The effects of cells on oxygen transfer in bioreactors

Cells may affect oxygen transfer rates by three mechanisms: respiration of cells accumulated at the gas/liquid interface, physical presence of cells as solid particles, and modification of the medium by cells. These effects were studied experimentally in bubble-aerated bioreactors using baker's yeast at different cell concentrations, agitation speeds, aeration rates, and specific oxygen uptake rates. The overall effect of cells was to enhance oxygen transfer rates. The physical presence of cells as solid particles was found to retard oxygen transfer, presumably due to the lower oxygen permeability in the cell layer accumulated near the bubble surfaces. Cell respiration and medium modification, on the other hand, enhanced oxygen transfer rates. The retardation by nonrespiring cells and the enhancement due to cell respiration were found stronger at higher agitation speeds and lower aeration rates employed. This was attributed to the higher interfacial cell accumulation associated with the smaller bubbles produced under these conditions in the systems studied.     

Experimental evaluation of liquid film resistance in oxygen transport to microbial cells

A membrane probe was used to monitor the dissolved oxygen concentrations in continuous cultures of Candida utilis and Micrococcus roseus growing at low dissolved oxygen concentrations and various agitation levels. For the yeast fermentations, increasing the agitation level within the range of 0.1 to 0.3 w per liter lowered steady-state dissolved oxygen concentrations in the fermentor. The steady-state dissolved oxygen concentration in the fermentor was not influenced by the agitation level within the range of 0.3 to 1.8 w per liter. With M. roseus, no effect of agitation on steady-state dissolved oxygen concentrations in the fermentor was observed within the range of 0.1 to 1.8 w per liter. It was concluded that, under the conditions used, a measurable transfer barrier from the liquid to the yeast cells existed at agitation levels below 0.3 w per liter and that this barrier did not exist at agitation levels above 0.3 w per liter. The transfer barrier from the liquid to the yeast surface could be represented by a stagnant film of liquid 0.6 × 10^-4 cm thick surrounding the cell at an agitation level of 0.10 w per liter. This film represented an oxygen concentration drop of 1.3 × 10^-7 M from the bulk of the medium to the cells under the experimental conditions.     

The use of flow cytometry to study the impact of fluid mechanical stress on Escherichia coli W3110 during continuous cultivation in an agitated bioreactor

Continuous culture fermentations of Escherichia coli W3110 have been carried out at controlled dissolved oxygen levels of 40% and 10% of saturation. Satisfactory and reproducible results were obtained. Agitation speeds of 400 and 1200 rpm at an aeration rate of 1 vvm have been used as well as an aeration rate of 3 vvm at 400 rpm. The upper levels of these variables represent much higher agitation and aeration intensities than those normally used in practical fermentations. The fermentations were monitored by mass spectrometry and optical density, and cell samples were studied by flow cytometry, SEM, and TEM. Protocols were developed so the state of both cell membranes and cell size could be measured by flow cytometry. Under all the conditions of agitation and aeration, flow cytometric analysis indicated that both cell membranes were intact and that a cytoplasmic membrane potential existed; also the cell size did not change, results confirmed by SEM and TEM. There were no detectable changes in off-gas analysis or optical density during the continuous fermentation nor in the cell structure as revealed by SEM or TEM, except at the highest agitation intensity. Under the latter conditions, after 7 h, the outer polysaccharide layer on the cell was stripped away. It is concluded that any changes in biological performance of this E. coli cell line due to variations in agitation or aeration intensity or scale of operation cannot be attributed to fluid dynamic stresses associated with the turbulence generated by impellers or with bursting bubbles.     

