Heat Generation and its Impact on Lamp Fouling During Cheese Whey Sterilization using Ultraviolet Radiation

Summary In previous studies we found that lamp fouling was a major limitation when tubular ultraviolet reactors were used for sterilization of cheese whey over an extended period of time. Heat generation by ultraviolet lamps causes the temperature of the flowing fluid to rise and thus enhances fouling. In this study, the heat generated by a low pressure mercury ultraviolet lamp during continuous sterilization of cheese whey in three tubular reactors having different gap sizes (18, 13 and 6 mm) was calculated using a heat balance formula. The technique quantified the heat produced in and lost from each reactor. The heat balance calculations showed that lamp heat generation decreased with decreasing gap size (50.48, 47.71 and 31.91 kJ/h for 18, 13 and 6 mm gap sizes, respectively). However, the heat gain per unit volume and consequently the steady state temperature of the cheese whey effluent increased with decreasing gap size (91.79, 159.03 and 319.12 kJ/l and 44.5, 53.4 and 62.8 °C for 18, 13 and 6 mm gap sizes, respectively). A strong correlation between the amount of heat gain per unit volume and the amount of fouling material accumulated on the quartz surface was realized. The amount of accumulated fouling material increased with decreasing gap size (14.42, 15.31 and 25.26 g on wet basis for 18, 13 and 6 mm gap sizes, respectively). A new design in which the direct contact between the lamp and the flowing cheese whey is avoided and lamp cooling is introduced should be investigated.     

Reduced fouling and enhanced microbial inactivation during online sterilization of cheese whey using UV coil reactors in series

The effectiveness of coil UV reactor series for the online sterilization of cheese whey was compared to those of the single conventional and coil reactors at various flow rates (5–70 mL/min). The residence time varied from 168 to 12 min and from 48 to 24 min for the single and the series reactors, respectively. Hundred percent destruction efficiency could not be achieved in the single reactors whereas in the coil reactor series the destruction efficiency reached 100% at the flow rates of 35 and 40 mL/min. The rate of microbial destruction was described by polynomial equation for the single coil reactor and by exponential equations for the single conventional reactor and the coil reactor series. The temperature of the effluent decreased with the increase in flow rate in all the reactors. The maximum effluent temperatures in the single conventional reactor, single coil reactor and coil reactor series were 45.8, 46.1, and 36.4 °C (Δt = 20.8, 21.1, 11.4 °C), respectively. The flow in all the reactors was laminar (R _e = 1.39–20.10) and the Dean number was in the range of 1.09–15.41 in the coil reactors. Visual observation revealed less fouling on the UV lamps of coil reactors than on that of the conventional reactor due to the impact of Dean flow. The total operating time during which 100% destruction efficiency is achieved prior to the advent of fouling was 240 min in the coil reactor series compared to only 45 min in the conventional reactor.     

Packed- and fluidized-bed biofilm reactor performance for anaerobic wastewater treatment

