Co-digestion of manure and whey for in situ biogas upgrading by the addition of H2: process performance and microbial insights

In situ biogas upgrading was conducted by introducing H₂ directly to the anaerobic reactor. As H₂ addition is associated with consumption of the CO₂ in the biogas reactor, pH increased to higher than 8.0 when manure alone was used as substrate. By co-digestion of manure with acidic whey, the pH in the anaerobic reactor with the addition of hydrogen could be maintained below 8.0, which did not have inhibition to the anaerobic process. The H₂ distribution systems (diffusers with different pore sizes) and liquid mixing intensities were demonstrated to affect the gas-liquid mass transfer of H₂ and the biogas composition. The best biogas composition (75:6.6:18.4) was obtained at stirring speed 150 rpm and using ceramic diffuser, while the biogas in the control reactor consisted of CH₄ and CO₂ at a ratio of 55:45. The consumed hydrogen was almost completely converted to CH₄, and there was no significant accumulation of VFA in the effluent. The study showed that addition of hydrogen had positive effect on the methanogenesis, but had no obvious effect on the acetogenesis. Both hydrogenotrophic methanogenic activity and the concentration of coenzyme F₄₂₀ involved in methanogenesis were increased. The archaeal community was also altered with the addition of hydrogen, and a Methanothermobacter thermautotrophicus related band appeared in a denaturing gradient gel electrophoresis gel from the sample of the reactor with hydrogen addition. Though the addition of hydrogen increased the dissolved hydrogen concentration, the degradation of propionate was still thermodynamically feasible at the reactor conditions.     

Venturi aeration and thermophilic aerobic sewage sludge digestion in small-scale reactors

Summary The aeration performance of two venturi aeration reactors (operating volumes 381 and 251) was studied for an air-water system. It was found that the mass transfer coefficient (k _la) could be described in terms of the superficial gas velocity (V _s) alone by the simple expressionk _La=aV _infb ^supS with constantsa=0.313,b=0.579 for the 38-1 reactor anda=0.214,b=0.534 for the 25-1 reactor. A similar relationship was obeyed when the 38-1 reactor was aerated with a diffuser tile (a=17.0,b=1.52). A linear relationship betweenk _La and gas hold-up was observed for the 38-1 reactor with both venturi and diffuser aeration. The 25-1 reactor was used successfully for the thermophilic aerobic digestion of sewage sludge. A mean sludge temperature rise of 30°C was observed. Chemical oxygen demand, pH, and total solids content of the digested sludge differed significantly from the feed sludge and were similar to values obtained for full-scale thermophilic aerobic digestion. No significant differences between inorganic solids content, dissolved oxygen concentration, or redox potential were observed between feed and digested sludge.     

Impact of nozzle operation on mass transfer in jet aerated loop reactors. Characterization and comparison to an aerated stirred tank reactor

The impact of mass transfer on productivity can become a crucial aspect in the fermentative production of bulk chemicals. For highly aerobic bioprocesses the oxygen transfer rate (OTR) and productivity are coupled. The achievable space time yields can often be correlated to the mass transfer performance of the respective bioreactor. The oxygen mass transfer capability of a jet aerated loop reactor is discussed in terms of the volumetric oxygen mass transfer coefficient k_La [h^?1] and the energetic oxygen transfer efficiency E [kgO₂ kW^?1 h^?1]. The jet aerated loop reactor (JLR) is compared to the frequently deployed aerated stirred tank reactor. In jet aerated reactors high local power densities in the mixing zone allow higher mass transfer rates, compared to aerated stirred tank reactors. When both reactors are operated at identical volumetric power input and aeration rates, local k_La values up to 1.5 times higher are possible with the JLR. High dispersion efficiencies in the JLR can be maintained even if the nozzle is supplied with pressurized gas. For increased oxygen demands (above 120 mmol L^?1 h^?1) improved energetic oxygen transfer efficiencies of up to 100 % were found for a JLR compared to an aerated stirred tank reactor operating with Rushton turbines.     

