Whole cell biocatalyst for biodiesel fuel production utilizing Rhizopus oryzae cells immobilized within biomass support particles

As part of a research program aimed at producing biodiesel fuel from plant oils enzymatically cells of Rhizopus oryzae (R. oryzae) IFO4697 (with a 1,3-positional specificity lipase) immobilized within biomass support particles (BSPs) were investigated for the methanolysis of soybean oil. The R. oryzae cells easily became immobilized within the BSPs during batch operation. To enhance the methanolysis activity of the immobilized cells under the culture conditions used, various substrate-related compounds were added to the culture medium. Among the compounds tested, olive oil or oleic acid was significantly effective. In contrast, no glucose was necessary. Immobilized cells were treated with several organic solvents, but none gave higher activity than untreated cells. When methanolysis was carried out with stepwise additions of methanol using BSP-immobilized cells, in the presence of 15% water the methyl esters (MEs) content in the reaction mixture reached 90% - the same level as that using the extracellular lipase. The process presented here, using a whole cell biocatalyst, is considered to be promising for biodiesel fuel production in industrial applications.     

The production of cellulase in a spouted bed fermentor using cells immobilized in biomass support particles

Continuous cellulase production by Trichoderma viride QM 9123, immobilized in 6 mm diameter, spherical, stainless steel biomass support particles, has been achieved using a medium containing glucose as the main carbon source. Experiments were carried out in a 10-L spouted bed fermentor. In this type of reactor-recycled broth is used to create a jet at the base of a bed of particles, causing the particles to spout and circulate. During the circulation, particles pass through a region of high shear near the jet inlet. This effectively prevents a buildup of excess biomass and thus enables steady-state conditions to be achieved during continuous operation. Continuous production of cellulase was achieved at significantly higher yield and productivity than in conventional systems. At a dilution rate of 0.15 h(-1) (nominal washout rate for freely suspended cells is 0.012 h(-1)), the yield of cellulase on glucose was 31% higher than that measured during batch operation, while the volumetric productivity (31.5 FPA U/L. h) was 53% greater than in the batch system. The specific cellulase productivity of the immobilized cells was more than 3 times that of freely suspended cells, showing that diffusional limitations can be beneficial. This offers significant opportunity for the further development of biomass support particles and associated bioreactors.     

Culture conditions for intracellular lipase production by Rhizopus chinensis and its immobilization within biomass support particles

Acetone-dried cells of Rhizopus chinensis (with a 1,3-positional specificity lipase) were investigated for the interestierification reaction of olive oil and methyl stearate. First, the culture conditions for intracellular lipase production were examined, and then the activities of dried cells obtained from immobilization in Biomass Support Particles (BSPs) were compared with those of freely suspended cells.It was clear from cultivation of freely suspended cells that intracellular lipase activity for the interesterification reaction was enhanced sifnificantly by the presence of oleic acid, oil, and tea oil, but that the presence of glucose reduced the activity.The specific activity of dried cells within BSPs increased 7-fold compared with that obrained from freely suspended cells.The process presented here, using immobilization within BSPs, can provide cells directly as a catalyst with high activity, where cells become immobilized simply during batch operation, and no special preparation of cells is necessary. Therefore, the reaction system using dried cells immobilized within BSPs is a promising interesterifcation process for industrial applications.     

Long-term cultivation of anchorage-independent animal cells immobilized within reticulated biomass support particles in a circulating bed fermentor

Summary Long-term cultivation of anchorage-independent animal cells immobilized within porous biomass support particles (BSPs) using a gas-stirred circulating bed fermentor (CBF) was investigated. Inoculation of mouse myeloma MPC-11 (ATCC CCL 167) cells into reticulated polyvinyl formal resin BSPs (3 × 3 × 3 mm; mean pore diameter, 60 m; porosity, 0.88) and the repeated batch culture of inoculated cells were performed under gentle circulation of BSPs, induced by sparging air from the base of the fermentor. The glucose uptake rate of cells decreased in the initial period just after the start of circulation, since a relatively large number of cells leaked from the BSPs. After that period, the uptake rate gradually increased and the leakage of cells diminished. In the meantime, when inoculated cells were incubated statically by introducing air into the upper part of the fermentor for the initial several days before circulating the BSPs, glucose consumption became very rapid and cell density in the BSPs reached at least 10⁷ cells/cm³ BSP. Thus, a long-term cultivation without significant leakage of cells and with high cell density in BSPs was successfully achieved in the CBF-BSP system.Offprint requests to: H. Yamaji     

