Modeling of antibiotics production in magneto three-phase airlift fermenter

A mathematical model is developed to describe the performance of a three-phase airlift reactor utilizing a transverse magnetic field. The model is based on the complete mixing model for the bulk of liquid phase and on the Michaelis-Menten kinetics. The model equations are solved by the explicit finite difference method from transient to steady state conditions. The results of the numerical simulation indicate that the magnetic field increases the degree of bioconversion. The mathematical model is experimentally verified in a three-phase airlift reactor with P. chrysogenum immobilized on magnetic beads. The experimental results are well described by the developed model when the reactor operates in the stabilized regime. At relatively high magnetic field intensities a certain discrepancy in the model solution was observed when the model over estimates the product concentration.     

Use of a tapered fluidized bed as a Continuous bioreactor

Reactor systems based on tapered fluidized beds are being developed for aqueous bioprocesses in which adhering microorganisms or immobilized active biological fractions are used. The use of a fluidized bed prevents biomass buildup, accommodates particulates in the feed stream, is compatible with gas sparging, and allows easy removal or addition of the active materials. The tapered reactor tends to stabilize the fluidized bed, thus allowing a much wider range of operating conditions. Preliminary experimental results and an empirical mathematical model of the tapered bed indicate that bed stability is associated with a decreasing velocity and void-fraction profile up the bed and the pressure drop across the bed decreases with increasing flow rates. The tapered fluidized bed bioreactor is being evaluated for use in the enzymatic production of hydrogen, microbiological denitrification, and microbiological degradation of coal conversion aqueous waste streams. The enzyme catalyzed conversion of lactose to glucose and galactose was used in the evaluation of the reactor concept.     

Analysis of a continuous, aerobic, fixed-film bioreactor. I. Steady-state behavior

The analysis of a continuous, aerobic, fixed-film bioreactor is performed by simulating the behavior of penicillin production in a three-phase fluidized bed. Rigorous mathematical models are developed for a fluidized-bed fermentor in which bioparticles are fluidized by the liquid medium and air. The steady-state performance of the fluidized-bed reactor is appraised in terms of penicillin productivity and outlet concentration by considering the two extremes in contacting patterns, complete back-mix and plug flow, in the absence of a growing biofilm. The results show that the complete back-mix contacting pattern is preferred over that of plug flow due to the nature of the penicillin kinetic relationships. It is also shown that for the dual-nutrient (glucose and oxygen) penicillin reaction system the optimum biofilm thickness does not equal the penetration depth of a limiting nutrient, but depends upon the total reactor configuration.     

Biodiesel production in a magnetically-stabilized, fluidized bed reactor with an immobilized lipase in magnetic chitosan microspheres

Biodiesel production by immobilized Rhizopus oryzae lipase in magnetic chitosan microspheres (MCMs) was carried out using soybean oil and methanol in a magnetically-stabilized, fluidized bed reactor (MSFBR). The maximum content of methyl ester in the reaction mixture reached 91.3 (w/v) at a fluid flow rate of 25 ml/min and a magnetic field intensity of 150 Oe. In addition, the MCMs-immobilized lipase in the reactor showed excellent reusability, retaining 82 % productivity even after six batches, which was much better than that in a conventional fluidized bed reactor. These results suggested that a MSFRB using MCMs-immobilized lipase is a promising method for biodiesel production.     

Continuous ethanol production by Zymomonas mobilis in a fluidized bed reactor. Part I. Kinetic studies of immobilization in macroporous glass beads

A model has been developed to calculate the ethanol production in a well-mixed fluidized bed reactor. This model takes into account diffusion and the reaction inside porous glass beads and the activity of suspended cells in the fluidized bed reactor. The associated model parameters have been determined from the literature and by kinetic studies with Zymomonas mobilis in a continuous stirred tank reactor. The model permits good predictions of steady-state data in a fluidized bed reactor at residence times longer than 1–1.5 h. The immobilization of Z. mobilis in a fluidized bed reactor results in high ethanol space-time yields of more than 50 g·^–1·h^–1 at a glucose conversion of 80% (glucose in substrate: 120 gl^–1). At 99% conversion a space-time yield of 30 g·^–1·^–1 can be achieved when two fluidized bed reactors operate as cascade.     