Carbon dioxide injection method for enhancing hydrogenotrophic denitrification of secondary wastewater effluent in fixed bed reactor

This study presents an optimal injection method for using carbon dioxide as a carbon source for the hydrogenotrophic denitrification of secondary wastewater effluent in a laboratory-scale fixed bed reactor (FBR). The FBR was operated under three conditions: a continuous CO₂ supply, periodic CO₂ supply, and without a CO₂ supply. The continuous operation of the FBR without carbon dioxide injection resulted in an increase in pH to 10 and a noticeable level of nitrite accumulation. The continuous co-injection of carbon dioxide and hydrogen gas decreased the pH to a range of 6 ～ 8, but the denitrification efficiency decreased to 29%. The co-injection of carbon dioxide decreased the maximum dissolved hydrogen concentration and hydrogen mass transfer rate by 25 and 61%, respectively. Compared to the continuous injection method, a periodic injection of carbon dioxide increased the denitrification efficiency from 28.6 to 85% as the hydrogen flow rate and hydraulic retention time (HRT) increased. With the periodic injection of carbon dioxide, the nitrite accumulation appeared to be insignificant as the hydrogen flow rate increased.     

Effect of stirrer speed,aeration rate and cell mass concentration on volumetric oxygen transfer coefficients (KLa) in the cultivation of Curvularia lunata in a batch reactor

Summary Curvularia lunata was grown in a stirred and aerated reactor for the production of extracellular rifamycin oxidase. Volumetric oxygen transfer coefficients (K_La) were measured for various stirrer speeds, rates of aeration and cell mass concentrations in the reactor. Stirrer speed and aeration rate were optimized and it was found that stirrer speeds of 400–500 rpm and aeration rates of 0.75–1 vvm were optimum for the maximum amount of enzyme production. It was noticed that the increase in cell mass decreased the oxygen transfer coefficient. It was also noticed that the organism formed pellets rather than mycelia when grown on glucose and with an increase in the concentration of glucose in the reactor, there was heavy pellet formation.     

Hydrodynamics and mass transfer in a tubular airlift photobioreactor

In photobioreactors, which are usually operated under light limitation,sufficient dissolved inorganic carbon must be provided to avoid carbonlimitation. Efficient mass transfer of CO₂ into the culture mediumisdesirable since undissolved CO₂ is lost by outgassing. Mass transferof O₂ out of the system is also an important consideration, due tothe need to remove photosynthetically-derived O₂ before it reachesinhibitory concentrations. Hydrodynamics (mixing characteristics) are afunctionof reactor geometry and operating conditions (e.g. gas and liquid flow rates),and are a principal determinant of the light regime experienced by the culture.This in turn affects photosynthetic efficiency, productivity, and cellcomposition. This paper describes the mass transfer and hydrodynamics within anear-horizontal tubular photobioreactor. The volume, shape and velocity ofbubbles, gas hold-up, liquid velocity, slip velocity, axial dispersion,Reynoldsnumber, mixing time, and mass transfer coefficients were determined intapwater,seawater, and algal culture medium. Gas hold-up values resembled those ofvertical bubble columns, and the hydraulic regime could be characterized asplug-flow with medium dispersion. The maximum oxygen mass transfer coefficientis approximately 7 h^–1. A regime analysisindicated that there are mass transfer limitations in this type ofphotobioreactor. A methodology is described to determine the mass transfercoefficients for O₂ stripping and CO₂ dissolution whichwould be required to achieve a desired biomass productivity. This procedure canassist in determining design modifications to achieve the desired mass transfercoefficient.     

Syngas fermentation to biofuel: Evaluation of carbon monoxide mass transfer coefficient (kLa) in different reactor configurations

