Optimum operating mode for a class of fermentation

This paper is concerned with optimization of the operating mode of a fermentor. Combining the various modes of operation—batch, semibatch, and continuous—the operating pattern which maximizes the desired metabolic product in a single fermentor is determined by using Kelley's transformation method with Pontryagin's maximum principle. Kelley's transformation method is a device which avoids the singular situation which occurs when the usual procedure of selecting the optimal control function by the maximum principle breaks down. This is the case in the problem considered in this paper. For lysine fermentation, the best operating mode depends on the fermentor capacity and operating time. The results of this study are summarized thus: (i) when the operating time is “long enough,” optimal conditions require that continuous operation follows either semibatch and/or batch operation, and (ii) when the fermentor capacity becomes “large enough,” semibatch operation becomes important.     

Fermentors with the power introduced by aerating gas

In the present work methods and results of investigations on optimal construction of fermentor elements by multifactor planning at a random number of levels of any factor are presented. The optimal design of column fermentor of 0.02–100 m³ volume with sieve plates containing downcomers and with power introduced by aerating gas has been worked out. Several alternative designs have been compared by examining mass transfer rates, power requirements, and other operating characteristics. Several fermentor designs with the power introduced by aerating gas are discussed with respect to their performance for cultivating various microorganisms (yeast and bacteria).     

Robust pole placement control of a fermentor

This paper deals with robust pole placement control of a continuous flow alcoholic fermention process. The strain used for experiments is Saccharomyces cerevisae UG5. The fermentor is subject to changs in pH, temperature, mixing, etc. The regularized pole placement adaptive control algorithm is used for regulation and tracking purposes. The substrate concentration and the dilution rate have been respectively selected as controlled and control variables. The eliminant matrix associated to the pole placement problem is non-singular if the identified input-output model has common poles and zeros. Two solutions have been adopted to deal with this ill-conditioning problem. The first solution consists of monitoring the determinant of the eliminant matrix and the second consists of adding a correction term to the highest degree coefficient of either the numerator or denominator of the process transfer function. A robust recursive identification scheme is used for parameters estimation. The fermentor was interfaced with PC computer using a multitasking operating system. Experiments carried out with the fermentor, illustrate the use of the regularized pole placement adaptive control algorithm.     

A continuous,multistage tower fermentor. II. Analysis of reactor performance

A method for analyzing the reactor behavior of a continuous, multistage tower fermentor is described. A model consisting of a system of interconnected, ideal subreactors is set up on the basis of the fermentor's configuration and flow pattern. The residence time distribution curve is used to test the validity of the model and the relative quantities of flow streams and regions in the model are determined. A least-square fitting procedure between measured and calculated distribution curves is used to identify the proper model. The application of this method to real cultivation conditions is also discussed. Using this approach, the multistage tower fermentor is shown to be equivalent to a cascade of four perfectly mixed tanks with a backtracking stream between stages. The extent of backflow under various conditions has also been determined.     

The tubular loop batch fermentor: Basic concepts

A tubular loop batch fermentor has been designed and constructed, and was found to behave in a similar manner to a conventional stirred tank reactor. It appeared that foaming could be greatly reduced as no air ever encountered the impeller. The fluid mechanics of pipe flow are considerably simpler than tank flow patterns. On this basis a design procedure for a large scale tubular fermentor was outlined, which had considerable advantages over the more complex scale-up problems of a tank fermentor.     

Analysis of two-stage recombinant bacterial fermentations using a structured kinetic model

A structured kinetic model has been employed to analyze the performance of a two-stage continuous fermentation of a recombinant Escherichia coli. Separating the cell growth phase from the gene expression phase in two fermentors minimizes the growth rate difference between the recombinant cells and the plasmid-free cells in the first fermentor, thereby increasing the plasmid stability. The plasmid-harboring cells from the first fermentor are continuously fed into the second fermentor, in which the foreign protein synthesis is turned on by the addition of the inducer. Consequently, the recombinant cells experience an immediate reduction in growth rates as soon as they enter the second stage and then recover to synthesize the foreign protein. To analyze the fermentation performance contributed by these cells with different intracellular foreign protein levels and growth rates, a novel method for determining the residence time distribution of the growing cells in the second stage has been formulated. Combined with this method, the structured kinetic model for recombinant bacterial cells is used to predict the plasmid stability and foreign productivity at various operation conditions, such as induction strength and dilution rates. This model can provide us with thorough understanding of the characteristics of the two-stage fermentations, and is useful for the development of large scale continuous cultures of recombinant bacteria.     