Effect of the interfacial surfactant layer on oxygen transfer through the oil/water phase boundary in perfluorocarbon emulsions

The effect of interfacial surfactant molecules on oxygen transfer through oil/water phase boundary has been studied in FlurO(2) (TM) emulsions, i.e., perfluorocarbon (PFC) emulsions developed as oxygen carriers in cell culture. Measurements of oxygen permeability were made with a polarographic oxygen electrode in pure PFCs and in emulsions with various PFC volume fractions. Comparison of the experimental results with the theoretically derived values of relative oxygen permeability clearly indicates that the mass transfer resistance caused by the interfacial surfactant layer in PFC emulsions is insignificant. Therefore, oxygen dissolved in the enclosed PFC phase is readily available to cells growing in the aqueous media and FlurO(2) emulsions with very fine emulsion particles (< 0.2 mum) can be used to effectively enhance gas/liquid interfacial oxygen transfer in bioreactors. The inadequacy in describing mass transfer in heterogeneous systems, such as the PFC emulsions, by conventional concentration-based oxygen diffusion coefficients has also been discussed.     

Enhancing penicillin fermentations by increased oxygen solubility through the addition of n-hexadecane

n-Hexadecane was added to fermentation media to increase the medium oxygen solubilities, thus enhancing oxygen transfer rates in penicillin fermentations. For shake flask fermentations, cells were found to grow faster in the flasks with n-hexadecane than those without. The addition of n-hexadecane to penicillin fermentations was shown to significantly increase cell growth and penicillin production and reduce formation of mycelial pellets. The result was attributed to the enhancement of oxygen transfer in mycelial fermentations due to the higher oxygen solubilities of fermentation media achieved by adding n-hexadecane.     

Oxygen absorption in stirred tanks: A correlation for ionic strength effects

A new correlation is given for the prediction of the volumetric coefficient for mass transfer (K_La) in stirred tanks from dispersed gas bubbles to basal salt solutions of ionic strengths representative of fermentation media. The correlation includes the effects of both the operating parameters (agitation power per unit volume and gas superficial velocity) and the physicochemical properties of the system: interfacial tension, viscosity, density, diffusion, coefficient and, in particular, ionic strength. The effect of the latter was found to be most significant in the Newtonian systems of water-like viscosity investigated; no previous correlations have included the effect of ionic strength. K_La values were determined by using a dissolved oxygen probe to monitor the steady-state oxygen tension in continuous flow experiments, and/or the rate of change of oxygen tension in unsteady-state semibatch experiments. In the latter cases, results were computed by a nonlinear, least squares computer program which fitted the experimental data to a model of probe transient response characteristics. The general applicability of the model and the computational procedure was verified by comparing the results to those obtained with the same electrolyte solution in the steady-state mode. The experiments were run over a wide range of agitation power inputs, including those typical of both soluble- and insoluble-substrate fermentations. The correlation appears to be valid for both oxygen mass transfer with and without homogeneous chemical reaction in the liquid phase; in the former case, for example, sulfite oxidation, knowledge of the chemical reaction enhancement factor is required. In addition to predicting oxygen transfer capabilities, the correlation may be used for other sparingly soluble gases of interest in fermentation systems, such as methane, hydrogen, and carbon dioxide.     

Dependence of morphology on agitation intensity in fed-batch cultures of Aspergillus oryzae and its implications for recombinant protein production

We previously reported that, although agitation conditions strongly affected mycelial morphology, such changes did not lead to different levels of recombinant protein production in chemostat cultures of Aspergillus oryzae (Amanullah et al., 1999). To extend this finding to another set of operating conditions, fed-batch fermentations of A. oryzae were conducted at biomass concentrations up to 34 g dry cell weight/L and three agitation speeds (525, 675, and 825 rpm) to give specific power inputs between 1 and 5 kWm(-3). Gas blending was used to control the dissolved oxygen level at 50% of air saturation except at the lowest speed where it fell below 40% after 60-65 h. The effects of agitation intensity on growth, mycelial morphology, hyphal tip activity, and recombinant protein (amyloglucosidase) production in fed-batch cultures were investigated. In the batch phase of the fermentations, biomass concentration, and AMG secretion increased with increasing agitation intensity. If in a run, dissolved oxygen fell below approximately 40% because of inadequate oxygen transfer associated with enhanced viscosity, AMG production ceased. As with the chemostat cultures, even though mycelial morphology was significantly affected by changes in agitation intensity, enzyme titers (AGU/L) under conditions of substrate limited growth and controlled dissolved oxygen of >50% did not follow these changes. Although the measurement of active tips within mycelial clumps was not considered, a dependency of the specific AMG productivity (AGU/g biomass/h) on the percentage of extending tips was found, suggesting that protein secretion may be a bottle-neck in this strain during fed-batch fermentations.     