Biodegradation of 3,4-dichloroaniline in a fluidized bed bioreactor and a steady-state biofilm Kinetic model

Mixed culture of microorganisms immobilized onto Celite diatomaceous earth particles were used to degrade 3,4-dichloroaniline (34DCA) in a three-phase draft tube fluidized bed bioreactor. Biodegradation was confirmed as the dominant removal mechanism by measurements of the concomitant chloride ion evolution. Degradation efficiencies of 95% were obtained at a reactor retention time of 1.25 h. A mathematical model was used to describe the simultaneous diffusion and reaction of 34DCA and oxygen in the biofilms on the particles in the reactor. The parameters describing freely suspended cell growth on 34DCA were obtained in batch experiments. The model was found to describe the system well for three out of four steady states and to predict qualitatively the experimentally observed transition in the biofilm kinetics from 34DCA to oxygen limitation.     

Ethanol fermentation in a magnetically fluidized bed reactor with immobilized Saccharomyces cerevisiae in magnetic particles

Ethanol fermentation by immobilized Saccharomyces cerevisiae cells in magnetic particles was successfully carried out in a magnetically stabilized fluidized bed reactor (MSFBR). These immobilized magnetic particles solidified in a 2 % CaCl(2) solution were stable and had high ethanol fermentation activity. The performance of ethanol fermentation of glucose in the MSFBR was affected by initial particle loading rate, feed sugar concentration and dilution rate. The ethanol theoretical yield, productivity and concentration reached 95.3%, 26.7 g/L h and 66 g/L, respectively, at a particle loading rate of 41% and a feed dilution rate of 0.4 h(-1) with a glucose concentration of 150 g/L when the magnetic field intensity was kept in the range of 85-120 Oe. In order to use this developed MSFBR system for ethanol production from cheap raw materials, cane molasses was used as the main fermentation substrate for continuous ethanol fermentation with the immobilized S. cerevisiae cells in the reactor system. Molasses gave comparative ethanol productivity in comparison with glucose in the MSFBR, and the higher ethanol production was observed in the MSFBR than in a fluidized bed reactor (FBR) without a magnetic field.     

Minimum fluidization velocity and friction factor in a liquid-solid inverse fluidized bed reactor

In the present study the hydrodynamic characteristics (bed expansion and pressure drop) of low-density polyethylene (LDPE) and polypropylene (PP) are studied in a liquid-solid inverse fluidized bed reactor as a function of particle diameter, liquid viscosity and density. The bed expansion and pressure drop data are used to determine the minimum fluidization velocity, U_mf and friction factor, P. It was found that the U_mf increased with an increase in the particle diameter and a decrease in solid density and was independent of initial bed height (solid loading). In addition, the U_mf decreased with an increase in the CMC concentration. The friction factor Reynolds number plot was found similar to that of classical fluidization. Dimensionless equations were proposed for the. prediction of the friction factor and the U_mf.     

Adsorption with biodegradation for decolorization of reactive black 5 by Funalia trogii 200800 on a fly ash-chitosan medium in a fluidized bed bioreactor-kinetic model and reactor performance

A non-steady-state mathematical model system for the kinetics of adsorption and biodegradation of reactive black 5 (RB5) by Funalia trogii (F. trogii) ATCC 200800 biofilm on fly ash-chitosan bead in the fluidized bed process was derived. The mechanisms in the model system included adsorption by fly ash-chitosan beads, biodegradation by F. trogii cells and mass transport diffusion. Batch kinetic tests were independently performed to determine surface diffusivity of RB5, adsorption parameters for RB5 and biokinetic parameters of F. trogii ATCC 200800. A column test was conducted using a continuous-flow fluidized bed reactor with a recycling pump to approximate a completely-mixed flow reactor for model verification. The experimental results indicated that F. trogii biofilm bioregenerated the fly ash-chitosan beads after attached F. trogii has grown significantly. The removal efficiency of RB5 was about 95 % when RB5 concentration in the effluent was approximately 0.34 mg/L at a steady-state condition. The concentration of suspended F. trogii cells reached up to about 1.74 mg/L while the thickness of attached F. trogii cells was estimated to be 80 μm at a steady-state condition by model prediction. The comparisons of experimental data and model prediction show that the model system for adsorption and biodegradation of RB5 can predict the experimental results well. The approaches of experiments and mathematical modeling in this study can be applied to design a full-scale fluidized bed process to treat reactive dye in textile wastewater.     