A constant-depth laboratory model film fermentor

A laboratory model constant-depth film fermentor was developed. Film grew on the surface of polytetrafluoroethylene (PTFE) plugs and was limited to a predetermined depth by mechanically removing excess film. Six film-forming organisms were isolated from river water and used to assess the operating characteristics of the fermentor. Film accumulation was logarithmic, and a steady state was maintained. Electron micrographs show early film development. The fermentor enables film to be grown on any substratum and allows discrete, reproducible, and representative samples to be taken.     

Oxygen transfer and mycelial growth in a tubular loop fermentor

A 22 m long. 20 liter tubular loop fermentor (TLF) has been tested for oxygen transfer characteristics and as a reactor for mycelial growth. Model calculations show that the flow pressure drop has an important influence on the axial oxygen profiles. A design model that accounts for this influence is presented. Using the model, K_L a values are calculated from the results of sulfite oxidation experiments. These are correlated with power consumption and aeration rates. The K_L a dependence on aeration rate was found to be less than found with tank reactors. The growth kinetics of three metabolite-producing mycelial organisms in the TLF are presented: a Streptomyces, a Fusarium, and a Acrophialophora. In order to determine the influence of reactor type on the growth and product formation, these cultures have been grown in tanks and shake flasks. The antibiotic, product spectrum of Streptomyces is compared on the basis of inhibition tests and it is shown that the distribution of products is reactor dependent. The Fusarium culture produced a previously unknown metabolite, whose concentration in the loop fermentor was four times higher than in a shake flask. The Acrophialophora culture grew twice as fast in the loop fermentor, but produced essentially none of the specific product. Power Consumptions of up to 8 kW/m³ in the tubular fermentor did not appear to harm the mycelia.     

Modelling effects of high product and substrate inhibition on oscillatory behavior in continuous bioreactors

In this study we consider a model for continuous bioreactors which incorporates the effects of high product and substrate inhibition on the kinetics as well as biomass and product yields. We theoretically investigate the possibility of various dynamic behaviors in the bioreactor over different ranges of operating parameters to determine the delineating process conditions which may lead to oscillatory behavior. Application of the singular perturbation technique allows us to derive explicit conditions on the system parameters which specifically ascertain the existence of limit cycles composed of concatenations of catastrophic transitions occurring at different speeds. We discover further that the interactions between the limiting substrate and the growing microorganisms can give rise to high frequency oscillations which can arise during the transients toward the attractor or during the low-frequency cycle. Such a study not only can describe more fully the kinetics in a fermentor but also assist in formulating optimum fermentor operating conditions and in developing control strategy for maintaining optimum productivity.     

Continuous culture in combined backmix-plug-flow-tubular-loop fermentor configurations

Several combinations of backmix, tubular-loop, and plug-flow fermentors with and without culture recycle were studied by computer simulations. The steady-state concentrations of cell mass in a continuous culture were calculated as a function of dilution rate using Monod growth kinetics. It was found theoretically and verified for one case experimentally that the maximum dilution rate, over which microbial cells were washed out from the fermentor, could be elevated well beyond the maximum specific growth rate if a particular fermentor combination was used. A combination of two backmix fermentors has been analyzed previously by Sinclair and Brown. Application of this type of fermentor combination as a seed tank for performing continuous culture of microbes in a plug-flow reactor was shown with special reference to fermentation production using the kinetics proposed by Luedeking and Piret, van Dedem and Moo-Young, and Brown and Vass.     