Lignocellulosic biomass such as agri‐residues, agri‐processing by‐products, and energy crops do not compete with food and feed, and is considered to be the ideal renewable feedstocks for biofuel production. Gasification of biomass produces synthesis gas (syngas), a mixture primarily consisting of CO and H₂. The produced syngas can be converted to ethanol by anaerobic microbial catalysts especially acetogenic bacteria such as various clostridia species.One of the major drawbacks associated with syngas fermentation is the mass transfer limitation of these sparingly soluble gases in the aqueous phase. One way of addressing this issue is the improvement in reactor design to achieve a higher volumetric mass transfer coefficient (k_La). In this study, different reactor configurations such as a column diffuser, a 20‐μm bulb diffuser, gas sparger, gas sparger with mechanical mixing, air‐lift reactor combined with a 20‐μm bulb diffuser, air‐lift reactor combined with a single gas entry point, and a submerged composite hollow fiber membrane (CHFM) module were employed to examine the k_La values. The k_La values reported in this study ranged from 0.4 to 91.08 h^?1. The highest k_La of 91.08 h^?1 was obtained in the air‐lift reactor combined with a 20‐μm bulb diffuser, whereas the reactor with the CHFM showed the lowest k_La of 0.4 h^?1. By considering both the k_La value and the statistical significance of each configuration, the air‐lift reactor combined with a 20‐μm bulb diffuser was found to be the ideal reactor configuration for carbon monoxide mass transfer in an aqueous phase. © 2010 American Institute of Chemical Engineers Biotechnol. Prog., 2011     

The Effect of Aeration on the Metabolism of Acetate by Aspergillus niger

1. The effect of passing different rates of air or graded concentrationsof CO₂, over cultures of A. niger growing on an acetate mediumhas been investigated. 2. There is a rate of aeration or concentration of CO₂ whichis optimal for most rapid utilization of acetate. High ratesof air-flow severely depress consumption of acetate, whereasvery slow rates only slightly increase the metabolic period. 3. Production of oxalate is not greatly affected by aerationor by different concentrations of CO₂ except where consumptionof acetate is reduced. 4. Citrate formation, is markedly affected by the experimentalconditions. Under optimal treatment citric acid yield is increasedby amounts up to 64 per cent. with controlled aeration and byamounts up to a further i80 per cent. with regulated concentrationof CO₂     

Syngas fermentation of Clostridium carboxidivoran P7 in a hollow fiber membrane biofilm reactor: Evaluating the mass transfer coefficient and ethanol production performance

Gasification followed by syngas fermentation is a unique hybrid process for converting lignocellulosic biomass into fuels and chemicals. Current syngas fermentation faces several challenges with low gas–liquid mass transfer being one of the major bottlenecks. The aim of this work is to evaluate the performance of hollow fiber membrane biofilm reactor (HFM-BR) as a reactor configuration for syngas fermentation. The volumetric mass transfer coefficient (K_La) of the HFM-BR was determined at abiotic conditions within a wide range of gas velocity/flowrate passing through the hollow fiber lumen and liquid velocity/flowrate passing through the membrane module shell. The K_La values of the HFM-BR were higher than most reactor configurations such as stir tank reactors and bubble columns. A continuous syngas fermentation of Clostridium carboxidivorans P7 was implemented in the HFM-BR system at different operational conditions, including the syngas flow rate, liquid recirculation between the module and reservoir, and the dilution rate. It was found that the syngas fermentation performance such as syngas utilization efficiency, ethanol concentration and productivity, and ratio of ethanol to acetic acid depended not only on the mass transfer efficiency but also the characteristics of biofilm attached on the membrane module (biofouling or abrading of the biofilm). The HFM-BR results in a highest ethanol concentration of 23.93 g/L with an ethanol to acetic acid ratio of 4.79. Collectively, the research shows the HFM-BR is an efficient reactor system for syngas fermentation with high mass transfer.     

Effects of light intensity and oxygen on photosynthesis and translocation in sugar beet

The mass transfer rate of ¹⁴C-sucrose translocation from sugar beet (Beta vulgaris, L.) leaves was measured over a range of net photosynthesis rates from 0 to 60 milligrams of CO₂ decimeters⁻² hour⁻¹ under varying conditions of light intensity, CO₂ concentration, and O₂ concentration. The resulting rate of translocation of labeled photosynthate into total sink tissue was a linear function (slope = 0.18) of the net photosynthesis rate of the source leaf regardless of light intensity (2000, 3700, or 7200 foot-candles), O₂ concentration (21% or 1% O₂), or CO₂ concentration (900 microliters/liter of CO₂ to compensation concentration). These data support the theory that the mass transfer rate of translocation under conditions of sufficient sink demand is limited by the net photosynthesis rate or more specifically by sucrose synthesis and this limitation is independent of light intensity per se. The rate of translocation was not saturated even at net photosynthesis rates four times greater than the rate occurring at 300 microliters/liter of CO₂, 21% O₂, and saturating light intensity.     

