Flow characteristics of a pilot-scale airlift fermentor

The effects of aeration on the flow characteristics of water in a glass pilot-scale airlift fermentor have been examined. The 55-L capacity fermentor consisted of a 15.2-cm-i.d. riser column with a 5.1-cm-i.d. downcomer tube. It was found that the average bubble size diminished with increased aeration. Typically, average bubble sizes ranged from 4.32 mm at a superficial gas velocity of 0.64 cm/s to 1.92 mm at 10.3 cm/s. A gas holdup of 0.19 was attained with superficial gas velocities (v_s) on the order of 10 cm/s, indicating the highly gassed nature of the fluid in the riser section of the fermentor. Circulation velocities of markers placed in the fermentor decreased with increasing aeration rates due to increased turbulence and axial liquid back mixing within the riser section. Actual volumetric liquid circulation rates remained relatively constant (0.36–0.49 L/s) for values of (v_s) up to 10 cm/s. Based on theoretical calculations, the ascending velocity of bubbles in a swarm reached 54 cm/s in the range of (v_s) values studied.     

Cultivation of a filamentous mould in an airlift bioreactor

Cephalosporin C biosynthesis was investigated in a pilot-plant external-loop airlift bioreactor for evaluating the capacity of this bioreactor to surpass the problems which arise from the morphology of the mould and the rheology of the broth. Some of the results were compared with those obtained in a stirred tank bioreactor. The dilution and the use of static mixers was necessary to overcome the effects of the high viscosities. The oxygen transfer rate represented 84% of that in the stirred bioreactor, but the efficiency of the power utilization was higher. The specific productivity of Cephalosporin C is comparable to that obtained in the stirred tank bioreactor, but the average specific power consumption was found to be 2/3 of that in the stirred vessel.     

Distributed parameter model of an airlift fermentor

A distributed parameter model for an airlift fermentor is presented. A riser represents the airlift fermentor, with plug flow in both gas and liquid phases, a well-mixed section that acts as gas separator, and a downcomer with plug flow. The set of equations proposed makes possible both the understanding and design of the system. Macroscopic balances shows a behavior that is very close to conventional continuous stirred tank fermentor from the viewpoint of biomass production. In addition, the model predicts concentration profiles of biomass, substrate and oxygen in the liquid, and oxygen in the gas phase. This allows estimation of optimal gas flow rate for sufficient oxygen transfer with minimum energy input.     

Hydrodynamics and mass transfer in an airlift loop fermentor

Summary The hydrodynamics and mass transfer behaviour of an airlift fermentor with an external loop (height 10m) has been investigated by measuring gas and liquid velocities, gas hold-up, liquid mixing and oxygen transfer coefficients. Liquid phase properties, i.e., ionic strength, viscosity and surface tension have been varied by altering the fermentation media. Results are compared with those from bubble column experiments performed in the same unit. It is shown, that more uniform two-phase flow in the airlift leads to advantages in scale-up and operation.Nomenclature a Specific interfacial area per volume of dispersion (m²/m³) - c Local concentration of tracer (kmol/m³) - c Concentration of tracer at infinite time (kmol/m³) - C_L Concentration of oxygen in the liquid bulk (kmol/m³) - C_L ^* Concentration of oxygen in the interface (kmol/m³) - D_ax Axial dispersion coefficient (cm²/s) - I Ionic strength (kmol/m³) - i Inhomogeneity [defined in Eq. (2)] - Rate of oxygen transfer (kmol/s) - t_c Circulation time (s) - t_M Mixing time (s) - V_R Volume of gas-liquid dispersion (m³) - V_SG Superficial gas velocity in up-flow column (m/s) Greek letter symbols _L Oxygen transfer coefficient (m/s) - Dynamic viscosity (m Pa s) - Surface tension (m N/m) Presented at the First European Congress on Biotechnology, Interlaken, September 25–29, 1978     

Development of a new commercial-scale airlift fermentor for rapid growth of yeast