Nonisothermal immobilized enzyme reaction in a packed-bed reactor

Summary This work investigates the reaction behavior of immobilized enzymes in a packed-bed reactor. The effect of heat generation due to exothermic enzyme reaction is considered. Conservations of substrate and energy constitute two coupled nonlinear partial differential equations which are simultaneously solved by a numerical method. It is found that substrate conversion is generally increased at higher temperature. However, the extent of temperature heavily depends on the magnitude of the dimensionless Michaelis constant which is defined as the ratio of Michaelis constant to inlet substrate concentration. At low dimensionless Michaelis constant, substrate conversion is considerably affected by temperature, but at high dimensionless Michaelis constant, the temperature effect is negligibly small. It is also found that maximum bulk temperature of reaction mixtures occurs around a dimensionless reactor length of 1.3 for the case with high substrate conversion.     

Sucrose biotransformation by immobilized Phaffia rhodozyma and continuous neokestose production in a packed-bed reactor

The effects of important production variables on the biotransformation of sucrose by immobilized cells of Phaffia rhodozyma were investigated. Cell concentration had negative effect on the maximum concentration of neokestose and the optimal concentration was 16?g/l (calculated by dry weight). The concentration of sucrose had a positive effect on the maximum concentration of neokestose within 1.170?mol/l. Elevating the reaction temperature increased the reaction rate but decreased the maximum concentration of neokestose. Sugar cane juice could be used as an inexpensive substrate for neokestose production. Additionally, a 30-d continuous neokestose production was found feasible in a packed bed reactor, indicating that the cell immobilization with chitosan-coated alginate has the potential for industrial production.     

Practical reactor systems for yeast cell immobilization using biomass support particles

The technique of cell immobilization using porous support particles (biomass support particles) has been successfully applied to yeast cells. Two reactor configurations exploiting the use of these particles have been developed and assessed for use in aseptic yeast fermentations. A liquid-fluidized bed fermenter has been devised for use with particles denser than the fermentation liquor whilst a gas-stirred circulating bed fermenter proved suitable for particles of essentially neutral buoyancy. Both systems have been operated successfully for extended periods of continuous operation. The utilization of biomass support particle technology in such reactors provides a practical and robust system for immobilized cell reactors. This technology offers significant opportunities for further development.     

Growth kinetics of animal cells immobilized within porous support particles in a perfusion culture

The growth kinetics of anchorage-independent animal cells [mouse myeloma MPC-11 (ATCC CCL 167) immobilized within porous polyvinyl formal resin biomass support particles (BSPs; 3 × 3 × 3 mm cubes; mean pore diameter, 60 µm) was analyzed by measuring intracellular and extracellular lactate dehydrogenase (LDH) activities in a perfusion culture. First, the intracellular LDH content of cells immobilized within the BSPs was assayed in a shake-flask culture and found to remain almost comparable to that of non-immobilized cells in the exponential growth phase under static culture. Then, cells inoculated in the BSPs were grown in a continuous stirred-tank bioreactor. Using the LDH content of non-immobilized cells, the density of immobilized cells and the numbers of leaked and dead cells were evaluated, respectively, by the intracellular LDH activity of immobilized and leaked cells and the LDH activity in cell-free culture supernatant. In the initial period, immobilized cells exhibited exponential growth at a constant apparent specific growth rate; however, the acutal specific growth rate, which takes into consideration cell death and cell leakage, decreased significantly. In the stationary phase, the actual specific growth rate maintained a constant but markedly lower value than during exponential growth.     

Urocanic acid production using whole cells immobilized in a hollow fiber reactor

The feasibility of using hollow fiber membrane dialyzers (C-DAK) for immobilization of microbial whole cells was investigated. The cells are located on the shell side of the dialyzer, while substrates and products are free to diffuse across the hollow fiber membranes. The biochemical reaction studied was the conversion of L -histidine to urocanic acid and catalyzed by L -histidine ammonia-lyase. C-DAK dialyzers containing a heat-treated suspension of Pseudomonas fluorescens ATCC 11299b (with L -histidine ammonia–lyase activity) were incorporated into constant volume recycle reactor systems for continuous product formation. A simple model successfully correlated the data and predicted performance. It was found that the reaction was not likely to be diffusion limited, and such a cell immobilization scheme is convenient and workable for continuous production of biochemicals.     