Interactions between surfactants and biomass during liquid–liquid extraction

Fermentation systems can contain may surface‐active compounds that can interfere with downstream separation processes. This work examines the interactions that can occur between surfactants and biomass during solute mass transfer in a liquid–liquid extraction system. Adding the surfactants sodium dodecyl sulfate and dodecyl trimethyl ammonium bromide to the aqueous phase caused a substantial increase in the mass transfer of chloramphenicol between water and octanol. Further investigation of the interfacial region using an optical Schlieren apparatus revealed that these increases were due to interfacial turbulence that gave rise to a rapid surface renewal convective mass transfer mechanism. When microbial biomass was present with sodium dodecyl sulfate, an increase in the mass transfer rate was again found, however, to a lesser extent. In contrast, dodecyl trimethyl ammonium bromide did not promote mass transfer and it is postulated that electrical interactions between the surfactant and the cell surface prevented adsorption of either at the interface. The interaction between the antifoaming agent polypropylene glycol 2000 and extraction system components was also investigated, with both positive and negative effects being recorded under varying conditions. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2009     

Twenty-four-well plate miniature bioreactor high-throughput system: assessment for microbial cultivations

High-throughput (HT) miniature bioreactor (MBR) systems are becoming increasingly important to rapidly perform clonal selection, strain improvement screening, and culture media and process optimization. This study documents the initial assessment of a 24-well plate MBR system, Micro (micro)-24, for Saccharomyces cerevisiae, Escherichia coli, and Pichia pastoris cultivations. MBR batch cultivations for S. cerevisiae demonstrated comparable growth to a 20-L stirred tank bioreactor fermentation by off-line metabolite and biomass analyses. High inter-well reproducibility was observed for process parameters such as on-line temperature, pH and dissolved oxygen. E. coli and P. pastoris strains were also tested in this MBR system under conditions of rapidly increasing oxygen uptake rates (OUR) and at high cell densities, thus requiring the utilization of gas blending for dissolved oxygen and pH control. The E. coli batch fermentations challenged the dissolved oxygen and pH control loop as demonstrated by process excursions below the control set-point during the exponential growth phase on dextrose. For P. pastoris fermentations, the micro-24 was capable of controlling dissolved oxygen, pH, and temperature under batch and fed-batch conditions with subsequent substrate shot feeds and supported biomass levels of 278 g/L wet cell weight (wcw). The average oxygen mass transfer coefficient per non-sparged well were measured at 32.6 +/- 2.4, 46.5 +/- 4.6, 51.6 +/- 3.7, and 56.1 +/- 1.6 h(-1) at the operating conditions of 500, 600, 700, and 800 rpm shaking speed, respectively. The mixing times measured for the agitation settings 500 and 800 rpm were below 5 and 1 s, respectively.     

Mathematical simulation of a biofilm process

A mathematical model has been developed for a fixed-film biological process (film flow over a flat plate) that describes bulk liquid transport, diffusional transport of oxygen and organics across a stagnant film, diffusional transport of oxygen and organics into the biofilm, biochemical reactions by the individual cells within the biofilm, biofilm growth, and cell density changes within the biofilm due to cellular decay. Simulation studies are presented to show how contact time and diffusion layer thickness affect process performance.     