To grow yeast rapidly, it is necessary to supply sufficient oxygen to the yeast and to effectively remove the heat of the fermentation. We succeeded in developing a commercial-scale fermentor for growing a food yeast (Candida utilis) to produce RNA rapidly. This fermentor is an internal-loop airlift type with vertical heat transfer tubes between inner and the outer columns. The volume of the fermentor is 145 m³ (working volume 75 m³). The oxygen transfer rate (OTR) was 9.9 kg-O₂/m³/h using a superficial gas velocity of 30 cm/s based on the outer column. Much of the heat of fermentation and the energy resulting from aeration could be removed effectively by the heat transfer tubes. This unique airlift fermentor was driven at a dilution rate of 0.43 h⁻¹ for about 70 d, with the yeast concentration being maintained at 22.8 kg-dry cell/m³. The yeast production rate was 9.79 kg-dry cell/m³/h. Compared with a traditional stirred-type fermentor, two Vogelbush-type fermentors and another airlift fermentor, our fermentor was far superior with respect to OTR and yeast productivity.     

Oxygen transfer to mycelial fermentation broths in an airlift fermentor

Oxygen transfer rates and gas holdups were measured in mycelial fermentation broths of Chaetomium cellulolyticum and Neurospora sitophila, each cultured in a 1300-L pilot-plant-scale airlift fermentor. These cultures exhibited highly non-Newtonian flow behavior coupled with a substantial decrease in oxygen transfer rates. The volumetric mass transfer coefficients in these cultures were found to be 65-70% lower than those in water. The data were compared with the available correlations obtained for simulated fermentation broths. In general, the data for C. cellulolyticum are in satisfactory agreement with the correlations for the model media but the data for N. sitophila are higher than that predicted by the correlations. Model media based correlations are found to be applicable to the fermentation processes if the culture medium does not possess a high yield stress.     

Mixing time and oxygen transfer characteristics of double draft tube airlift fermentor

Despite the increasing importance of airlift fermentors, very little published information is available on how the geometric configurations of the draft tubes and the air-sparging system affect the mixing and oxygen transfer characteristics of the fermentor. A 14-L air-lift fermentor was designed and build with a fixed liquid height to diameter ratio of 1.5 utilizing four equally spaced air jets at the bottom. Two jet orifice sizes were used, 1.27 and 3.81 mm i.d., and for each jet size the following four geometric configurations were used: Single inner concentric draft tube, single outer concentric draft tube, two concentric draft tubes, and no draft tubes where the fermentor was operated as a shallow bubble column. It was found that the presence of draft tubes stabilized liquid circulation patterns and gave systemically higher mixing times than those obtained in the absence of draft tubes. In addition, the double draft tube geometry resulted in higher mixing times than the single draft tubes. For the power unit volume range 20 to about 250 W/m³ the larger 3.81-mm orifices gave systemically higher k_L a values than the smaller 1.27-mm i.d. orifices. At 200 W/m³ the use of a single outer draft tube with the 3.81-mm orifices resulted in 94% increase in k_L a values over that obtained with no draft tubes. However, the effect of draft tube geometry on k_L a values when the 1.27-mm orifices were used was not significant. The air bubble formation characteristics at the jet orifices were found to be different, which reflected the differences observed in mass transfer and mixing characteristics. The power economy for oxygen transfer was found to be depend strongly on the orifice size and less on the geometric configuration of draft tubes.     

A distributed parameter model for an airlift fermentor. Effects of pressure

A previously presented model for an airlift fermentor is extended by considering the variations of pressure along the tubes. The fluid dynamics of the system is represented with the acid of correlations obtained from experiments. Only oxygen concentrations are considerations are considered. The influences of the various parameters affecting the system are analyzed. The model allows prediction of oxygen concentrations in the different points of an airlift fermentor and calculation of the best values of the gas flow rate.     