Anaerobic degradation performance of a laboratory-scale packed-bed reactor (PBR) was compared with two fluidized-bed biofilm reactors (FBRs) on molasses and whey feeds. The reactors were operated under constant pH (7) and temperature (35 degrees C) conditions and were well mixed with high recirculation rates. The measured variables were chemical oxygen demand (COD), individual organic acids, gas composition, and gas rates. As carrier, sand of 0.3-0.5 mm diameter was used in the FBR, and porous clay spheres of 6 mm diameter were used in the PBR. Startup of the PBR was achieved with 1-5 day residence times. Start-up of the FBR was only successful if liquid residence times were held low at 2-3 h. COD degradations of 86% with molasses (90% was biodegradable) were reached in both the FBR and PBR at 6 h residence time and loadings of 10 g COD/L day. At higher loadings the FBR gave the best performance; even at 40-45 g COD/L day, with 6 h residence times, 70% COD was degraded. The PBR could not be operated above 20 g COD/L day without clogging. A comparison of the reaction rates show that the PBR and FBR per formed similarly at low concentrations in the reactors up to 1 g COD/L, while above 3 g COD/L the rates were 17.4 g COD/L day for the PBR and 38.4 g COD/L day for the FBR. This difference is probably due to diffusion limitations and a less active biomass content of the PBR compared with the fluidized bed.The results of dynamic step change experiments, in which residence times and feed concentrations were changed hanged at constant loading, demonstrated the rapid response of the reactors. Thus, the response times for an increase in gas rate or an increase in organic acids due to an increase in feed concentration were less than 1 day and could be explained by substrate limitation. Other slower responses were observed in which the reactor culture adapted over periods of 5-10 days; these were apparently growth related. An increase in loading of over 100% always resulted in large increases inorganic acids, especially acetic and propionic, as well as large increases in the CO(2) gas content. In general, the CO(2) content of the gas was very low, due to the large amount of dissolved CO(2) that exited with the liquid phase at low residence times. The performance of the FBR with whey was comparable to its performance with molasses, and switching of molasses to whey feed resulted in immediate good performance without adaptation.     

The macro nutrient removal efficiencies of a vertical flow constructed wetland fed with demineralized cheese whey powder solution

This study aims to remove the macro-sized nutrients that are present in the cheese whey powder solution through the use of constructed wetland systems. For this purpose, 70% and 40% demineralized solutions of cheese whey powder were used. For both concentrations, control reactors are run in parallel with Typha angustifolia planted reactors for the duration of a 92 day period. Zeolite and gravel were used as the filling material. The planted reactor, which was fed with the 70% solution, was named as Cheese Whey Powder Solution (CWPS) 1 and its unplanted control was named CWPS 2 while the reactor, which was fed with the 40% solution, was named as CWPS 3 and its unplanted control was named CWPS 4. The removal of COD, PO4-P and NH4-N were obtained as 37.47%, 45.62%, and 68.88% in CWPS 1; 24.89%, 35.74%, and 63.15% in CWPS 2; 51.15%, 54.96%, and 64.13% in CWPS 3; and 28.35%, 23.99%, and 65.92% in CWPS 4, respectively.     

Biomethanation of cheese whey using anaerobic upflow fixed film reactor

Performance of anaerobic upflow fixed film reactors for biomethanation of high-strength cheese whey using different support material such as charcoal, gravel, brick pieces, PVC pieces and pumice stones at 37°C has been studied. Among them the charcoal fixed film reactor showed the best performance when operated at 2 d hydraulic retention times (HRT), achieving maximum COD removal of 81% (COD influent=70 g/l) and improved total gas production (6.7 l/d/l digester) with high methane content (72%).     

Anaerobic digestion of cheese whey using up-flow anaerobic sludge blanket reactor

Anaerobic treatment of cheese whey using a 17·5-litre up-flow anaerobic sludge blanket reactor was investigated in the laboratory. The reactor was studied over a range of influent concentration from 4·5 to 38·1 g chemical oxygen demand per litre at a constant hydraulic retention time of 5 days. The reactor start-up and the sludge acclimatization were discussed. The reactor performance in terms of methane production, volatile fatty acids conversion, sludge net growth and chemical oxygen demand reduction were also presented in this paper. Over 97% chemical oxygen demand reduction was achieved in this experiment. At the influent concentration of 38·1 g chemical oxygen demand per litre, an instability of the reactor was observed. The results indicated that the up-flow anaerobic sludge blanket reactor process could treat cheese whey effectively.     