Biodiesel synthesis in a solvent-free system by recombinant Rhizopus oryzae: comparative study between a stirred tank and a packed-bed batch reactor

A simultaneous synthesis of biodiesel, as fatty acid methyl esters, and monoacylglycerols catalysed by the recombinant Rhizopus oryzae lipase immobilized by adsorption on Relizyme OD/403M is presented. The use of this 1(3)-positional specific lipase prevents the formation of glycerol as a by-product, thus avoiding its drawbacks. The synthesis was carried out in a solvent-free system and it has been studied in two different reactor systems: stirred tank and packed-bed reactor. Stirred tank reactor presented a high-initial reaction rate and achieved a 33.6% yield, which corresponds to a value of 50.4% of the maximum yield that can be achieved with a 1(3)-positional specific lipase. In packed-bed reactor there was a smaller initial reaction rate, but it was achieved a 49.1% yield, which corresponds to a 73.6% of the maximum yield. When a second batch is performed, the yield decreased only 4% when packed-bed reactor is employed whereas a drastic decrease is observed in a stirred tank operation. Therefore, packed-bed reactor showed a best performance and minor damage to the biocatalyst.     

Continuous interesterification of oils and fats using dried fungus immobilized in biomass support particles

The industrial feasibility of an interesterification process using acetone-dried fungus (as a lipase catalyst) immobilized in biomass support particles (BSPs) was examined by continuous interesterification between olive oil and methyl stearate, where the water content of the reaction mixture (C_w) was controlled at a given value. The C_w affected not only the inactivation rate of lipase in the cells but also the production rate of the by-product (diglycerides). The optimal C_w was determined as about 100 ppm. The half-life of lipase in the cells was about 1200 h at the optimal C_w, suggesting that the interesterification process using the immobilized fungus is industrially feasible.     

Continuous production of monoacylglycerols from palm olein in packed-bed reactor with immobilized lipase PS

A packed-bed reactor (PBR) system using immobilized lipase PS as biocatalyst was developed for continuous monoacylglycerols (MAG) production. The condition for continuous MAG production using immobilized lipase PS (IM-PS) of 1.5 g (550 U) in PBR (0.68 cm i.d., 25 cm long) was optimized. The effect of molar ratio of glycerol to palm olein, water content in glycerol and residence time on MAG production was investigated. The optimal glycerol to palm olein molar ratio and water content in glycerol were 12:1 and 10% (w/w), respectively. The yield of MAG increased with increasing residence time. At a residence time of 7.5 h gave the highest yield of MAG of 60%. The long-term operation gave the highest yield of MAG 61.5% at 24 h of the operation time with the productivity of 1.61 g MAG/day. A half-life of the long-term process was 35 days of the operation time with the productivity of 0.81 g MAG/day. Furthermore, the large scale of MAG production was performed continuously with IM-PS of 15 g (5500 U) in PBR (1.5 cm i.d., 50 cm long). The highest yield of MAG in large-scale operation of 70.1% and the 11-fold increasing in productivity of 18.3 g MAG/day were obtained at 24 h of the operation time.     

Characteristics of immobilized Rhizopus oryzae in polyurethane foam cubes

Summary Rhizopus oryzae was immobilized in polyurethane foam cubes. The effects of the cube size on cell immobilization, cell growth and L(+)-lactic acid production were studied. By the natural attachment method, R. oryzae could be easily immobilized in the polyurethane foam cubes larger than 2.5 × 5 × 5 mm³. The use of small cubes for R. oryzae immobilization was very effective to increase the productivity of L(+)-lactic acid by the immobilized cells. Although it was difficult for smaller cubes to be completely full of the mycelia, increasing the inoculum size in immobilizations was effective to increase the immobilization ratio (a ratio of the number of the cubes containing cells to the total number of cubes).     