A horizontal bioreactor for ethanol production by immobilized cells

The one-parameter-tanks-in-series model was found to be an adequate model for the characterization of flow dynamics in a horizontal immobilized cell reactor, when blue dextran was used as tracer. Isobutanol proved to be inadequate, because it diffused inside the beads and thus caused tailing in RTD. The CO₂ evolution rate displayed the most pronounced effect on axial liquid dispersion. At high CO₂ production rates and low dilution rates each stage of the reactor behaved like a well-mixed reactor. At lower CO₂ evolution rates the number of tanks (N) related to the reactor increased up to 10. The medium flow rate affects axial dispersion to a minor degree. An increase of the dilution rate from 0.328 to 1.34 h^?1 resulted in a slight rise of N from 3.5 to 5 at high CO₂ production and from 4 to 7 at medium CO₂ production rates. Variation in the bead hold up showed the same characteristic axial mixing behavior as reflected by changing the medium flow rate. The quantitative correlation between axial mixing and the most significant fermentation parameters (dilution rate, CO₂ evolution rate and bead hold up) allow to develop an overall model, which besides kinetic expressions also contains terms related to the flow dynamics of the reactor. In the third part of this communication such a model will be presented and compared with actual fermentation data.     

The air‐lift photobioreactors with flow patterning for high‐density cultures of microalgae and carbon dioxide removal

A photobioreactor containing microalgae is a highly efficient system for converting carbon dioxide (CO₂) into biomass. Using a microalgal photobioreactor as a CO₂ mitigation system is a practical approach to the problem of CO₂ emission from waste gas. In this study, a marine microalga, Chlorella sp. NCTU‐2, was applied to assess biomass production and CO₂ removal. Three types of photobioreactors were designed and used: (i) without inner column (i.e. a bubble column), (ii) with a centric‐tube column and (iii) with a porous centric‐tube column. The specific growth rates (μ) of the batch cultures in the bubble column, the centric‐tube and the porous centric‐tube photobioreactor were 0.180, 0.226 and 0.252 day^?1, respectively. The porous centric‐tube photobioreactor, operated in semicontinuous culture mode with 10% CO₂ aeration, was evaluated. The results show that the maximum biomass productivity was 0.61 g/L when one fourth of the culture broth was recovered every 2 days. The CO₂ removal efficiency was also determined by measuring the influent and effluent loads at different aeration rates and cell densities of Chlorella sp. NCTU‐2. The results show that the CO₂ removal efficiency was related to biomass concentration and aeration rate. The maximum CO₂ removal efficiency of the Chlorella sp. NCTU‐2 culture was 63% when the biomass was maintained at 5.15 g/L concentration and 0.125 vvm aeration (volume gas per volume broth per min; 10% CO₂ in the aeration gas) in the porous centric‐tube photobioreactor.     

Modeling of carbon dioxide mass transfer behavior in attached cultivation photobioreactor using the analysis of the pH profiles

The CO₂ mass transfer model associated with growth kinetics of microalgal biofilm in attached cultivation photobioreactor was developed and verified by using the analysis of pH profiles which were in equilibrium with inorganic carbon components concentrations (CO₂, H₂CO₃, HCO₃ ⁻ and CO₃ ²⁻) in medium. Model simulation results showed that the model well presented the biofilm growth process. The overall volumetric mass transfer coefficient of CO₂ was more influenced by CO₂ concentration in aerated gas but less by gas aeration rate and medium circulation rate. Other bio-kinetic parameters related with the microalgal biofilm such as CO₂ diffusion coefficient in biofilm, Monod maximum utilization rate of CO₂, lag phase duration of biofilm and half-saturation CO₂ concentration in the biofilm were independent on operational conditions. The pH profiles provided a way to monitor the variations of inorganic carbon concentrations of medium and to regulate the cultivation of attached microalgal biofilm by CO₂ supplement.