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     

Intensification of biodiesel synthesis using zigzag micro-channel reactors

Zigzag micro-channel reactors have been fabricated and used for continuous alkali-catalyzed biodiesel synthesis. The influences of the main geometric parameters on the performance of the micro-channel reactors were experimentally studied. It has been found that the zigzag micro-channel reactor with smaller channel size and more turns produces smaller droplets which result in higher efficiency of biodiesel synthesis. Compared to conventional stirred reactors, the time for high methyl ester conversion can be shortened significantly with the methyl ester yield of 99.5% at the residence time of only 28 s by using the optimized zigzag micro-channel reactor, which also exhibits less energy consumption for the same amount of biodiesel during biodiesel synthesis. The results indicate that zigzag micro-channel reactors can be designed as compact and mini-fuel processing plant for distributive applications.     

Attainable region analysis for continuous production of second generation bioethanol

Background

Despite its semi-commercial status, ethanol production from lignocellulosics presents many complexities not yet fully solved. Since the pretreatment stage has been recognized as a complex and yield-determining step, it has been extensively studied. However, economic success of the production process also requires optimization of the biochemical conversion stage. This work addresses the search of bioreactor configurations with improved residence times for continuous enzymatic saccharification and fermentation operations. Instead of analyzing each possible configuration through simulation, we apply graphical methods to optimize the residence time of reactor networks composed of steady-state reactors. Although this can be easily made for processes described by a single kinetic expression, reactions under analysis do not exhibit this feature. Hence, the attainable region method, able to handle multiple species and its reactions, was applied for continuous reactors. Additionally, the effects of the sugars contained in the pretreatment liquor over the enzymatic hydrolysis and simultaneous saccharification and fermentation (SSF) were assessed.

Results

We obtained candidate attainable regions for separate enzymatic hydrolysis and fermentation (SHF) and SSF operations, both fed with pretreated corn stover. Results show that, despite the complexity of the reaction networks and underlying kinetics, the reactor networks that minimize the residence time can be constructed by using plug flow reactors and continuous stirred tank reactors. Regarding the effect of soluble solids in the feed stream to the reactor network, for SHF higher glucose concentration and yield are achieved for enzymatic hydrolysis with washed solids. Similarly, for SSF, higher yields and bioethanol titers are obtained using this substrate.

Conclusions

In this work, we demonstrated the capabilities of the attainable region analysis as a tool to assess the optimal reactor network with minimum residence time applied to the SHF and SSF operations for lignocellulosic ethanol production. The methodology can be readily modified to evaluate other kinetic models of different substrates, enzymes and microorganisms when available. From the obtained results, the most suitable reactor configuration considering residence time and rheological aspects is a continuous stirred tank reactor followed by a plug flow reactor (both in SSF mode) using washed solids as substrate.

     

Optimization of Operating Temperature for Continuous Immobilized Glucose Isomerase Reactor with Pseudo Linear Kinetics

In this work, the optimal operating temperature for the enzymatic isomerization of glucose to fructose using a continuous immobilized glucose isomerase packed bed reactor is studied. This optimization problem describing the performance of such reactor is based on reversible pseudo linear kinetics and is expressed in terms of a recycle ratio. The thermal deactivation of the enzyme as well as the substrate protection during the reactor operation is considered. The formulation of the problem is expressed in terms of maximization of the productivity of fructose. This constrained nonlinear optimization problem is solved using the disjoint policy of the calculus of variations. Accordingly, this method of solution transforms the nonlinear optimization problem into a system of two coupled nonlinear ordinary differential equations (ODEs) of the initial value type, one equation for the operating temperature profile and the other one for the enzyme activity. The ODE for the operating temperature profile is dependent on the recycle ratio, operating time period, and the reactor residence time as well as the kinetics of the reaction and enzyme deactivation. The optimal initial operating temperature is selected by solving the ODEs system by maximizing the fructose productivity. This results into an unconstrained one‐dimensional optimization problem with simple bounds on the operating temperature. Depending on the limits of the recycle ratio, which represents either a plug flow or a mixed flow reactor, it is found that the optimal temperature of operation is characterized by an increasing temperature profile. For higher residence time and low operating periods the residual enzyme activity in the mixed flow reactor is higher than that for the plug flow reactor, which in turn allows the mixed flow reactor to operate at lower temperature than that of the plug flow reactor. At long operating times and short residence time, the operating temperature profiles are almost the same for both reactors. This could be attributed to the effect of substrate protection on the enzyme stability, which is almost the same for both reactors. Improvement in the fructose productivity for both types of reactors is achieved when compared to the constant optimum temperature of operation. The improvement in the fructose productivity for the plug flow reactor is significant in comparison with the mixed flow reactor.     

