Investigation of the structure of two-phase flow fermentation model media in bubble-column bioreactors

Summary Electrical conductivity microprobes have been used to estimate the transverse variation of bubble size, local gas holdup and local specific gas/liquid interfacial area in bench scale bubble column bioreactors containing fermentation model media. Inserted O₂-electrodes and plane parallel windows alter the structure of the two phase flow. Even slight tilting of the column strongly influences the transverse profiles of the bubble size and local gas holdup. The larger bubbles are collected at the wall, where they can be redispersed. These observations open up new possibilities for the construction of bubble column bioreactors.     

Investigation of the structure of two-phase flow model-media in bubble-column bioreactors

Summary By applying photographic, electrical conductivity, and electrooptical methods, the transverse variation of bubble size and velocity, the local gas hold up, and the local specific gas/liquid interfacial area were estimated in a bench scale bubble-column bioreactor containing model cultivation media. The liquid velocity profile, the transverse turbulence intensity variations, and the turbulence energy dissipation scale were also measured by a hot film turbulence probe and constant temperature anemometer technique.A significant relationship was found between the two-phase flow fluid dynamical state and the transverse variation of the various properties.Symbols M mass - L length - T time - a gas/liquid interfacial area L² - specific gas/liquid interfacial area with regard to the bubbling layer volume L^–1 - D transverse coordinate (measured from the wall of the column) L - d bubble diameter L - d mean bubble diameter L - d_e dynamic equilibrium (maximum stable) bubble diameter L - d_p primary bubble diameter L - d_s Sauter bubble diameter L - E specific energy dissipation rate with regard to the volume of the liquid ML^–1T^–3 - EV_L energy dissipation rate ML²T^–3 - , since =1 g/cm³, E has the same numerical value as E. Therefore, the symbol E is used everywhere in the present paper for E for simplicity and called energy dissipation rate (S.s^–2=Stokes.s^–2) L²T^–3 - E_G or local relative gas holdup - f (r) cross correlation function - g acceleration of gravity LT^–2 - h longitudinal distance from the aerator L - relative turbulence intensity - N_O number of u and crossings T^–1 - n_B bubble frequency T^–1 - r distance between two points 1 and 2 of the cross correlation function L - t time - u instantaneous liquid velocity LT^–1 - mean liquid velocity LT^–1 - mean square fluctuation velocity L²T^–2 - turbulence intensity LT^–1 - w_SG superficial gas velocity LT^–1 - w_SL superficial liquid velocity LT^–1 - or E_G local relative gas holdup LT^–1 - energy dissipation scale L - kinematic liquid viscosity L²T^–1 - liquid density M L^–3 - surface tension M T^–2 - dynamic turbulence pressure M L^–1T^–2 Indices p primary (at the aerator) - e equilibrium (far from the aerator)     

Investigation of the structure of two-phase flow model-media in bubble-column bioreactors

Summary By applying photographic, electrical conductivity, and electrooptical methods, the transverse variation of bubble size and velocity, the local gas holdup, and the local specific gas/liquid interfacial area were estimated in a bench scale bubble-column bioreactor containing distilled water. The liquid velocity profile, the transverse turbulence intensity variations, and the turbulence energy dissipation scale were also measured by a hot film turbulence probe and constant temperature anemometer technique.     

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

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

Phenanthrene biodegradation by an algal-bacterial consortium in two-phase partitioning bioreactors

An algal-bacterial consortium formed by Chlorella sorokiniana and a phenanthrene-degrading Pseudomonas migulae strain was able to biodegrade 200-500 mg/l of phenanthrene dissolved in silicone oil or tetradecane under photosynthetic conditions and without any external supply of oxygen. Phenanthrene was only removed when provided in organic solvent, which confirms the potential of two-phase systems for toxicity reduction. Phenanthrene was degraded at highest rates when provided in silicone oil rather than in tetradecane since this solvent probably sequestered the PAH, reducing its mass transfer to the aqueous phase. The influence of phenanthrene concentration, amount of inoculum and light intensity on pollutant removal was also investigated and, under the best conditions, phenanthrene was degraded at 24.2 g m(-3).h(-1). In addition to being cost-effective and mitigating the release of greenhouse gases into the atmosphere, photosynthetic oxygenation was especially beneficial to the use of two-phase partitioning bioreactors since it prevented solvent emulsification and/or volatilization and evidence was found that the microalgae release biosurfactants that could further enhance phenanthrene degradation.     

