Continuous propionate production from whey permeate using a novel fibrous bed bioreactor

Continuous production of propionate from whey lactose by Propionibacterium acidipropionici immobilized in a novel fibrous bed bioreactor was studied. In conventional batch propionic acid fermentation, whey permeate without nutrient supplementation was unable to support cell growth and failed to give satisfactory fermentation results for over 7 days. However, with the fibrous bed bioreactor, a high fermentation rate and high conversion were obtained with plain whey permeate and de-lactose whey permeate. About 2% (wt/vol) propionic acid was obtained from a 4.2% lactose feed at a retention time of 35 to 45 h. The propionic acid yield was approximately 46% (wt/vol) from lactose. The optimal pH for fementation was 6.5, and lower fermentation rates and yields were obtained at lower pH values. The optimal temperature was 30 degrees C, but the temperature effect was not dramatic in the range of 25 to 35 degrees C. Addition of yeast extract and trypticase to whey permeate hastened reactor startup and increased the fermentation rate and product yields, but the addition was not required for long-term reactor performance. The improved fermentation results with the immobilized cell bioreactor can be attributed to the high cell density, approximately 50 g/L, attained in the bioreactor, Cells were immobilized by loose attachement to fiber surfaces and entrapment in the void spaces within the fibrous matrix, thus allowing constant renewal of cells. Consequently, this bioreactor was able to operate continuously for 6 months without encountering any clogging, degeneration, or contamination problems. Compared to conventional batch fermentors, the new bioreactor offers many advantages for industrial fermentation, including a more than 10-fold increase in productivity, acceptance of low-nutrient feedstocks such as whey permeate, and resistance to contamination. (c) 1994 John Wiley & Sons, Inc.     

Performance of cell immobilized packed bed bioreactor for continuous fermentation of alcohol

Experiments were conducted in a packed bed bio-reactor consisting of entrapped yeast cells in alginate matrix for continuous production of alcohol. The variables include initial substrate level, reactor diameter, diameter of the bead and residence time. The influence of these parameters on the conversion of substrate was studied. The film and pore diffusional effects were observed by varying the column and bead diameters, respectively. The pseudo first order reaction rate constant was calculated and correlated with the bead diameter. The effectiveness factor and the Thiele modulus were estimated. A correlation was proposed for fractional conversion in terms of operating variables. It is possible to predict the residence time required and volumetric productivity achieved in a bioreactor for any given initial substrate concentration at any fractional conversion obtained.List of Symbols a _m m²/kg surface are per unit mass of catalyst particle - D m diameter of the reactor - D _e m²/s effective diffusivity - d m particle diameter - h m bed height - k m/s first order reaction rate constant - k m³/(kg · s) pseudo first order reaction rate constant - k _in m³/(kg · s) intrinsic reaction rate constant, (=K/gh) - k _m m/s mass transfer coefficient - P kmol/(m³ · s) volumetric productivity - Q m³/s flow rate of the feed - S kmol/m³ substrate concentration at any time - S _o kmol/m³ initial substrate concentration - S _p kmol/m³ substrate concentration on the gel bead surface - t s reaction time - T (kg · cat · s)/m³ space time (weight of the biocatalyst/flow rate of the feed) - v kmol/(kg · cat · s) reaction rate - V _pfr m³ volume of the packed bed reactor - X [1-(S/S _o)] fraction of the substrate converted in to product Greek Symbols effectiveness factor - Thiele modulus - kg/m³ density of the catalyst particle - s residence time, (= D² h/4Q) - voidage     

Model for continuous production of solvents from whey permeate in a packed bed reactor using cells of Clostridium acetobutylicum immobilized by adsorption onto bonechar

Summary A mathematical model has been developed to describe the operation of a packed bed reactor for the continuous production of solvents from whey permeate. The model has been used to quantitate the amounts of different physiological/ morphological types of biomass present in the reactor. The majority of biomass is inert, i.e. it neither grows nor produces solvent. Only relatively small amounts of biomass actively grow (vegetative, non-solvent-producing cells), while even smaller amounts are responsible for solvent production (clostridial, solvent-producing cells).     

Lactic acid from acid whey permeate in a membrane recycle bioreactor

Whey permeate was obtained by ultrafiltration of cottage cheese whey and supplemented with yeast extract. The lactose in the permeate was converted into lactic acid by Lactobacillus bulgaricus in a high-performance membrane bioreactor configured in the cell recycle mode. At a cell concentration of 10 g l⁻¹, optimum productivity of lactic acid was 35 g l⁻¹ h⁻¹. Increasing the cell concentration to 30 g l⁻¹ enabled the use of a dilution rate of 1 h⁻¹ with complete substrate utilization. At 60 g l⁻¹, productivity was over 80 g l⁻¹ h⁻¹ with complete substrte utilization; this is vastly superior to conventional batch fermentations.     