     

13CO2 labeling kinetics in maize reveal impaired efficiency of C4 photosynthesis under low irradiance

C₄ photosynthesis allows faster photosynthetic rates and higher water and nitrogen use efficiency than C₃ photosynthesis, but at the cost of lower quantum yield due to the energy requirement of its biochemical carbon concentration mechanism. It has also been suspected that its operation may be impaired in low irradiance. To investigate fluxes under moderate and low irradiance, maize (Zea mays) was grown at 550 µmol photons m⁻² s^−l and ¹³CO₂ pulse-labeling was performed at growth irradiance or several hours after transfer to 160 µmol photons m⁻² s⁻¹. Analysis by liquid chromatography/tandem mass spectrometry or gas chromatography/mass spectrometry provided information about pool size and labeling kinetics for 32 metabolites and allowed estimation of flux at many steps in C₄ photosynthesis. The results highlighted several sources of inefficiency in low light. These included excess flux at phosphoenolpyruvate carboxylase, restriction of decarboxylation by NADP-malic enzyme, and a shift to increased CO₂ incorporation into aspartate, less effective use of metabolite pools to drive intercellular shuttles, and higher relative and absolute rates of photorespiration. The latter provides evidence for a lower bundle sheath CO₂ concentration in low irradiance, implying that operation of the CO₂ concentration mechanism is impaired in this condition. The analyses also revealed rapid exchange of carbon between the Calvin–Benson cycle and the CO₂-concentration shuttle, which allows rapid adjustment of the balance between CO₂ concentration and assimilation, and accumulation of large amounts of photorespiratory intermediates in low light that provides a major carbon reservoir to build up C₄ metabolite pools when irradiance increases.

Analysis of metabolite pools, sizes, and fluxes reveals that multiple interlocking factors decrease the efficiency of photosynthesis in low irradiance in maize.     

Effects of air flow rate, storage temperature, and harvest maturity on respiration and ripening of tomato fruits

The interactive effects of aeration rate, storage temperature, harvest maturity, and storage duration on respiration and ripening of tomato fruits (Lycopersicum esculentum var. Roma) were studied. Slow aeration rate strongly reduced the climacteric but did not affect ripening. Low temperature slowed ripening and reduced respiratory rates, but low temperature did not delay attainment of the climacteric maxima. The effect of air flow rate on the content of CO₂ in the fruits' internal atmospheres was investigated. The possibility that CO₂ is not the primary cause of respiratory inhibition under slow air flow rate is discussed.     

Jet aeration as alternative to overcome mass transfer limitation of stirred bioreactors

In industrial biotechnology increasing reactor volumes have the potential to reduce production costs. Whenever the achievable space time yield is determined by the mass transfer performance of the reactor, energy efficiency plays an important role to meet the requirements regarding low investment and operating costs. Based on theoretical calculations, compared to bubble column, airlift reactor, and aerated stirred tank, the jet loop reactor shows the potential for an enhanced energetic efficiency at high mass transfer rates. Interestingly, its technical application in standard biotechnological production processes has not yet been realized. Compared to a stirred tank reactor powered by Rushton turbines, maximum oxygen transfer rates about 200% higher were achieved in a jet loop reactor at identical power input in a fed batch fermentation process. Moreover, a model‐based analysis of yield coefficients and growth kinetics showed that E. coli can be cultivated in jet loop reactors without significant differences in biomass growth. Based on an aerobic fermentation process, the assessment of energetic oxygen transfer efficiency [kgO₂ kW^?1 h^?1] for a jet loop reactor yielded an improvement of almost 100%. The jet loop reactor could be operated at mass transfer rates 67% higher compared to a stirred tank. Thus, an increase of 40% in maximum space time yield [kg m^?3 h^?1] could be observed.     

