentrations of 150?g/l. Different values of dilution rate and recycle ratio were employed (D?=?0.11–0.33?h^?1, α?=?5.4–18.0) and the temperature was of 32?°C. The kinetic parameters were similar on both scales and the model predictions agreed well with the large-scale experimental data.     

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.