Effect of carrier size on the performance of a three-phase circulating-bed biofilm reactor for removing toluene in gas stream

A series of steady-state and short-term experiments on a three-phase circulating-bed biofilm reactor (CBBR) for removing toluene from gas streams were conducted to investigate the effect of macroporous-carrier size (1-mm cubes versus 4-mm cubes, which have the same total surface area) on CBBR performance. Experimental conditions were identical, except for the carrier size. The CBBR with 1-mm carriers (the 1-mm CBBR) overcame the performance limitation observed with the CBBR with 4-mm carriers (the 4-mm CBBR): oxygen depletion inside the biofilm. The 1-mm CBBR consistently had the superior removal efficiencies of toluene and COD, higher than 93% for all, and the advantage was greatest for the highest toluene loading, 0.12 M/m2-day. The 1-mm carriers achieved superior performance by minimizing the negative effects of oxygen depletion, because they had 4.7 to 6.8 times thinner biofilm depths. The 1-mm carriers continued to provide protection from excess biomass detachment and inhibition from toluene. Finally, the 1-mm CBBR achieved volumetric removal capacities up to 300 times greater than demonstrated by other biofilters treating toluene and related volatile hydrocarbons.     

Continuous production of ammonium lactate by Streptococccus cremoris in a three-stage reactor

Batch and continuous fermentation studies were performed to optimize the production of ammonium lactate from whey to optimize the production of ammonium lactate from whey permeate. The product known as fermented ammoniated condensed whey permeate (FACWP) is a very promising animal feed. After an initial screening of four strains which produce predominantly L(+)- lactic acid, the desired isomer [D(-)-lactic acid is toxic], Streptococcus cremoris 2487 was chosen for further study. In batch mode, pH between 6.0 and 6.5 and 35 degrees C provided optimum incubation conditions. To stimulate a plug flow reactor, three CSTRs (continuous stirred tank reactors) were connected in tandem. For a 7.5-h retention time, 1.6-fold and 1.3-fold higher productivities were obtained for three-stage than for the single- and two-stage reactors, respectively. Various retentions times were examined (5, 7.5, and 10 h; 5g/L yeast extract). Although maximum lactate productivity occurred at a 5-h residence time (5.38 g/L H. 75% lactose utilization), lactose utilization was more complete at 7.5 h (4.38 g/L h productivity, 91% lactose utilization and a productivity, 91% lactose utilization). Retention time was increased to 15 h to obtain 95.9% lactose utilization and a productivity of 2.42g/L h for 2g/L yeast extract. Based on this lower yeast extract concentration, it was determined that ammonium lactate production and subsequent concentration by 11-fold would yield a product (FACWP) 17% more than soybean meal (crude protein contents are equivalent, 44%) at current market prices.     