Gallotannin hydrolysis by immobilized fungal mycelia in a packed bed bioreactor.

Hydrolysis of gallotannin to gallic acid by immobilized mycelia of Aspergillus niger MTCC 282, Aspergillus fischerii MTCC 150, Fusarium solani MTCC 350 and Trichoderma viride MTCC 167 in a packed bed bioreactor was studied. Fungal mycelia preinduced with 5 g L-1 gallotannin were immobilized in calcium alginate gel (1.5%) and the resultant beads were packed in a column to a bed volume of 175 mm3. Gallotannin dissolved in distilled water was passed through the column and the eluate was recycled after adjusting pH to 6 with ammonium hydroxide (10%). Maximum hydrolysis of gallotannin was recorded by immobilized mycelia of F. solani and T. viride at 35 degrees and 45 degrees C after 175 and 60 min of residency period respectively. Optimum substrate concentration required for maximum hydrolysis was 10 g L-1 at pH 5 for both the fungi. Immobilized mycelia of A. niger and A. fischerii revealed maximum operational stability. Loss of activity after eighth run was in the order of-A. niger (no loss), A. fischerii (7.5%), F. solani (18%) and T. viride (18%). Stability in terms of retention of enzyme activity after 150 days of storage at 4 degrees C was A. niger (58%), A. fischerii (26.8%), F. solani (83%) and T. viride (85.1%).     

A novel recycle batch immobilized cell bioreactor for propionate production from whey lactose

Recycle batch fermentations using immobilized cells of Propionibacterium acidipropionici were studied for propionate production from whey permeate, de-lactose whey permeate, and acid whey. Cells were immobilized in a spirally wound fibrous sheet packed in a 0.5-L column reactor, which was connected to a 5-L stirred tank batch fermentor with recirculation. The immobilized cells bioreactor served as a breeder for these recycle batch fermentations. High fermentation rates and conversions were obtained with these whey media without nutrient supplementation. It took approximately 55 h to ferment whey permeate containing approximately 45 g/L lactose to approximately 20 g/L propionic acid. Higher propionate concentrations can be produced with various concentrated whey media containing more lactose. The highest propionic acid concentration obtained with the recycle batch reactor was 65 g/L, which is much higher than the normal maximum concentration of 35 to 45 g/L reported in the literature. The volumetric productivity ranged from 0.22 g/L . h to 0.47 g/L . h, depending on the propionate concentration and whey medium used. The corresponding specific cell productivity was 0.033 to 0.07 g/L . g cell. The productivity increased to 0.68 g/L . h when whey permeate was supplemented with 1% (w/v) yeast extract. Compared with conventional batch fermentation, the recycle batch fermentation with the immobilized cell bioreactor allows faster fermentation, produces a higher concentration of product, and can be run continually without significant downtime. The process also produced similar fermentation results with nonsterile whey media. (c) 1995 John Wiley & Sons, Inc.     

Optimization of a packed bed bioreactor with immobilized cells using experimental design

A central composite design was employed for the optimization of heterogeneous enzymatic hydrolysis of sucrose. The reaction was catalyzed by whole yeast cells of Saccharomyces cerevisiae immobilized in Ca-pectate gel. Bioreactor volumetric productivity was chosen as an optimization criterion, while temperature and gel biomass concentration were optimization parameters. Sucrose inlet concentration of 700 kg m^–3 and outlet conversion of 65% were constant in all experiments. In the temperature range 51–73 °C and biomass concentration range 11–39 kg m^–3 (dry mass of cells), the dependence of bioreactor productivity on the two factors was described by a second order polynom regression equation. No simple optimum was revealed by the experimental design. The bioreactor productivity increased within the whole experimental range of biomass concentration, whereas a temperature optimum was found to be between 60 and 65 °C.List of Symbols b _j jth regression coefficient - c _Si kg m^–3 inlet sucrose concentration - F m³ min^–1 flow rate - F F distribution - f _LF degrees of freedom of lack of fit variance - f _P degrees of freedom of pure error variance - N total number of runs - n ₀ number of runs in the centre of design - P kg m^–3 min^–1 productivity - s _LF ² lack of fit variance - SS _LF lack of fit sum of squares - S _p ² pure error variance - SS _P pure error sum of squares - SS _R total residual sum of squares - V _b m³ bioreactor bed volume - X _O outlet conversion - x ₁ 1st factor - coded temperature - x ₂ 2nd factor - coded biomass concentration - y kgm^–3min^–1 measured response (productivity) - kg m^–3 min^–1 estimated response (productivity) - y _Oi kg m^–3 min^–1 measured response in the centre of design - ¯y ₀ kg m^–3 min^–1 average of response in the centre of design     