Milking microalga Dunaliella salina for beta-carotene production in two-phase bioreactors

A new method was developed for production of beta-carotene from Dunaliella salina. Cells were grown in low light intensity and then transferred to a production bioreactor illuminated at a higher light intensity. It was a two-phase bioreactor consisting of an aqueous and a biocompatible organic phase. Mixing of the cells and extraction were performed by recirculation of the organic phase. Two experiments were performed. In the first experiment, bioreactors were operated at two different solvent recirculation rates of 150 and 200 mL min(-1). The beta-carotene extraction rate increased significantly at the higher recirculation rate, without exerting any influence on cell number and viability. A second experiment was carried out at a recirculation rate (200 mL min(-1)) appropriate for the study of long-term production of beta-carotene. The results show that D. salina at high light intensity remained viable for a long period (>47 days) in the presence of a biocompatible organic phase; however, cell growth was very slow. beta-Carotene could be continuously extracted to the organic phase; the cells continued to produce beta-carotene and the extracted molecules were continuously reproduced. As a result, beta-carotene was continuously removed ("milked") from the cells. beta-Carotene extraction efficiency in this system was >55%, and productivity was 2.45 mg m(-2) day(-1), much higher than that of commercial plants.     

Recent advances in two-phase partitioning bioreactors for the treatment of volatile organic compounds

Biological processes are considered to be the most cost-effective technology for the off-gas treatment of volatile organic compounds (VOC) at low concentrations. Two-phase partitioning bioreactors (TPPBs) emerged in the early 1990s as innovative multiphase systems capable of overcoming some of the key limitations of traditional biological technologies such as the low mass transfer rates of hydrophobic VOCs and microbial inhibition at high VOC loading rates. Intensive research carried out in the last 5 years has helped to provide a better understanding of the mass transfer phenomena and VOC uptake mechanisms in TPPBs, which has significantly improved the VOC biodegradation processes utilizing this technology platform. This work presents an updated state-of-the-art review on the advances of TPPB technology for air pollution control. The most recent insights regarding non-aqueous phase (NAP) selection, microbiology, reactor design, mathematical modeling and case studies are critically reviewed and discussed. Finally, the key research issues required to move towards the development of efficient and stable full-scale VOC biodegradation processes in TPPBs are identified.     

Apparent viscosity for non-Newtonian fermentation media in bioreactors

The apparent viscosity of non-Newtonian fermentation media is examined. The present state of this subject is discussed. The energy dissipation rate concept is used for a new evaluation of the apparent viscosity in bioreactors, i.e. stirred tank and bubble column bioreactors. The proposed definition of the apparent viscosity is compared with the definitions available in the literature.List of Symbols A _d m ² downcomer cross-sectional area - A _r m ² riser cross-sectional area - a m^–1 specific surface area - C constant in eq. (13) - D m column diameter - D _I m impeller diameter - g m s^–2 gravitational acceleration - h J m^–2 s^–1 K^–1 heat transfer coefficient - K Pa s ⁿ consistency index in a power-law model - k constant in eq. (3) - k _L m s ^–1 liquid-phase mass transfer coefficient - N s^–1 impeller speed - n flow index in a power-law model - P W power input - Re Reynolds number ND _I ^/2 /(/) - U _sg m s ^–1 superficial gas velocity - (U _sg ) _r m s^–1 superficial gas velocity based on riser - V-m³ liquid volume - v ₀ m s^–1 friction velocity Greek Symbols s^–1 shear rate - _c s^–1 characteristic shear rate - W kg^–1 energy dissipation rate per unit mass - W kg^–1 characteristic energy dissipation rate per unit mass - Pa s viscosity - _app Pa s apparent viscosity - kg m^–3 density - Pa shear stress     

A restructured framework for modeling oxygen transfer in two-phase partitioning bioreactors

This communication proposes a mechanistic modification to a recently published method for analyzing oxygen mass transfer in two-phase partitioning bioreactors (Nielsen et al., 2003), and corrects an oversight in that paper. The newly proposed modification replaces the earlier empirical approach, which treated the two liquid phases as a single, homogeneous liquid phase, with a two-phase mass transfer model of greater fundamental rigor. Additionally, newly developed empirical models are presented that predict the mass transfer coefficient of oxygen absorption in both aqueous medium and an organic phase (n-hexadecane) as a function of bioreactor operating conditions. Experimental values and theoretical predictions of mass transfer coefficients in two-phase dispersions, k(L)a(TP), are compared. The revised approach more clearly demonstrates the potential for oxygen mass transfer enhancement by organic phase addition, one of the motivations for employing a distinct second phase in a partitioning bioreactor.     