Biofiltration of ethylbenzene vapours: influence of the packing material

In order to investigate suitable packing materials, a soil amendment composed of granular high mineralized peat (35% organic content) locally available has been evaluated as carrier material for biofiltration of volatile organic compounds in air by comparison with a fibrous peat (95% organic content). Both supports were tested to eliminate ethylbenzene from air streams in laboratory-scale reactors inoculated with a two-month conditioned culture. In pseudo-steady state operation, experiments at various ethylbenzene inlet loads (ILs) were carried out. Maximum elimination capacity of about 120 g m(-3) h(-1) for an IL of 135 g m(-3) h(-1) was obtained for the fibrous peat. The soil amendment reactor achieved a maximum elimination capacity of about 45 g m(-3) h(-1) for an inlet load of 55 g m(-3) h(-1). Ottengraf-van den Oever model was applied to the prediction of the performance of both biofilters. The influence of gas flow rate was also studied: the fibrous peat reactor kept near complete removal efficiency for empty bed residence times greater than 1 min. For the soil amendment reactor, an empty bed residence time greater than 2 min was needed to achieve adequate removal efficiency. Concentration profiles along the biofilter were also compared: elimination occurred in the whole fibrous peat biofilter, while in the soil amendment reactor the biodegradation only occurred in the first 65% part of the biofilter. Results indicated that soil amendment material, previously selected to increase the organic content, would have potential application as biofilter carrier to treat moderate VOC inlet loads.     

Recovery of residual soluble protein by two-step precipitation process with concomitant COD reduction from the yeast-cultivated cheese whey

The present study was conducted to recover the residual soluble protein after cultivation of yeast (K. marxianus) in cheese whey. Cheese whey continuous fermentation with cell recycle system was carried out at 40 °C and pH 3.5. The yeast biomass was separated from the fermented broth by centrifugation and residual soluble protein from fermented whey supernatant was precipitated by heat treatment (at 100 °C, pH 4.5 and 10 min incubation). The maximum soluble protein recovery up to 53 % was achieved at pH 4.5 with 54 % residual COD removal. However, gravity sedimentable precipitates were obtained at pH 3.5 with 47 % protein recovery. Therefore, the reactor (scale up) study was conducted at pH 3.5 with agitation, which resulted in 68 % of residual soluble protein recovery and simultaneously residual COD removal of 62 %. Further precipitation/coagulation of soluble protein was also evaluated using carboxymethylcellulose (CMC) and then two precipitation (thermal followed by CMC precipitation) processes were combined to increase the protein precipitation, which finally reached up to 81 % of total soluble protein recovery from the supernatant. This optimized process could be applied to recover the residual protein left after fermentation of cheese whey without centrifugation.     

Characterization of a pilot plant airlift tower loop bioreactor: II. Evaluation of global mixing properties of the gas phase during yeast cultivation

Saccharomyces cerevisiae was cultivated in a 4-m(3) pilot plant airlift tower loop reactor with a draft tube in batch and continuous operations and for comparison in a laboratory airlift tower loop reactor of 0.08 m(3) volume. The reactors were characterized during and after the cultivation by measuring the distributions of the residence times of the gas phase with pseudostochastic tracer signals and mass spectrometer and by evaluating the mixing in the liquid phase with a pulse-shaped volatile tracer signal and mass spectrometer as a detector. The mean residence times and the intensities of the axial mixing in the riser and downcomer, the circulation times of the gas phase, and the fraction of the recirculated gas phase were evaluated and compared.     

Dialysis Continuous Process for Ammonium-Lactate Fermentation of Whey: Experimental Tests

Laboratory experiments were conducted to validate theoretical predictions describing a dialysis continuous process for the fermentation of whey lactose to ammonium lactate, in which the fermentor contents are poised at a constant pH by adding ammonia solution and dialyzed through a membrane against water. Dried sweet-cheese whey was rehydrated to contain 230 mg of lactose per ml, supplemented with 8 mg of yeast extract per ml, charged into a 5-liter fermentor without sterilization, adjusted in pH (5.3) and temperature (44°C), and inoculated with Lactobacillus bulgaricus. The fermentor and dialysate circuits were connected, and steady-state conditions were established. A series of such conditions was managed nonaseptically for 94 days to study the process and to demonstrate efficiency and productivity. As time progressed, the fermentation remained homofermentative and increased in conversion efficiency, although membrane fouling necessitated dialyzer cleaning about every 4 weeks. With a retention time of 19 h, 97% of the substrate was converted into products. Relative to nondialysis continuous or batch processes for the fermentation, the dialysis continuous process enabled the use of more concentrated substrate, was more efficient in the rate of substrate conversion, and additionally produced a second effluent of less concentrated but purer ammonium lactate.     