Continuous biocatalytic synthesis of epoxypropane using a biofilm reactor

Mixed culture methanotrophic attached biofilms immobilized on diatomite particles in a three-phase fluidized bed reaction system were developed. Methane monooxygenase (MMO) activity on diatomite particles increased as soon as the lag phase ended. More than 90% of the MMO activity in the fluidized bed was attached. A biofilm concentration of 3.3c3.7mg dry weight cell (dwc) per g dry solid (DS) was observed. Batch experiments were performed to explore the possibility of producing epoxypropane by a propene–methane co-oxidation process. The effect of methane on the epoxidation of propene and the effect of propene on the growth of methanotroph was also studied. In continuous experiments, optimum mixed gas containing 35 methane, 20 propene and 45% oxygen were continuously circulated through the fluidized bed reactor to deliver substrates and extract product. Initial epoxypropane productivity was 110–150 μmol/day. The bioreactor operated continuously for 53 days without obvious loss of epoxypropane productivity.     

Maltodextrin hydrolysis in a fluidized-bed immobilized enzyme reactor

The present work deals with maltodextrin hydrolysis by glucoamylase immobilized onto corn stover in a fluidized bed reactor. An industrial enzyme preparation was covalently grafted onto corn stover, yielding an activity of up to 372 U/g and 1700 U/g for support particle sizes of 0.8 and 0.2 mm, respectively. A detailed kinetic study, using a differential reactor, allowed the characterization of the influence of mass transfer resistance on the reaction catalyzed by immobilized glucoamylase. A simple and general mathematical model was then developed to describe the experimental conversion data and found to be valid.     

Continuous ethanol production by immobilized yeast in a fluidized reactor

Summary In order to minimize the adverse effect of CO₂ gas in a packed bed immobilized yeast reactor, a fluidized bed reactor was used for the continuous production of ethanol from glucose. Immobilized yeast was prepared by entrapping whole cells of Saccharomyces cerevisiae within a Caalginate matrix. It was found that the efficiency of the ethanol production in a fluidized bed reactor was 100% better than that for a packed bed reactor system. The alcohol productivity obtained was 21 g/l/hr in a fluidized bed reactor at 94% of conversion level.     

Continuous ethanol production by Zymomonas mobilis in a fluidized bed reactor. Part II: Process development for the fermentation of hydrolysed B-starch without sterilization

A continuous fluidized bed reactor operation system has been developed for ethanol production by Zymomonas mobilis using hydrolysed B-starch without sterilization. The operation system consists of two phases. In the first phase macroporous glass carriers in a totally mixed fluidized bed reactor were filled up totally with a monoculture of Z. mobilis by fast computer-controlled colonization, so that in the subsequent production phase no contaminants, especially lactic-acid bacteria, could penetrate into the carrier beads. In the production phase the high concentration of immobilized Z. mobilis cells in the fluidized bed reactor permits unsterile fermentation of hydrolysed B-starch to ethanol at short residence times. This results in wash-out conditions for contaminants from the substrate. Long-term experimental studies (more than 120 days) of unsterile fermentation of hydrolysed B-starch in the laboratory fluidized bed reactor (2.2 l) demonstrated stable operation up to residence times of 5 h. A semi-technical fluidized bed reactor plant (cascade of two fluidized bed reactors, each 55 l) was operated stably at a mean residence time of 4.25 h. Glucose conversion of 99% of the unsterile hydrolysed B-starch was achieved at 120 g glucose/l^–1 in the substrate, resulting in an ethanol concentration of 50 g·l^–1 and an ethanol space-time yield of 13 g·l^–1·h^–1. This is a factor of three compared to ethanol fermentation of hydrolysed B-starch with Z. mobilis in a continuous stirred tank reactor, which can only be operated stably under sterile conditions. Correspondence to: D. Weuster-Botz     

Estimation of axial dispersion in horizontal rotating tubular bioreactor by means of a structured model

A horizontal rotating tubular bioreactor (HRTB) is designed as the combination of a "thin layer bioreactor" and a "biodisc" reactor. The investigation of mixing in HRTB was done by the temperature step method in a wide range of process conditions [residence time (t_z=360036000 s) and bioreactor rotation speed (n=0.0830.917 s^у)]. In all experiments heat losses were detected. A mathematical model based on "tank in series" concept was developed to describe the mixing in HRTB - a "spiral flow" model (SFM) which has incorporated heat losses. However, the simulations of SFM could be used for calculation of temperature response curves for the case when there is no heat losses. These corrected curves were used then to estimate Bodenstein number as a parameter of standard dispersion model (SDM). The obtained Bodenstein numbers were in the range 10-17. The simulations showed that SFM was more capable to describe the mixing in HRTB giving better fitting with experimental measurements than SDM, indicating that mixing pattern in HRTB is too complex to be described with this relatively simple, one-parameter model.     