Mechanism of extraction of beta-carotene from microalga Dunaliellea salina in two-phase bioreactors

We show that it is possible to extract beta-carotene selectively from Dunaliella salina in two-phase bioreactors. The cells continue to produce beta-carotene and the extracted part is substituted by newly produced molecules. This process is called "milking." We performed several experiments to understand the exact mechanism of the extraction process. The results show that direct contact between the cells and the biocompatible organic solvent was not a requirement for the extraction but it accelerated the extraction. Electron microscopy photographs showed an undulated shape of the cell membrane and a space between the cell and the chloroplast membranes in the cells growing in the presence of dodecane (a biocompatible solvent). Extra-chloroplast beta-carotene globules located in the space between the cell and the chloroplast membranes were observed in these cells as well. It was shown that dodecane was taken up by the cells. The concentration of dodecane in the cells was about 13 pg.cll(-1). It can be concluded that dodecane uptake by the cells is responsible for the morphological changes in the cells and leads to more activity in the cell membrane. The results suggest two possible modes of extraction. One of the mechanisms is transport of the globules from the chloroplast to the space between the cell and the chloroplast membranes and subsequently from there to the outside by exocytosis. Another possible mode for the extraction could be release of beta-carotene from the globules as a result of alterations in the membrane in response to the uptake of dodecane. beta-Carotene molecules diffuse from the chloroplast to the space between the cell and the chloroplast membranes and from there to the medium either by diffusion or by exocytosis after accumulation in the vesicles.     

A novel method of simulating oxygen mass transfer in two-phase partitioning bioreactors

An empirical correlation, based on conventional forms, has been developed to represent the oxygen mass transfer coefficient as a function of operating conditions and organic fraction in two-phase, aqueous-organic dispersions. Such dispersions are characteristic of two-phase partitioning bioreactors, which have found increasing application for the biodegradation of toxic substrates. In this work, a critical distinction is made between the oxygen mass transfer coefficient, k(L)a, and the oxygen mass transfer rate. With an increasing organic fraction, the mass transfer coefficient decreases, whereas the oxygen transfer rate is predicted to increase to an optimal value. Use of the correlation assumes that the two-phase dispersion behaves as a single homogeneous phase with physical properties equivalent to the weighted volume-averaged values of the phases. The addition of a second, immiscible liquid phase with a high solubility of oxygen to an aqueous medium increases the oxygen solubility of the system. It is the increase in oxygen solubility that provides the potential for oxygen mass transfer rate enhancement. For the case studied in which n-hexadecane is selected as the second liquid phase, additions of up to 33% organic volume lead to significant increases in oxygen mass transfer rate, with an optimal increase of 58.5% predicted using a 27% organic phase volume. For this system, the predicted oxygen mass transfer enhancements due to organic-phase addition are found to be insensitive to the other operating variables, suggesting that organic-phase addition is always a viable option for oxygen mass transfer rate enhancement.     

Biodegradation of PCBs in two-phase partitioning bioreactors following solid extraction from soil

This article demonstrates the feasibility of a novel process concept for the remediation of PCB contaminated soil. The proposed process consists of PCB extraction from soil using solid polymer beads, followed by biodegradation of the extracted PCBs in a solid-liquid two-phase partitioning bioreactor (TPPB), where PCBs are delivered from the polymer beads to the degrading organisms. The commercially available thermoplastic polymer Hytrel was used to extract Aroclor 1242 from contaminated artificial soil in bench scale experiments. Initial PCB contamination levels of 100 and 1,000 mg kg(-1) could be reduced to 32% +/- 1 to 41% +/- 7 of the initial value after 48 h mixing in the presence of a mobilizing agent at polymer-to-soil ratios of 1% (w/w) and 10% (w/w). The decrease of detectable PCBs in the soil was consistent with an increase of PCBs in the polymer beads. It was further shown that Aroclor 1242 could be delivered to the PCB degrading organism Burkholderia xenovorans LB400 in a solid-liquid TPPB via Hytrel beads. A total of 70 mg Aroclor 1242 could be degraded in a 1 L solid-liquid TPPB within 80 h of operation.     