Real-time monitoring of shake flask fermentation and off gas using triple disposable noninvasive optical sensors

Bioprocess development is a data-driven process requiring a large number of experiments to be conducted under varying conditions. Small-scale upstream bioprocess development is often performed in shake flasks because they are inexpensive and can be operated in parallel. However, shake flasks are often not equipped to accurately monitor critical process parameters such as pH, dissolved oxygen, and CO2 concentrations. Therefore, there is no definitive information on oxygen supply of growing cells, CO2 formation, and pH changes. Here we describe several shake flask fermentations where all three parameters are monitored by disposable noninvasive optical sensors. The sensitive element of these sensors is a thin, luminescent patch affixed inside the flask. Small electronic devices for excitation and fluorescence detection are positioned outside the shake flask for noninvasive monitoring. By measuring the process parameters throughout the course of the E. coli fermentations, we obtain information that is not routinely available in shake flask fermentations. For example, for cultures with only a few millimeters liquid depth, oxygen limitation can occur at relatively low agitation speeds. Under certain conditions oscillations in dissolved oxygen can occur. An increase in shaker speed and a decrease in culture volume can increase the oxygen availability and reduce the duration of oxygen limitation.     

Enhancement of gas-liquid mass transfer rate of apolar pollutants in the biological waste gas treatment by a dispersed organic solvent

Dispersed water-immiscible solvents are known to enhance oxygen transfer rates in oxygen-limited aerobic fermentations. Here, this technique is applied to improve the mass transfer rate of poorly water-soluble gaseous pollutants during the biological treatment of waste gases. In a stirred-tank reactor, the enhancement of mass transfer rates was studied as a function of the pollutant solubility in water. The solvent used was FC40 (up to 10% v/v) and the model gaseous pollutants were toluene and oxygen (moderately and poorly water-soluble, respectively).

The overall volumetric mass transfer coefficient from the gas to the bulk liquid (k_la_gl) was measured under nonsteady-state conditions in the absence of micro-organisms. It was found to be essentially constant for the solvent volume fractions tested and for both toluene and oxygen. Using the values of k_la_gl and the partition coefficient gas/liquid (m_gl), the enhancement of the mass transfer rate by solvent addition could be predicted theoretically. A good agreement between the theoretical evaluation and the experimental results from experiments in the presence of biological consumption was observed. An enhancement of the mass transfer rate by a factor of 1.1 was found for toluene using a dispersion containing 10% (v/v) FC40 while the oxygen transfer rate increased by a factor of two at the same solvent volume fraction. It was further demonstrated theoretically for other gaseous compounds that the addition of solvent has a more pronounced effect on the enhancement of the transfer rate in the case of poorly water-soluble compounds compared to moderately water-soluble ones.     

Studies on fluid dynamics of the flow field and gas transfer in orbitally shaken tubes

Orbitally shaken cylindrical bioreactors [OrbShake bioreactors (OSRs)] without an impeller or sparger are increasingly being used for the suspension cultivation of mammalian cells. Among small volume OSRs, 50‐mL tubes with a ventilated cap (OSR50), originally derived from standard laboratory centrifuge tubes with a conical bottom, have found many applications including high‐throughput screening for the optimization of cell cultivation conditions. To better understand the fluid dynamics and gas transfer rates at the liquid surface in OSR50, we established a three‐dimensional simulation model of the unsteady liquid forms (waves) in this vessel. The studies verified that the operating conditions have a large effect on the interfacial surface. The volumetric mass transfer coefficient (k_La) was determined experimentally and from simulations under various working conditions. We also determined the liquid‐phase mass transfer coefficient (k_L) and the specific interfacial area (a) under different conditions to demonstrate that the value of a affected the gas transfer rate more than did the value of k_L. High oxygen transfer rates, sufficient for supporting the high‐density culture of mammalian cells, were found. Finally, the average axial velocity of the liquid was identified to be an important parameter for maintaining cells in suspension. Overall these studies provide valuable insights into the preferable operating conditions for the OSR50, such as those needed for cell cultures requiring high oxygen levels. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 33:192–200, 2017     

Oxygen mass transfer enhancement via fermentor headspace pressurization.