Continuous production of L-phenylalanine by Rhodotorula glutinis immobilized cells using a column reactor

Studies have been conducted on L-phenylalanine (L-Phe) production and phenylalanine ammonia lyase (PAL) stabilization in the presence of several optimum effectors and reducing agents under bioconversion of transcinnamic acid (t-CA) conditions during repeated batch operations. L-Phe production was maximized and reuseability of PAL catalyst was extended to eight consecutive cycles (repeated batches) in the presence of optimum effectors (glutamic acid, polyethylene glycol and glycerol), thioglycolic acid and sparging with nitrogen gas. These best optimum bioconversion conditions desensitize the PAL catalyst to substantially elevated higher substrate t-CA concentrations and inhibit inactivation of PAL enzyme over longer reaction periods compared to the control. The fed batch mode operation of bioconversion of total t-CA (300 mM) to L-Phe was superior (65.2%, conversion), comparing with conventional batch and repeated batch (58.4%, conversion) operations after 120 h. Gamma irradiation process was employed to polymerize and crosslink polyvinyl alcohol (PVA) with N,N'-methylene-bisacrylamide (BIS) agent. The use of immobilized PAL biocatalyst containing cells in PVA-BIS copolymer gel carrier produced by radiation polymerization is obviously advantageous with regards to the yield of L-Phe which was increased in average 1.2-fold when compare to those obtained with free cells during optimum bioconversion process. When comparing the magnitudes of gamma irradiation effects on immobilized entrapped yeast cells in PVA-BIS copolymer gel carrier using scanning electron microscopy it was show that yeast cells were protected and capable to overcome these conditions and had normal shape and other features as free (unirradiated) intact yeast cells. Optimum conditions for continuous production of L-Phe by PVA-BIS copolymer carrier entrapped yeast cells in a packed bed column reactor in recycle fed-batch mode were investigated. Under these optimum conditions L-Phe accumulated to concentration 240.1 mM represts a total conversion yield of 80% (w/w) from (300 mM) t-CA after 84 h of reaction process, which was higher than that obtained after 120 h of reaction, 65.2% (w/w) from (300 mM) t-CA with free cells in fed-batch mode. The results also demonstrated that during about 4 weeks of repeated continuous recycle fed batch mode experiments (using immobilized cells in packed bed reactor), the final production of L-Phe concentrations decreased gradually in eight consecutive runs with no sign of breakage or disintegration of the carrier gel beads.     

Continuous production of ellagic acid in a packed-bed reactor

Ellagic acid is a high-value bioactive compound that is used in the food, cosmetic and pharmaceutical industries. The aim of this work was to develop a continuous system for ellagic acid production. Ellagitannase produced by solid-state fermentation and attached to polyurethane foam particles was used as a biocatalyst in a continuous bioreactor for the hydrolysis of ellagitannins from pomegranate by-product. A packed-bed reactor containing the biocatalyst (22.22 Units per gram of dry solid, U gds⁻¹) was fed with a pomegranate ellagitannins solution (0.1%, w/v) at a flow rate of 0.27 mL min⁻¹ at 60 °C. The bioreactor completed several biotransformations while maintaining the hydrolysis rate (60%) with a half-life of 10 continuous cycles of ellagic acid production. Volumetric productivity and ellagic acid yield were 1.09 g L⁻¹ h⁻¹ and 235.89 mg g⁻¹ of pomegranate ellagitannins during the first 70 min of hydrolysis, respectively. The developed biocatalyst showed good operational and mechanical stability and may be successfully used for ellagitannin hydrolysis in a continuous system. This is the first report of high-yield continuous production of ellagic acid using an auto-immobilized enzyme.     

Preparation of immobilized whole cell biocatalyst and biodiesel production using a packed-bed bioreactor

Rhizopus oryzae NBRC 4697 was selected from among promising candidates as a biocatalyst for biodiesel production. This microorganism was immobilized on to polyurethane foam coated with activated carbon for reuse, and, for biodiesel production. Vacuum drying of the immobilized cells was found to be more efficient than natural or freeze-drying processes. Although the immobilized cells were severely inhibited by a molar ratio of methanol to soybean oil in excess of 2.0, stepwise methanol addition (3 aliquots at 24-h feeding intervals) significantly prevented methanol inhibition. A packed-bed bioreactor (PBB) containing the immobilized whole cell biocatalyst was then operated under circulating batch mode. Stepwise methanol feeding was used to mitigate methanol inhibition of the immobilized cells in the PBB. An increase in the feeding rate (circulating rate) of the reaction mixture barely affected biodiesel production, while an increase in the packing volume of the immobilized cells enhanced biodiesel production noticeably. Finally, repeated circulating batch operation of the PBB was carried out for five consecutive rounds without a noticeable decrease in the performance of the PBB for the three rounds.     