Cultivation of Tetrahymena thermophila in a 1.5-m3 airlift bioreactor

A large-scale cultivation system for the mass cell production and extraction of the protozoon Tetrahymena thermophila has been developed on the basis of a low-cost complex nutrient medium. Cell growth and the production of extracellular proteases were investigated using a 15-l stirred-tank reactor and 13-l and 1500-l airlift reactors. Processes using defined and complex medium formulations were compared. After cell mass production by 1200 l cell suspension in the large airlift bioreactor, two different extraction methods, based on the use of an extraction decanter and a sedimentation procedure, were compared and followed by cell lyophilization. Cell sedimentation was shown to be the more efficient extraction method as it enabled cell retention/separation while preserving the cell structure. Maximum cell growth was achieved in the stirred-tank bioreactor, supporting the hypothesis that higher shear forces reduce the particle size of the medium, which is responsible for an optimized nutrient supply. The highest glucose uptake rates were found in defined medium lacking the nutrient particles that are present in complex medium formulations. The cell-specific proteolytic activity in culture supernatants of airlift bioreactors using complex medium conditions was higher than that of a culture broth with cells grown under defined medium formulations. Received: 24 September 1998 / Received revision: 23 November 1998 / Accepted: 29 November 1998     

Bioaugmentation as a tool for improving the start-up and stability of a pilot-scale partial nitrification biofilm airlift reactor

The effectiveness of bioaugmentation in the improvement of the start-up of a biofilm airlift reactor to perform partial nitrification was investigated. Two identical biofilm airlift reactors were inoculated. The non-bioaugmented reactor (NB-reactor) was inoculated with conventional activated sludge, whereas the bioaugmented reactor (B-reactor) was seeded with the same conventional activated sludge but bioaugmented with nitrifying activated sludge from a pilot plant performing full nitritation under stable conditions (100% oxidation of influent ammonium to nitrite). The fraction of specialized nitrifying activated sludge in the inoculum of the B-reactor was only 6% (measured as dry matter). To simplify comparison of the results, operational parameters were equivalent for both reactors. Partial nitrification was achieved significantly faster in the B-reactor, showing a very stable operation. The results obtained by fluorescence in situ hybridization assays showed that the specialized nitrifying biomass added to the B-reactor remained in the biofilm throughout the start-up period.     

Cultivation of microorganisms in an air-solid fluidized bed fermentor with agitators

The productivity of a cell mass of Saccharomyces cerevisiae and enzymes of Eupenicillium javanicum increased by cultivation in anair-solid fluidized bed fermentor with agitators. The usefulness of the apparatus for the fluidized bed culture was verified. The productivity of amyiase and protease of the fungus by fluidized bed culture was twice as high as that by stationary culture, considering the dry weight of cells and the enzyme activity. Physiological properties of yeast cells were changed buy the fluidized bed culture; there was a decrease in the cell size of yeast and the changes to the aerobic properties of the yeast cells resulting from excessive supply of oxygen with a high flowrate of air.     

Cultivation of filamentous fungi in the disc fermenter

Summary A method of growing filamentous fungi in a novel disc fermenter is described. Growth occurs as a layer on the discs and the fermenter design permits aseptic sampling of the attached biomass. Observations concerning oxygen and nutrient exchange between medium and biomass are reported.     

Two-phase airlift fermentor operation with elicitation for the enhanced production of enzophenanthridine alkaloids in cell suspensions of Escherichia californica

Approaches to increasing the productivity of benzophenanthridine alkaloids in suspension cultures in Escherichia californica were made in an airlift fermentor under different culture conditions. Elicitation with yeast extract elicitor reduced the time required to obtain a certain amount of alkaloid production. In a two-phase airlift fermentor with compounded silicone fluid, total alkaloid concentration in silicone fluid was 153.1 mg/L and that in the aqueous cellular phase was 8.2 mg/L at day 21 from inoculation. The large accumulation capacity of silicone fluid made it possible to store correspondingly large amounts of total alkaloid and increased the alkaloid production. Act day 21 from inoculation, the volumetric alkaloid productivity and the netproduction in a two-phase airlift fermentor were 1.4 and 1.5 times higher than those of normal airlift fermentor operation. This performance was furthermore enhanced by elicitation. Elicitation in two-phase airlift fermentor operation increased the volumetric productivity and the new production 3.3- and 3.5-fold compared to those of normal airlift fermentor operation. (c) 1994 John Wiley & Sons, Inc.     