Bioreactor headspace pressurization represents an excellent means of enhancing oxygen mass transfer to a culture. This method is particularly effective in situations where stirring or vigorous aeration is difficult. Because it in itself introduces no undesirable hydrodynamic force, the proposed method is also attractive for cells susceptible to agitation and sparging. Experiments were first conducted in an ideal fermentor by sparging air into a sulfite solution free from extraneous microbial effects. An increased oxygen mass transfer rate resulting from pressurization led to a superior cell growth rate and a higher maximum cell density in both of the microbial systems studied: a bacterial (Escherichia coli) culture up to 2.72 bar and a fragile algal (Ochromonas malhamensis) culture with pressure programming. Applying pressurization increased the maximum dry cell weight from 1.47 g/L to 1.77 g/L in the E. coli culture and increased the maximum viable cell density from 4 x 10(7) cells/mL to 10(8) cells/mL in the algal culture. An additional advantage is that formation of undesirable products under oxygen limitation, e.g., acetic acid in the E. coli culture, can be suppressed. A significant (over 250%) improvement in the oxygen transfer rate can be achieved with existing fermentors with little modification as they are already designed to withstand reasonable pressure from autoclaving. This method is simple, clean, inexpensive, and easily implemented, and it can be applied alongside other existing methods of oxygen mass transfer enhancement.     

Regime analysis of a Baeyer–Villiger bioconversion in a three-phase (air–water–ionic liquid) stirred tank bioreactor

The aim of this work was to conduct a regime analysis on a three-phase (air–water–ionic liquid) stirred tank bioreactor of the Baeyer–Villiger bioconversion process, using [MeBuPyrr][BTA] ionic liquid as the dispersed phase. The regime analysis based on characteristic times of the different mechanisms involved (mixing, mass transfer, reaction) can yield a quantitative estimate of bioreactor performance. The characteristic time obtained for oxygen uptake rate (54 s⁻¹) was among the characteristic times determined for oxygen transfer (13–129 s⁻¹) under different operating conditions, suggesting that the oxygen transfer rate under certain operating conditions could be a limiting step in the bioconversion process. Further enhancement of oxygen transfer rates requires proper selection of the bioreactor operational conditions, and improved design of the ionic liquid used as oxygen transfer vector.     

The Effect of Organic and Metal Oxide Interfacial layers on the Performance of Inverted Organic Photovoltaics

We study the origin of the improvement of the power conversion efficiency (PCE) of inverted organic solar cells when an interfacial insulating organic layer of polyoxyethylene tridecyl ether (PTE) is introduced between the indium tin oxide (ITO) bottom electrode and the TiO_x interfacial layer. XPS and UPS measurements are used to investigate the energy level alignment at the interfaces within the ITO/TiO_x and ITO/PTE/TiO_x structures and to identify any effects due to chemical interaction and interfacial dipoles. Scanning electron microscopy studies show that the surface structure of the TiO_x layer is affected, when it is coated on top of the PTE layer. Surface contact angle measurements show that the incorporated interfacial layer of PTE is more hydrophilic than ITO and thus PTE modified TiO_x becomes more hydrophilic. This, in combination with the surface gaps of the PTE interfacial layer, is likely to lead to changed wetting and hydrolysis properties of TiO_x when coated on ITO/PTE than on ITO alone. The different TiO_x layer quality is reflected in improved electron selectivity, leading to enhanced fill factor, reduced parasitic resistance effects and higher power conversion efficiency for inverted solar cells with a PTE interfacial layer between ITO and TiO_x.     

Prediction of gas-liquid mass transfer coefficient in sparged stirred tank bioreactors

Oxygen mass transfer in sparged stirred tank bioreactors has been studied. The rate of oxygen mass transfer into a culture in a bioreactor is affected by operational conditions and geometrical parameters as well as the physicochemical properties of the medium (nutrients, substances excreted by the micro-organism, and surface active agents that are often added to the medium) and the presence of the micro-organism. Thus, oxygen mass transfer coefficient values in fermentation broths often differ substantially from values estimated for simple aqueous solutions. The influence of liquid phase physicochemical properties on kLa must be divided into the influence on k(L) and a, because they are affected in different ways. The presence of micro-organisms (cells, bacteria, or yeasts) can affect the mass transfer rate, and thus kLa values, due to the consumption of oxygen for both cell growth and metabolite production. In this work, theoretical equations for kLa prediction, developed for sparged and stirred tanks, taking into account the possible oxygen mass transfer enhancement due to the consumption by biochemical reactions, are proposed. The estimation of kLa is carried out taking into account a strong increase of viscosity broth, changes in surface tension and different oxygen uptake rates (OURs), and the biological enhancement factor, E, is also estimated. These different operational conditions and changes in several variables are performed using different systems and cultures (xanthan aqueous solutions, xanthan production cultures by Xanthomonas campestris, sophorolipids production by Candida bombicola, etc.). Experimental and theoretical results are presented and compared, with very good results.     