Wax ester synthesis by lipase-catalyzed esterification with fungal cells immobilized on cellulose biomass support particles

Esterification reactions between long-chain alcohol and oleic acid were performed for producing wax esters. The reaction can be catalyzed efficiently by cell-bound lipase of Rhizopus niveous fungal cells immobilized within cellulose biomass support particles. Carrying out the reaction in a solvent-free system is feasible by adding a molecular sieve for dehydration purposes. To optimize the yield, addition of a molecular sieve should be performed gradually during the whole course starting from the beginning of the reaction. The influence of reaction conditions such as temperature and substrate concentrations on reaction rates and yields were investigated; however, this reaction system is under the influence of both internal and external mass transfer resistance. Conducting the reaction in an organic solvent system with hexane or heptane as the solvent can eliminate diffusional effects. Reaction kinetics were subjected to detailed study in this system. The kinetics of the reaction can be represented satisfactorily by a Ping-Pong Bi Bi mechanism with deadend inhibition by alcohol.     

Denaturable immobilized enzymatic reaction in a packed-bed reactor with and without substrate inhibitions

Summary An immobilized enzymatic reaction in a packed-bed reactor is investigated in this paper. The thermal denaturation of immobilized enzyme caused by excessive reacting temperature rise is considered. An unsteady state dispersion model is employed to examine the dynamic behaviors of the substrate concentration, temperature and enzyme activity along the reactor. Also included in the present paper is the effect of substrate inhibition which occurs rather frequently in many enzymatic reactions. Comparison of results of the immobilized enzymatic reactions with and without substrate inhibitions are made to show the extent the substrate inhibition affects the enzymatic reaction. Furthermore, the effects of heat reaction and the Peclet number which characterize the reaction and flow behaviors, respectively, on the system considered are analyzed in detail.     

A novel multi-stage preculture strategy of Rhizopus oryzae ME-F12 for fumaric acid production in a stirred-tank reactor

This study has developed a novel multi-stage preculture strategy to control the morphology of filamentous Rhizopus oryzae in a 3.3-l stirred-tank reactor (STR), consequently enhancing the fumaric acid production. Using multi-stage precultures as inoculum, the morphology of R. oryzae was maintained as large clumps, small fluffy pellets, and entangled filaments. The highest fumaric acid production of 42.5 g/l with a yield of 55.6% was obtained in association with the small fluffy pellets which were formed in the third preculture at pH 3.0. The results indicated that the use of the multi-stage precultures as inoculum in the STR is a promising approach for commercial production of fumaric acid.     

Anaerobic biodegradation of a petrochemical waste-water using biomass support particles

During the anaerobic biodegradation of effluent from a dimethyl terephthalate (DMT) manufacturing plant, reduction in chemical oxygen demand (COD) degradation and biogas formation was observed after the waste-water concentration exceeded 25% of added feed COD. This condition reverted back to normal after 25–30 days when the DMT waste-water concentration in the feed was brought down to a non-toxic level. However, the above effects were observed only after the concentration of DMT waste-water reached more than 75% of added feed COD when biomass support particles (BSP) were augmented to the system. In the BSP system, a biomass concentration of up to 7000 mg/l was retained and the sludge retention time increased to > 200 days compared to 2200 mg/l and 8–10 days, respectively, in the system without BSP (control). Formaldehyde in the waste-water was found to be responsible for the observed toxicity. The BSP system was found to resist formaldehyde toxicity of up to 375 mg/l as against 125 mg/l in the control system. Moreover, the BSP system recovered from the toxicity much faster (15 days) than the control (25–30 days). The advantages of the BSP system in anaerobic treatment of DMT waste-water are discussed. Correspondence to: C. Ramakrishna