Ethanol production from whey permeate by immobilized yeast cells

The ability of two yeast strains to utilize the lactose in whey permeate has been studied. Kluyveromyces marxianus NCYC 179 completely utilized the lactose (9.8%), whereas Saccharomyces cerevisiae NCYC 240 displayed an inability to metabolize whey lactose for ethanol production. Of the two gel matrices tested for immobilizing K. marxianus NCYC 179 cells, sodium alginate at 2% (w/v) concentration proved to be the optimum gel for entrapping the yeast cells effectively. The data on optimization of physiological conditions of fermentation (temperature, pH, ethanol concentration and substrate concentration) showed similar effects on immobilized and free cell suspensions of K. marxianus NCYC 179, in batch fermentation. A maximum yield of 42.6 g ethanol l^?1 (82% of theoretical) was obtained from 98 g lactose l^?1 when fermentation was carried at pH 5.5 and 30°C using 120 g dry weight l^?1 cell load of yeast cells. These results suggest that whey lactose can be metabolized effectively for ethanol production using immobilized K. marxianus NCYC 179 cells.     

Ethanol from hydrolyzed whey permeate using Saccharomyces cerevisiae in a membrane recycle bioreactor

A diauxic fermentation was observed during batch fermentation of enzyme-hydrolyzed whey permeate to ethanol by Saccharomyces cerevisiae. Glucose was consumed before and much faster than galactose. In the continuous membrane recycle bioreactor (MRB), sugar utilization was a function of dilution rate and concentration of sugars. At a cell concentration of 160 kg/m³, optimum productivity was 31 kg/(m³ · h) at ethanol concentration of 65 kg/m³. Low levels of acetate (0.05–0.1 M) reduced cell growth during continuous fermentation, but also reduced galactose utilization.     

Lactic acid production from whey permeate by immobilized Lactobacillus casei

Two matrices have been assessed for their ability to immobilize Lactobacillus casei cells for lactic acid fermentation in whey permeate medium. Agar at 2% concentration was found to be a better gel than polyacrylamide in its effectiveness to entrap the bacterial cells to carry out batch fermentation up to three repeat runs. Of the various physiological parameters studied, temperature and pH were observed to have no significant influence on the fermentation ability of the immobilized organism. A temperature range of 40–50°C and a pH range of 4.5–6.0 rather than specific values, were found to be optimum when fermentation was carried out under stationary conditions. In batch fermentation ～90% conversion of the substrate (lactose) was achieved in 48 h using immobilized cell gel cubes of 4 × 2 × 2 mm size, containing 400 mg dry bacterial cells per flask and 4.5% w/v (initial) whey lactose content as substrate. However, further increase in substrate levels tested (>4.5% w/v) did not improve the process efficiency. Supplementation of Mg²⁺ (1 mM) and agricultural by-products (mustard oil cake, 6%) in the whey permeate medium further improved the acid production ability of the immobilized cells under study.     

Experimental studies and two-dimensional modelling of a packed bed bioreactor used for production of galacto-oligosaccharides (GOS) from milk whey

In the present study, extensive experimental investigations and detailed theoretical analysis of a two-dimensional packed bed bioreactor, employed for the production of galacto-oligosaccharides (GOS) from milk whey were performed. Model equations, in one- and two-dimensions, capable of predicting the substrate concentration distribution in the bioreactor were developed by coupling mass balance equation with appropriate velocity distribution equation and solved numerically. Validation of the proposed model equations was done by a set of experimental data obtained from the bioreactor. The effects of reactor to catalyst particle diameter ratio (d _t/d _p), feed flowrate (10^?6–10^?9 m³ s^?1), and initial lactose concentration (50–200 kg m^?3) on substrate concentration distribution were investigated in detail. While, the distribution of substrate concentration in axial direction was independent of d _t/d _p, it was observed that for d _t/d _p <40, significant radial concentration distribution existed. It was further observed that the substrate conversion and product yield obtained experimentally showed an excellent agreement (97 ± 2 %) with the results predicted by the two-dimensional model equation, whereas, the results predicted by the one-dimensional model equation did not lie within the desired confidence level (<90 %). The results were confirmed by both curve fitting and statistical analysis. The prediction of substrate concentration distribution in axial and radial directions using the developed two-dimensional model equation is necessary for computing the bioreactor volume to achieve the desired GOS yield.     