Control of Interspecies Electron Flow during Anaerobic Digestion: Role of Floc Formation in Syntrophic Methanogenesis

The flora of an anaerobic whey-processing chemostat was separated by anaerobic sedimentation techniques into a free-living bacterial fraction and a bacterial floc fraction. The floc fraction constituted a major part (i.e., 57% total protein) of the total microbial population in the digestor, and it accounted for 87% of the total CO₂-dependent methanogenic activity and 76% of the total ethanol-consuming acetogenic activity. Lactose was degraded by both cellular fractions, but in the free flora fraction it was associated with higher intermediary levels of H₂, ethanol, butyrate, and propionate production. Electron microscopic analysis of flocs showed bacterial diversity and juxtapositioning of tentative Desulfovibrio and Methanobacterium species without significant microcolony formation. Ethanol, an intermediary product of lactose-hydrolyzing bacteria, was converted to acetate and methane within the flocs by interspecies electron transfer. Ethanol-dependent methane formation was compartmentalized and closely coupled kinetically within the flocs but without significant formation of H₂ gas. Physical disruption of flocs into fragments of 10- to 20-μm diameter initially increased the H₂ partial pressure but did not change the carbon transformation kinetic patterns of ethanol metabolism or demonstrate a significant role for H₂ in CO₂ reduction to methane. The data demonstrate that floc formation in a whey-processing anaerobic digestor functions in juxtapositioning cells for interspecies electron transfer during syntrophic ethanol conversion into acetate and methane but by a mechanism which was independent of the available dissolved H₂ gas pool in the ecosystem.     

Scale-up and application of a cyclone reactor for fermentation processes

A cyclone reactor for microbial fermentation processes was developed with high oxygen transfer capabilities. Three geometrically similar cyclone reactors with 0.5?l, 2.5?l and 15?l liquid volume, respectively, were characterized with respect to oxygen mass transfer, mixing time and residence time distribution. Semi-empirically correlations for prediction of oxygen mass transfer and mixing times were identified for scale-up of cyclone reactors. A volumetric oxygen mass transfer coefficient k _L a of 1.0?s^?1 (available oxygen transfer rate with air: 29?kg?m^?3?h^?1) was achieved with the cyclone reactor at a volumetric power input of 40?kW?m^?3 and an aeration gas flow rate of 0.2?s^?1. Continuous methanol controlled production of formate dehydrogenase (FDH) with Candida boidinii in a 15?l cyclone reactor resulted in more than 100% improvement in dry cell mass concentration (64.5?g?l^?1) and in about 100% improvement in FDH space-time yield (300?U?l^?1?h^?1) compared to steady state results of a continuous stirred tank reactor.     

kLa of stirred tank bioreactors revisited

By means of improved feedback control k_La measurements become possible at a precision and reproducibility that now allow a closer look at the influences of power input and aeration rate on the oxygen mass transfer. These measurements are performed online during running fermentations without a notable impact on the biochemical conversion processes. A closer inspection of the mass transfer during cultivations showed that at least the number of impellers influences mass transfer and mixing: On the laboratory scale, two hollow blade impellers clearly showed a larger k_La than the usually employed three impeller versions when operated at the same agitation power and aeration rate. Hollow blade impellers are preferable under most operational conditions because of their perfect gas handling capacity. Mixing time studies showed that these two impeller systems are also preferable with respect to mixing. Furthermore the widths of the baffle bars depict a significant influence on the k_La. All this clearly supports the fact that it is not only the integral power density that finally determines k_La.     

Studies on the production of lipase from recombinant Staphylococcus carnosus

Summary Production of lipase from recombinant Staphylococcus carnosus pLipPS2 was studied in standard stirred tank bioreactors. Only low lipase activity was obtained under conventional operating conditions, i.e., moderate to high stirring speeds and aeration rates for keeping the dissolved oxygen concentration at high levels. Additional targetted experiments indicated that the reason for the observed low lipase activity is lipase inactivation due to surface forces and shear stress at the gas/liquid interface. Therefore, a cultivation strategy is proposed that minimizes gas/liquid interfacial area and maximizes the driving concentration for O₂ mass transfer by controlling the dissolved oxygen to low values by gentle stirring and low aeration rates. Thus, high lipase activities can be obtained even in larger scale standard stirred tank bioreactors. Offprint requests to: W.-D. Deckwer