Determining specific biomass activity in anaerobic wastewater treatment processes

An experimental method for the measurement of specific gas production rate was developed and tested with biomass samples taken from anaerobic fluidized bed reactors, operating with a variety of carriers with molasses, condensate from cellulose production and brewery wastewater as feeds. The method is based on reactor sampling and offline gas volume measurement during a known time interval. Important factors are biomass and liquid sampling under oxygen-free conditions, using the liquid from the reactor as substrate, providing sufficient mixing and maintaining the physical integrity of the biomass. The method was developed in such a way that small samples (20 ml) were taken under anaerobic conditions (poising agent) for short-term (2–3 min.) gas rate measurements in a small fluidized bed (25 ml) batch reactor with U-tube. Biomass content was measured by an instrumental nitrogen method (Dumas), followed by weight determination of the carrier. The gas rates measured with the test system, and their dependence on substrate concentration, were in good agreement with those directly measured from the continuous fluidized bed reactor. Additions of molasses and acetate to the sample proved that the influence of concentration on the biomass activity can be obtained only by operating the continuous reactor at the concentration levels of interest. Comparison between the reactors showed large differences in the specific activity and the total reactor activity. It was found when comparing two reactors, that the values of the specific and the total activities permitted the calculation of the relative biomass quantities. In this way the influence of the carrier-type could be evaluated.     

Comparison of a batch, fed-batch and continuously operated stirred-tank reactor for the enzymatic synthesis of (R)-mandelonitrile by using a process model

The suitability of a batch, fed-batch and continuously operated stirred-tank reactor for the enzymatic production of (R)-mandelonitrile in an aqueous-organic biphasic system was investigated by using a process model. The considered biphasic system is 10-50% (v/v) 100 mM sodium citrate buffer of pH 5.5 dispersed in methyl tert-butyl ether. The constraints were that 750 moles of benzaldehyde per cubic meter should react towards (R)-mandelonitrile with an enantiomeric excess of 99% and a conversion of 98%. A continuously operated stirred-tank reactor could not meet the constraints, but the production in a batch or fed-batch reactor was feasible. The choice for a batch or fed-batch reactor is dependent on the influence of the costs for reactor operation and for the enzyme on the product costs. The choice for operating at a small or large aqueous-phase volume fraction is dependent on the costs and reusability of the enzyme. The volumetric productivity is maximal when operating as batch. The enzymatic productivity and turnover are maximal when operating as fed batch. In the fed-batch mode, the enzymatic productivity increased by 24-37%, the turnover increased by 50-60% and the volumetric productivity decreased by 33-71% as compared to a batch reactor. By enhancement of mass transfer both the volumetric and enzymatic productivity can be increased considerably, while the turnover is only slightly decreased.     

Citric acid production by immobilized Aspergillus niger in a fluidized bed reactor

Summary Citric acid production by immobilized of Aspergillus niger in a fluidized bed reactor was performed, evaluating the productivity and the stability of the process when pulsing device was used. The application of a pulsing flow to fluidized bed reactor and the feed nitrogen limited allow to control of bioparticles morphology avoiding bed compactation. When operated at optimum pulsation frequency (0.3 s^–1) the stability of the bioreactor was maintained for more than 30 days, increasing the citric acid production in more than 52.2%.     

Pilot-scale culture ofCoffea arabica in a novel loop fluidised bed reactor

A novel bubble free loop fluidized bed reactor for plant cell cultures was developed and tested usingCoffea arabica as a model cell line. The effects of main operational parameters like morphology and size of inoculum, oxygen supply as well as recirculation of sparingly soluble gases on cell growth and alkaloid production rates in this reactor were studied and the results were compared with standard shake flask experiments. By on-line monitoring of biomass and oxygen uptake rates the main kinetic parameters for cell growth and alkaloid production were evaluated. It was demonstrated that the novel reactor is easy to run and is particularly adequate for measuring kinetic parameters necessary for scale up.     

Modelling a solid-state fluidized bed fermenter for Ethanol production with S. cerevisiae

A model is proposed to describe the performance of a new type of fermenter for ethanol production, the fluidized bed gas-solid fermenter, with respect to scaling-up effects. Based on the fact that in the fluid bed the substrate is not supplied continuously to each particle, two scale-up parameters are derived, circulation time τ and specific substrate supply Δm _G,P , which are shown to influence reactor efficiency significantly. The validity of the model is checked by comparing the calculated yield coefficients for ethanol, cell mass and carbon dioxide to the results of fermentation experiments performed under aerobic conditions in a laboratory-scale reactor and a semi-technical fermenter.