Continuous butanol production from whey permeate with immobilized Clostridium beyerinckii LMD 27.6

Summary The aim of this study was to find the conditions necessary for the continuous butanol production from whey permeate with Clostridium beyerinckii LMD 27.6, immobilized in calcium alginate beads. The influence of three parameters on the butanol production was investigated: the fermentation temperature, the dilution rate (during start-up and at steady state) and the concentration of calcium ions in the fermentation broth. It was found that both a fermentation temperature of 30° C and a dilution rate of 0.1 h^-1 or less during the start-up phase are required to achieve continuous butanol production from whey permeate. Butanol can be produced continuously from whey permeate in reactor productivities sixteen times higher than those found in batch cultures with free C. beyerinckii cells on whey media.     

Lactic acid from cheese whey permeate. Productivity and economics of a continuous membrane bioreactor

The economics of incorporating membrane modules in several steps in the conversion of whey permeate to lactic acid was studied. Membrane recycle fermenters operating at a cell concentration of 40 g l^–1 resulted in a productivity of 22.5 g l^–1h^–1 with a lactate concentration of 89 g l^–1 and a yield of 0.89. The membrane units (reverse osmosis for preconcentrating whey permeate, hollow-fiber ultrafiltration for clarification and for cell recycling) contribute about 28% of the total fixed capital costs and less than 5% of the operating cost. The two largest costs are whey transportation and yeast extract, contributing about 35% and 38% to the total product cost of US $ 0.98/kg 85% lactate. Without these two costs, unpurified lactate could be produced for $ 0.27/kg.     

Design of immobilized enzyme reactors for the continuous production of fructose syrup from whey permeate

Biocatalyst inactivation is inherent to continuous operation of immobilized enzyme reactors, meaning that a strategy must exist to ensure a production of uniform quality and constant throughput. Flow rate can be profiled to compensate for enzyme inactivation maintaining substrate conversion constant. Throughput can be maintained within specified margins of variation by using several reactors operating in parallel but displaced in time. Enzyme inactivation has been usually modeled under non-reactive conditions, leaving aside the effect of substrate and products on enzyme stability. Results are presented for the design of enzyme reactors under the above operational strategy, considering first-order biocatalyst inactivation kinetics modulated by substrate and products. The continuous production of hydrolyzed-isomerized whey permeate with immobilized lactase and glucose isomerase in sequential packed-bed reactors is used as a case study. Kinetic and inactivation parameters for immobilized lactase have been determined by the authors; those for glucose isomerase were taken from the literature. Except for lactose, all other substrates and products were positive modulators of enzyme stability. Reactor design was done by iteration since it depends on enzyme inactivation kinetics. Reactor performance was determined based on a preliminary design considering non-modulated first-order inactivation kinetics and confronted to such pattern. The new pattern of inactivation was then used to redesign the reactor and the process repeated until reactor performance (considering modulation) matched the assumed pattern of inactivation. Convergence was very fast and only two iterations were needed.     

Production of solvents (ABE fermentation) from whey permeate by continuous fermentation in a membrane bioreactor

A continuous bioreactor where cells were recycled using a cross-flow microfiltration (CFM) membrane plant was investigated for the production of solvents (ABE fermentation) from whey permeate using Clostridium acetobutylicum P262. A tubular CFM membrane plant capable of being backflushed was used.The continuous fermentations were characterized by cyclic solventogenic and acidogenic behaviour, and ultimately degenerated to an acidogenic state. Steady-state solvent production was obtained for only short periods. This degeneration is attributed to the complex morphological behaviour of this strain of organism on this substrate.It is postulated that to achieve steady-state solvent production over extended periods of time, it is necessary to maintain a balance among the various morphological cell forms, i.e. acid-producing vegetative cells, solvent-producing clostridial cells, and inert forms, e.g. spores.     