A method for estimating oxygen availability of stationary plant cell cultures in liquid media

A method for estimating the oxygen availability in plant cell cultures grown in stationary liquid media (e.g. many protoplast cultures) was developed. The method is based on short-term measurements of respiration rate versus oxygen concentration on a sample of cells, suspended in liquid media. From such data it is possible to estimate the oxygen concentration at the bottom of a stagnant liquid culture, by calculating the amount of oxygen reaching the cells by diffusion. As an example, rape (Brassica napus L. cv. Omega) hypocotyl protoplasts were grown with different oxygen concentrations at the site of the cells, obtained by varying the cell density, the height of the liquid layer and the oxygen content of the gas phase. The number of surviving calli was positively correlated with the estimated oxygen availability in the range between 60 and 350 M O₂, below 60 M all cells died. This indicates that oxygen availability can be a limiting factor in the range usually encountered in protoplast cultures, and that the method can be useful when designing optimal growth conditions for stationary cultures of plant cells.Abbreviations C₁ bulk oxygen concentration in agitated medium - C_o oxygen concentration in medium at the gas-liquid interface, in equilibrium with the gas - C_x oxygen concentration at cell level - D diffusion constant of oxygen in water - K_La oxygen transfer rate - l height of liquid above cells - n number of cells per ml - R_x respiration rate per cell     

Studies on Oxygen Transfer in Submerged Fermentations

This paper refers to the application of gas analyzers for the determination of oxygen transfer rate, showing examples in the studies and the performances of submerged fermentations. Oxygen and carbon dioxide analyzers were set to monitor the gas streams to and from the fermentor. Continuous data on the concentrations of oxygen and carbon dioxide in the air streams were thus provided throughout the fermentation. Distinctive characters of this method were applicability to fermentors in practice and ability of obtaining data directly relating to the fermentations.

The modification of sulfite oxidation method for the determination of oxygen transfer rate from air into liquid or of a measure of aeration effectiveness was made. The proposed method was the application of gas analyzers in the studies on submerged fermentation. Some comparative discussions were made between this and the conventional titrimetric method. This modified method could be applied to biological systems with no alteration, therefore, it was made possible to compare the sulfite solution with the biological systems in relation to the problems on oxygen transfer.     

Mechanism of enhanced oxygen transfer in fermentation using emulsified oxygen-vectors

Limitations of oxygen transfer in fermentation can be solved using auxiliary liquids immiscible in the aqueous phase. The liquids (called oxygen-vectors) used in this study were hydrocarbon (n-dodecane) and perfluorocarbon (forane F66E) in which oxygen is highly soluble (54.9 mg/L in n-dodecane and 118 mg/L in forane F66E at 35 degrees C in contact with air at atmospheric pressure). It has been demonstrated that the use of n-dodecane emulsion in a culture of Aerobacter aerogenes enabled a 3. 5-fold increase of the volumetric oxygen transfer coefficient(k(L)a) calculated on a per-liter aqueous phase basis. The droplet size of the vector played a crucial role in the phenomena. When a static contact between gas bubble and vector droplet was established in water, the vector covered the bubble, in agreement with positive values of the spreading coefficient for these fluids. The determination of the oxygen transfer coefficients (k(L)) in a reactor with a definite interfacial area enabled the main resistance to be located in the boundary layer of the waterside either for a gas-water or a vector-water interface. Because oxygen consumption by weakly hydrophobic cells can only occur in the aqueous phase, the oxygen transfer is achieved according to the following pathway: gas-vector-water-cell. Finally, a mechanism for oxygen transfer within this four-phased system is proposed.