Analysis of a continuous, aerobic, fixed-film bioreactor. II. Dynamic behavior

The dynamic analysis of a continuous, aerobic, fixed-film bioreactor has been performed. Rigorous mathematical models have been developed for a fluidized-bed fermentor with biofilm growth. The transient performance of the reactor is appraised in terms of outlet penicillin concentration for constant, as well as variable carbon substrate feed rates. The effect of the reactor oxygen transfer capacity is elucidated for those cases employing substrate feeding strategies. The results show that penicillin production in a continuous, fixed-film bioreactor reaches a maximum with processing time, but subsequently decreases as cell mass accumulates and substrate deficiencies occur. The maximum production level can be maintained for increased operating times if the substrate supply is continuously increased. The duration of this prolonged production is a direct function of the rate of increase and the operating time at which the increase is initiated. The oxygen transfer capacity of the reactor was found to be important to the effectiveness of a feeding strategy.     

Ethanol production by Zymomonas mobilis CP4 from sugar cane chips

Summary The fermentation of large sugar cane chips (1.0–1.5 in) to ethanol by Zymomonas mobilis CP4 (Z. mobilis) was studied in two glass fermentors operating with culture circulation for agitation (the EX-FERM type): a. A laboratory scale(2.5 liter) cylindrical vessel; b. A bench scale (8 liter) wide vessel. Z. mobilis cultures consumed 89–96% of the cane sucrose, converting it to ethanol by 90–97% of the theoretical yield in the laboratory scale fermentor and by 83–90% in the bench scale fermentor culture. Comparative Saccharomyces spp. cultures in laboratory fermentor consumed 96–98% of the cane sucrose, with ethanol conversion of only 75–79% of the theoretical yield.These preliminary results indicated that sucrose in agricultural size sugar cane chips was ethanol fermentable as compared to small size sugar cane chips or to sugar cane juice. Z. mobilis CP4 cultures converted sucrose more efficiently to ethanol than Saccharomyces spp. as shown in the laboratory scale fermentor studies.The ethanol yields in a wide bench scale fermentor cultures were slightly lower than in a laboratory fermentor.     

Performance of a two-stage fermentor with cell recycle for continuous production of lactic acid

The performasnce of a recycle two-stage fermentor with cell separators after each stage is analyzed numerically for continuous production of lactic acid. In this system, the bleed broth withdrawn from the first stage is provided to the second fermentor to reuse viable cells in the bleed. Biological rate expressions and parametric values are taken from the literature. The effects of operating parameters on the concentrations of total and viable cells, substrate and product in each stage, the lactic acid productivity and the substrate conversion are examined and discussed. With respect to overall productivity and conversion, it is found that the present fermentor system is more efficient than a conventional chemostat fermentor with cell recycle.     

A method for starting a fermentor with immobilized spores of the genus Clostridium aseptically

Summary A method has been developed to start a fermentor with immobilized Clostridium butylicum spores aseptically.     

Ethanol fermentation in a yeast immobilized tubular fermentor

In this article, a mathematical model describing the kinetics of ethanol fermentation in a whole cell immobilized tubular fermentor is proposed. Experimental results show reasonable agreement with the proposed model. A procedure for treating the fermentation data for determining the ethanol inhibition constants k(1) and k(2) is described. The ethanol productivity of the immobilized cell fermentor is compared with those of traditional fermentors. Experimental studies indicate that with Saccharomyces cerevisiae (NRRL Y132) culture, ethanol productivity in the range 21.2-83.7 g ethanol L(-1) h(-1) at ethanol concentration of 76-60 g/L can be achieved. This is comparable to or higher than those reported in the literature for yeast. The product yield factor of 0.5 g ethanol/g glucose was obtained. The immobilized cell fermentor does not show washout at dilution rates of 7 h(-1) and shows good stability over a 650-h operating period.     

A fiber-optic retroreflective turbidimeter for continuously monitoring cell concentration during fermentation

A fiber-optic retroreflective turbidimeter has been developed to automatically and continuously assay the cell concentration in a fermentor by measuring the turbidity of the solution as a function of the light scattered at 180° to the incident light. The output signal is nearly directly proportional to the cell concentration in a fermentor when the sample stream contains from 0 to more than 50 g of cells per liter (wet weight). The device consists of a bifurcated fiber-optics light pipe with its distal end inserted into a flow cell through which the material to be analyzed passes. A light source on one proximal branch of the light pipe illuminates the sample stream; light that is back-scattered from participates in the stream re-enters the light pipe and is returned to a photodetector on the other proximal branch of the light pipe. A signal conditioning system connected to the optical head by a cable provides gain and zero adjustment.     