Foaming and media surfactant effects on the cultivation of animal cells in stirred and sparged bioreactors.

Foam formation and the subsequent cell damage/losses in the foam layer were found to be the major problems affecting cell growth and monoclonal antibody (MAb) production in stirred and sparged bioreactors for both serum-supplemented and serum-free media. Surfactants in the culture media had a profound effect on cell growth by changing both the properties of bubbles and the qualities of foam formed. Comparable cell growth and MAb production in sparged bioreactors and in stirred and surface-aerated control cultures were observed only in Pluronic F-68 containing culture media. In media devoid of Pluronic F-68, cells became more sensitive to direct bubble aeration in the presence of antifoam agent which was used to suppress foam formation. Compared with serum-supplemented medium, more severe cell damage effects were observed in serum-free medium. In addition, serum-free medium devoid of cells was partially degraded under continuous air sparging. The mechanism of this damage effect was not clear. Pluronic F-68 provided protective effect to cells but not to the medium. A theoretical model based on the surface active properties of Pluronic F-68 was proposed to account for its protective effect on cell growth. Optimum media surfactant composition in terms of maximum cell growth and minimum foam formation was proposed for stirred and sparged animal cell bioreactor.     

Transient performance of two-phase partitioning bioreactors treating a toluene contaminated gas stream

Two-phase partitioning bioreactors (TPPBs) consist of a cell-containing aqueous phase and an immiscible organic phase that sequesters and delivers toxic substrates to cells based on equilibrium partitioning. The immiscible organic phase, which acts as a buffer for inhibitory substrate loadings, makes it possible for TPPBs to handle high volatile organic compound (VOC) loadings, and in this study the performance of liquid n-hexadecane and solid styrene butadiene (SB) polymer beads used as partitioning phases were compared to a single aqueous phase system while treating transient loadings of a toluene contaminated air stream by Achromobacter xylosoxidans Y234. The TPPBs operated as well-mixed stirred tanks, with total working volumes of 3 L (3 L aqueous for the single-phase system, 2 L aqueous and 1 L n-hexadecane for the solvent system, and 2.518 L aqueous volume and 500 g of SB beads for the polymer system). Two 60-min step changes (7 and 17 times the nominal loading rates, termed "small" and "large" steps, respectively) were imposed on the systems and the performance was characterized by the overall removal efficiencies, instantaneous removal efficiency recovery times (above 95% removal), and dissolved oxygen recovery times. For the small steps, with a nominal loading of 343 g/m3/h increasing to 2,400 g/m3/h, the TPPB system using n-hexadecane as the second phase performed best, removing 97% of the toluene fed to the system compared with 90% for the polymer beads system and only 69% for the single-phase system. The imposed large transient gave similar results, although the impact of the presence of a second sequestering phase was more pronounced, with the n-hexadecane system maintaining much reduced aqueous toluene concentrations leading to significantly improved performance. This investigation also showed that the presence of both n-hexadecane and SB beads improved the oxygen transfer within the systems.     

Substrate mass transport in two-phase partitioning bioreactors employing liquid and solid non-aqueous phases

The mass transfer of phenol and butyl acetate to/from water was studied in two-phase partitioning bioreactors using immiscible organic solvents and solid polymer beads as the partitioning phases in a 5-L stirred tank bioreactor. Virtually instantaneous mass transfer was observed with phenol in water/2-undecanone, and with butyl acetate in water/silicone oil systems. The mass transfer of butyl acetate to silicone oil was rapid irrespective of the viscosity of the partitioning phase. When Hytrel(?) polymer beads were employed as the partitioning phase, substrate transport to the polymer was found not to be externally mass transfer limited, but rather internally by substrate diffusion into the polymer. In contrast to gaseous, poorly soluble substrates studied in other works, mass transfer of soluble substrates such as phenol and butyl acetate to the polymer was unaffected by impeller speed but rather by polymer mass fraction.     