Laboratory glass fermenter on the basis of the airlift principle

A 1.5-1 minifermenter consisting of RASOTHERM glass on the basis of the airlift principle was constructed and tested in the Institute of Biotechnology. The development of this fermenter bridged the gap between shake flasks and lab-scale fermenters and provided a possibility for the continuous cultivation of extremely halophilic bacteria. It was demonstrated that the fermenter can be used for cultivating bacteria that are sensitive to shear stress. It can also be recommended for purposes of cultivation of plant and animal cells because of this advantage and the possibility of this fermenter to be sterilized.     

Cultivation of cell cultures of Berberis wilsonae in 20-l airlift bioreactors

Suspension cultures of Berberis wilsonae produce 4 berberine-type alkaloids: berberine, palmatine, columbamine and jatrorrhizine. In particular the formation of the phenolic alkaloids columbamine and jatrorrhizine and of berberine proves to be dependent on the concentration of dissolved oxygen. With higher aeration rates, berberine and jatrorrhizine yields can be increased considerably. Thus we reached an alkaloid yield of more than 3 g × 1^–1 with 50% dissolved oxygen tension in the medium. As far as we know this is one of the best results in fermenting of alkaloid-producing cell cultures.Abbreviations pO₂ dissolved oxygen concentration in % saturation (using air) - HPLC high-performance liquid chromatography - vvm volume air × volume medium^–1 × minute^–1 - rpm revolutions per minute - IAA indole-3-acetic acid - 2,4-D 2,4-dichlorophenoxy acetic acid     

Cultivation of Bacillus thuringiensis in an airlift reactor with wire mesh draft tubes

An aeration strategy was proposed for foam control in an airlift reactor with double wire mesh draft tubes. The airlift reactor was employed in the cultivation of Bacillus thuringiensis for thuringiensin production. The aeration strategy involved two situations. If the foam rose and touched the foam probe, the air flow rate was dropped to a low value for a certain period. However, if the DO value was already below 10% of the saturation when the air flow rate was dropped, the conventional foam control was employed. The production of thuringiensin based on the proposed strategy was up to 70% higher than that of using the conventional cultivation method with addition of antifoam agents for foam control.     

Ethanol fermentation in a continuous tower fermentor

A mutant of Saccharomyces cerevisiae, which forms large, multicellular flocs in liquid culture, rapidly fermented media containing high concentrations of glucose (100-180 g/L) in a continuous nonaerated tower fermentor at 30 degrees C. The fermentor operated continuously for seven months. Batch and tower fermentor data were fitted to a kinetic model incorporating linear ethanol inhibition and Monod dependence on glucose. Conversion, ethanol yield, and ethanol productivity were related to the apparent fermentation time for initial glucose concentrations of 130 and 180 g/L. Productivities of 8-12 g ethanol/L h were achieved through the yeast bed giving conversions exceeding 90% of the theoretical yield.     

Dynamic reoptimization of a fed-batch fermentor

Traditionally, fed-batch biochemical process optimization and control use complicated models and off-line optimizers with no on-line model adaptation and re-optimization. This work demonstrates the applicability, effectiveness, and economic potential, of a simple phenomenological model for modeling, and a novel optimizer for on-line re-optimization and control of an aerobic fed-batch fermentor.     

Growth of Saccharomycopsis fibuligera in a continuous-stirred-tank fermentor

Growth rates and amylase production rates were determined for the yeast Saccharomycopsis fibuligera grown on a simulated potato processing waste in a continuous-stirred-tank fermentor. S. fibuligera formed large multicellular flocs in the fermentor, and cell growth was reduced at low dilution rates because of mass-transfer resistance. The average Thiele modulus, which is the measure of extent of substrate diffusion, had a value ranging from ?_av = 2.2 for D = 0.10 to 0.3 for D = 0.40. Growth rates were described by the Monod equation modified to include mass-transfer effects. This modified Monod equation was used to predict growth rates from measured floc-size distribution. Experimentally determined growth rates were in close agreement with these predicted values.