Modelling mass transfer and agitator performance in multiturbine fermentors

A methodology for mathematically analyzing agitator performance and mass transfer in large multiturbine production fermentors is presented. The application of this approach provides a method for determining axial dissolved oxygen profiles under conditions of known mass transfer rates as a function of agitation-aeration characteristics. A stagewise approach is used which divides the fermentor into a series of mixing cells. This allows for each turbine and mixing cell to be individually optimized. The model also permits the determination of the mass transfer coefficient for each turbine based upon limited dissolved oxygen data. The primary limitation of this approach rests in the limited data and correlations available for multiturbine systems. The structure of the modelling approach can serve as a basis for testing single turbine correlations and adapting them to multiturbine systems. The step-by-step details of the mathematical analysis are presented and interpreted. A series of computer simulations demonstrate the effect of typical fermentor operating variables on the axial dissolved oxygen profile. Further simulations demonstrate the effect of modifying agitator blade numbers on the dissolved oxygen profile and agitator power requirement.     

Combined discrete particle and continuum model predicting solid-state fermentation in a drum fermentor

The development of mathematical models facilitates industrial (large-scale) application of solid-state fermentation (SSF). In this study, a two-phase model of a drum fermentor is developed that consists of a discrete particle model (solid phase) and a continuum model (gas phase). The continuum model describes the distribution of air in the bed injected via an aeration pipe. The discrete particle model describes the solid phase. In previous work, mixing during SSF was predicted with the discrete particle model, although mixing simulations were not carried out in the current work. Heat and mass transfer between the two phases and biomass growth were implemented in the two-phase model. Validation experiments were conducted in a 28-dm3 drum fermentor. In this fermentor, sufficient aeration was provided to control the temperatures near the optimum value for growth during the first 45-50 hours. Several simulations were also conducted for different fermentor scales. Forced aeration via a single pipe in the drum fermentors did not provide homogeneous cooling in the substrate bed. Due to large temperature gradients, biomass yield decreased severely with increasing size of the fermentor. Improvement of air distribution would be required to avoid the need for frequent mixing events, during which growth is hampered. From these results, it was concluded that the two-phase model developed is a powerful tool to investigate design and scale-up of aerated (mixed) SSF fermentors.     

Evidence for the occurrence of an oxygen limitation during soil bioremediation by solid-state fermentation

Bioremediation methods are a promising way of dealing with soil and subsoil contamination by organic substances. This biodegradation process is supported by micro-organisms which use the organic carbon from the pollutants as energy source and cells building blocks. The scope of this work is to study the main parameters of the process and the physical limiting steps. Several ground samples from an actual petroleum hydrocarbon contaminated site have been tested. Four fixed bed column reactors and one rotating fermentor are used, enabling the study of the influence of different operating variables on the biodegradation kinetics. The stoichiometric equation for bacteria growth and pollutant degradation has been established, allowing the determination of mass balances. Biodegradation monitoring is achieved by continuously measuring the emissions of carbon dioxide. Biodegradation rates and pollution load decrease in the two kinds of bioreactors are also compared.     

Equipment for hydrocarbon fermentations

Although air-lift fermentors have been employed industrially and in the laboratory, little information has been published on the effects of design on performance. With respect to both liquid circulation and mass transfer, not only the actual rates but the efficiency in relation to power consumption is strongly influenced by lift height and diameter, submergence ratio, and air-flow rate. Relatively wide tubes, operating at high submergence ratios and rather low air-flow rates favor high efficiency. Since these conditions lead to rather low absolute values of circulation and mass-transfer rates, the microbial population which can be supported will also be rather small. Mass transfer can be increased by the insertion of an orifice some distance; above the air-inlet point and by suitable arrangement of the discharge from the air lift into the headspace of the fermentor.