Biodegradation of phenol at high initial concentrations in two-phase partitioning batch and fed-batch bioreactors

A two-phase organic-aqueous system was used to degrade phenol in both batch and fed-batch culture. The solvent, which contained the phenol and partitioned it into the aqueous phase, was systematically selected based on volatility, solubility in the aqueous phase, partition coefficient for phenol, biocompatibility, and cost. The two-phase partitioning bioreactor used 500 mL of 2-undecanone loaded with high concentrations of phenol to deliver the xenobiotic to Pseudomonas putida ATCC 11172 in the 1-L aqueous phase, at subinhibitory levels. The initial concentrations of phenol selected for the aqueous phase were predicted using the experimentally determined partition coefficient for this ternary system of 47.6. This system was initially observed to degrade 4 g of phenol in just over 48 h in batch culture. Further loading of the organic phase in subsequent experiments demonstrated that the system was capable of degrading 10 g of phenol to completion in approximately 72 h. The higher levels of phenol in the system caused a modest increase in the duration of the lag phase, but did not lead to complete inhibition or cell death. The use of a fed-batch approach allowed the system to ultimately consume 28 g of phenol in approximately 165 h, without experiencing substrate toxicity. In this system, phenol delivery to the aqueous phase is demand based, and is directly related to the metabolic activity of the cells. This system permits high loading of phenol without the corresponding substrate inhibition commonly seen in conventional bioreactors. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 55: 155-162, 1997.     

Investigation of the structure and proteolytic activity of papain in aqueous miscible organic media

The stability of papain was studied in aqueous-organic mixtures by means of residual proteolytic activity along with various spectroscopic analyses (fluorescence and ATR-FTIR combined with isotopic exchange with D₂O). The investigated systems contained 1 or 10% (v/v) of an aqueous buffered solution (pH 8.0) in acetonitrile (ACN), methanol (MeOH) or dimethyl formamide (DMF). The results evidenced that papain retained almost all its catalytic activity after 24 h of incubation in the presence of ACN, and a more compact conformation of the enzyme was detected. Papain suffered an important loss of enzymatic activity (ca. 80%) after 24 h incubation in MeOH although, no global conformational change and minor secondary structure rearrangements were detected. This observation suggests that somehow the active site region was altered. On the other hand, papain suffered a complete inactivation when exposed to those media containing DMF. Fluorescence analyses revealed that an irreversible conformational change took place after 24 h incubation, and a moderate increase in β-sheet and β-turn structures was the most relevant finding when secondary structure was analyzed. The evidences demonstrated that the organic solvents induce a more rigid and compact structure of papain regardless of the organic:buffer ratio investigated. In turn, these modifications affect the active catalytic site in the particular case of MeOH and DMF. These findings were in agreement with the thermo-stability of the enzyme performed after heating at 353 K in all the studied media, that is the presence of ACN did not substantially affect the secondary structure of papain. Nevertheless, the α-helix domain demonstrated to be less thermally stable than the β-sheet domain, turning into aggregated structures after heating, especially in the presence of MeOH and DMF.     

Large-scale production of monoclonal antibodies in defined serum-free media in airlift bioreactors

Forty- and ninety-liter airlift bioreactors have been used successfully to grow hybridoma cell lines in chemically defined serum-free media. In the airlift bioreactor, hybridoma cell growth and monoclonal antibody productivity are comparable to that obtained by conventional cell culture. At sparging rates of 0.60-1.20 vvh (volume of sparged gas per bioreactor volume per hour), the airlift bioreactor achieves rapid mixing and adequate oxygen mass transfer. Foaming is minimal and inconsequential for serum-free media and media supplemented with 5%-10% fetal bovine serum. The use of serum-free medium facilitates monoclonal antibody purification and enhances the purity of the final MAb product.     

Methanogenic population structure in a variety of anaerobic bioreactors

The methanogenic community structures of six anaerobic sludges were examined using culture-independent techniques. The sludges were obtained from full-scale and laboratory-scale bioreactors, treating a variety of low- and high-strength, simple and complex wastewaters at psychrophilic (10-14 degrees C), mesophilic (37 degrees C) and thermophilic (55 degrees C) temperatures. Amplified rDNA restriction analysis identified 18 methanogenic operational taxonomic units in the six samples. 16S rRNA gene sequencing and phylogenetic reconstruction demonstrated that five separate groups of methanogens were represented with Methanosaeta-like species dominant in all sludges, but particularly in samples from a psychrophilic bioreactor treating low-strength synthetic sewage (75% of all clones detected).