An original procedure for physical simulation of upflow anaerobic sludge blanket reactors

A procedure for sludge blanket reactors physical simulation is presented. To simulate the liquid phase, a solution of 1.0 g/l of polyvinyl alcohol provided the desired rheological behavior. Biological granules presented in UASB reactors were simulated using granules of a water absorbent acrylic polymer capable to expand up to one hundred times in volume when moistened. The biochemical reactions that produces methane and carbon dioxide in anaerobic reactors were simulated reacting nitric acid and sodium bicarbonate. This procedure differs from gas injection since the gas is produced at the reactor core as it happens in the actual situation, thus the simulation is more realistic. Flow visualization and residence time distribution measurements were used to verify if the proposed procedure acceptably simulates UASB reactors treating wastewater. All tests were performed in a 10.5 l bench scale reactor and the results allow to recommend this method whenever flow visualization and reactor physical simulation are useful for reactor design and development.     

Performance of the anaerobic baffled reactor under steady-state and shock loading conditions

The anaerobic baffled reactor (ABR) contains a granulated, mixed anaerobic culture segregated into compartments. Operation of four reactors under a range of hydraulic retention times showed that this novel reactor design offers highly efficient performance in the conversion of carbon in the feed stream to methane and carbon dioxide. The design parameter varied was the number of compartments. COD removal at 20 h retention time was routinely over 95% in all reactors, with low washout of biomass. Very high specific reaction rates were achievable (although with a loss of efficiency) at low biomass concentrations and high loading rates. In order to optimize volumetric reaction rates, a tradeoff has to be made between high biomass concentration, granule size, and the resulting mass transfer limitations. Formate is shown to be an important intermediate in the process under conditions of high loading.     

Development of a continuous cell-recycle fermentation system for production of lactic acid by Lactobacillus paracasei

Experimental devices for stimulating productivity of lactic acid fermentation were installed and an electromagnetic flow-meter and a pneumatic diaphragm pump were employed to alleviate the fouling of the membrane and to improve the durability of membrane cell-recycle bioreactors (MCRBs). In this case, the continuous fermentation using a 5 L automatic fermentor lasted stably over 150 h, and could repeat periodically with simple intermittent on-line cleaning and sterilization of the membrane filtration system. Maximum value of OD₆₂₀ of 98.7 was obtained, six times greater than that of the fed-batch fermentation. Meanwhile, maximum productivity of 31.5 g/(L h) was recorded, 10 times greater than that occurred in the fed-batch fermentation. Compared with conventional MCRBs, the MCRB system with a diaphragm pump and tangential flow-rate controlling was more stable and durable. The tangential velocity of membrane module could be monitored and controlled on-line, and the possibility of contamination due to hose rupture could be eliminated.     

Anaerobic membrane reactor with phase separation for the treatment of cheese whey

Two-phase anaerobic digestion of cheese whey was investigated in a system consisting of a stirred acidogenic reactor followed by a stirred methanogenic reactor, the latter being coupled to a membrane filtration system to enable removal of soluble effluent whilst retaining solids. The acidogenic reactor was operated at a hydraulic retention time (HRT) of one day, giving maximum acidification of 52.25% with up to 5 g/l volatile fatty acids, of which 63.7% was acetic acid and 24.7% was propionic acid. The methanogenic reactor received an organic load up to 19.78 g COD/ld, corresponding to a HRT of 4 days, at which 79% CODs and 83% BOD(5) removal efficiencies were obtained. Average removals of COD, BOD(5) and TSS in the two-phase anaerobic digestion process were 98.5%, 99% and 100%, respectively. The daily biogas production exceeded 10 times reactor volume and biogas methane content was greater than 70%.