A kinetic model for methanogenesis of acetic acid in a multireactor system

Bioconversion of acetic acid to methane by a crude culture of methanogens in a continuous multireactor system was investigated. Culture of methanogens was drawn from an active cow-dung digester (12 days) and was grown in a semisynthetic medium (pH 6.3, 37 degrees C) with acetic acid as the sole carbon source. The solubilities of CO(2), HCO(3) (-), and CO(3) (2-) increased with the rise in pH and exercised considerable influence on the gas composition. Various mechanisms for methanogenesis of acetic acid based on the available pathways were considered. Experimental data were compared with these mechanisms, the best fit was determined, and the corresponding rate expression was identified. This mechanism predicted that, of the total methane produced, 72%;comes from acetic acid directly and 28%;via the CO(2) reduction route.     

Continuous mixed strain mesophilic lactic starter production in supplemented whey permeate medium using immobilized cell technology

The aim of this work was to study a new process for the continuous production of mixed-strain lactic acid bacteria starters using immobilized cells. Three strains of Lactococcus (two Lactococcus lactis subsp. lactis: KB and KBP, and one Lactococcus lactis subsp. lactis biovar diacetylactis: MD) were immobilized separately in kappa-carrageenan-locust bean gum gel beads. Continuous fermentations were carried out in a 1 L pH-controlled stirred tank reactor with a 30% (v/v) bead inoculum (strain ratio 1:1:1), continuously fed with a whey UF permeate medium, supplemented with 1.5% yeast extract and 0.1M KCl. The effects of three parameters-pH, temperature (T), dilution rate (D), and their interactions on the composition and activity of the culture in the effluent at pseudosteady state were studied according to a rotatable central composite design, during a 53-day fermentation. The process showed a high biological stability and no strain became dominant, or was eliminated from the bioreactor. The statistical analysis showed that the three strains were differently affected by the studied parameters, and that a large range of effluent starter composition can be achieved by varying D, pH, and T. However, the acidifying characteristics were not affected by the culture conditions. A cross-contamination from other strains of the mixed culture was observed in gel beads entrapping a pure culture at the fermentation onset, and led to a biomass redistribution within the beads. However, the strain ratio (KB:KBP:MD) observed after the 53-day experiment (1:2:2) was close to the initial bead ratio (1:1:1). The beads demonstrated a high mechanical stability throughout the 53-day continuous fermentation. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 56: 502-516, 1997.     

Microorganisms immobilized by membrane inclusion: kinetic measurements in a fixed bed bioreactor and oxygen consumption calculations

Cells living in the pores of macroporous carriers can be immobilized by coating the carriers with a porous membrane. To evaluate the performance of cells immobilized with such a technique, a fixed bed bioreactor was used to study the oxidation of D-sorbitol to L-sorbose by Acetobacter suboxydans. Comparisons were made of immobilized cells to cells living in the pores of a non-coated carrier and to cells living in the absence of a carrier (“submerged cells”). Productivity was similar in all three cultures (4.6–6.3?g sorbose?l^?1?h^?1). Biomass concentration at the outlet was highest for submerged cells (1.3?·?10⁹?cells?ml^?1) but was equal for coated and non-coated carriers (0.4?·?10⁹?cells?ml^?1). Examination of the coated carriers under the electron microscope revealed that only a thin layer near the surface was actually colonized by bacteria. Interestingly, when normalized on the basis of volume, sorbitol oxidation in the colonized layer appeared to be about 100-fold faster than in the bulk medium. A model was derived for oxygen relations inside the coated carriers. This model implicates that the inner parts of the carrier are not colonized by bacteria due to oxygen limitation. The findings indicate that coated carriers have potential to catalyze biotransformations at very high rates, and identify oxygen supply and confinement of cells to the carriers as issues that need further attention. The mathematical model for oxygen concentration profiles inside the coated carriers will be useful for designing improved carriers.     

Synthesis of 2-ethyl hexanol fatty acid esters in a packed bed bioreactor using a lipase immobilized on a textile membrane

An enzymatic process using a packed bed bioreactor with recirculation was developed for the scale-up synthesis of 2-ethylhexyl palmitate with a lipase from Candida sp. 99–125 immobilized on a fabric membrane by natural attachment to the membrane surface. Esterification was effectively performed by circulating the reaction mixture between a packed bed column and a substrate container. A maximum esterification yield of 98% was obtained. Adding molecular sieves and drying the immobilized lipase both decreased the water content at the reactor outlet and around the enzyme, which led to an increase in the rate of esterification. The long-term stability of the reactor was tested by continuing the reaction for 30 batches (over 300 h) with an average esterification yield of about 95%. This immobilized lipase bioreactor is scalable and is thus suitable for industrial production of 2-ethylhexyl palmitate.