Comparison of the performances of stirred tank and airlift tower loop reactors.

Following a consideration of the prerequisites for reactor comparison and the fundamental differences between stirred tank and airlift tower loop reactors, their performances are compared for the production of secondary metabolites: penicillin V by Penicillium chrysogenum, cephalosporin C by Cephalosporium acremonium, and tetracycline by Streptomyces aureofaciens. In stirred tank reactors, cell mass concentrations, volumetric productivities, and specific power inputs are higher than in airlift tower loop reactors. In the latter, efficiencies of oxygen transfer are higher, and specific productivities with regard to power input, substrate and oxygen consumptions, and yield coefficients of product formation with regard to substrate and oxygen consumptions are considerably higher than in stirred tank reactors. The prerequisites for improved performance are discussed.     

Interpretation of the gas residence time distributions in large stirred tank reactors

The behaviour of dispersed gas in large aerated stirred tank reactors is modelled by means of a Markov-process, which distinguishes between small recirculation bubbles with stagnant gas content, large rising bubbles with active gas content and exchange of stagnant and active gas contents, the gas exchange region at the impeller. The measurements of the gas residence time distributions (RTDs) in an 1.5 m³ aerated stirred tank reactor with water and Penicillium chrysogenum cultivation medium are interpreted by this model.List of Symbols CPR CO₂ production rate - OTR oxygen transfer rate - PRS pseudo random signal - RTD residence time distribution - V gas volume - recirculation coefficient - mean gas residence time Indices act active gas - ex gas exchange - stagn stagnant gas - tot total gas Dedicated to the 65th birthday of Professor Fritz Wagner.The authors thank Hoechst AG for the strain and the medium components, the GBF for the support of the experiments and H.M. Rüffer thanks the Verband der Chemischen Industrie for a Fond-der-Chemie scholarship.     

Citric acid production and morphology of Aspergillus niger as functions of the mixing intensity in a stirred tank and a tubular loop bioreactor

The relationship between Aspergillus niger morphology and citric acid production was investigated in two reactor systems with different configurations, a tubular loop and a stirred tank bioreactor, with operating volumes of 6 and 8 dm³, respectively. Morphology was quantified by image analysis. In each system, morphology, characterized by the parameter P (mean convex perimeter of clumps), and citric acid production, were agitation-dependent and closely linked. Increased agitation caused a reduction of clump sizes and results when both reactors demonstrate that the parameter P should not exceed a threshold value in order to achieve increased productivities. The results obtained from the two reactors were in agreement, both qualitatively and quantitatively. Reducing the fundamentally different mixing conditions of the two bioreactors to the order of the dimensionless mixing parameter relative mixing time (τ_m), results showed that the loop simulated the stirred tank. Also, relationships valid for one system accurately described the results obtained from the other system, demonstrating the validity of the relationship between morphology and productivity for the particular fermentation, regardless of the reactor type. Previous attempts to evaluate the use of loop configurations as scale-up tools and their performance as bioreactors, neglected the morphology of the producer micro-organisms. This study demonstrated the close link between morphology and productivity for citric acid production by A. niger, and identified a morphology parameter that was used successfully to characterize the process performance.     

Biological degradation of 2,4-dichlorophenoxyacetic acid: chloride mass balance in stirred tank reactors.

A mass balance was developed for the degradation of 2,4-dichlorophenoxyacetic acid by a mixed culture. Batch culture experiments showed the degradation to be an acid-producing step. Inorganic chloride concentration consistently correlated with the expected value and with base consumption to maintain a constant pH.     

Optimum design of a series of continuous stirred tank reactors containing immobilised growing cells

The optimum design of a series of continuously operated stirred-tank reactors containing immobilised growing cells is described. Optimal design is defined as the minimal total holding time over the reactor series to achieve a certain degree of conversion. The analysis is made under the assumptions that there is a constant and equal concentration of immobilised biomass in all bioreactors along the series, no diffusion limitation takes place, all growth of the immobilised biomass will lead to an increase in suspended biomass, and that maintenance of the immobilised cells can be neglected. It is shown that the use of more than three bioreactors in series is likely to be de trop.     

Co-immobilized aerobic/anaerobic mixed cultures in stirred tank and gaslift loop reactors

Co-immobilized Aspergillus awamori and Zymomonas mobilis cultures were investigated in a stirred tank reactor on synthetic medium with starch as substrate at various dissolved oxygen concentrations. In a gaslift loop reactor, freely suspended and immobilized A. awamori were cultivated on synthetic medium and soluble potato starch. In the same reactor, the growth and ethanol production of freely suspended and immobilized Z. mobilis cultures were studied on synthetic medium and glucose. Co-immobilized A. awamori and Z. mobilis were cultivated in batch and continuous operations in the gaslift loop reactor on synthetic medium with starch substrate at different dissolved oxygen concentrations. The interrelations between the different process variables are discussed.     

Cultivation of Phanerochaete chrysosporium and production of lignin peroxidases in submerged stirred tank reactors

Production of lignin peroxidases by Phanerochaete chrysosposorium in a submerged stirred tank reactor is affected by certain critical parameters, some of which have been investigated in the present paper. These factors are: inoculum, pellet size, certain organic compounds such as polypropylene glycol or polyethylene glycol, culture conditions and composition.A rich inoculum results in formation of small pellets, fast depletion of glucose, and no production of lignin peroxidase. Reduced inoculum size prolongs the development of the culture followed by an active so-called secondary phase. The activity of the culture, however, is just enough to decolorize the blue color of Remazol dye but not strong enough to show extracellular lignin peroxidase. The presence of polypropylene glycol (PPG), polyethylene glycol (PEG) or hexadecane in the culture activates the culture towards lignin peroxidase production. The favorable effect of PPG exists only in cultures made up with tap water and reduced inoculum size at pH 4.5. Trace elements but not vitamins may be left out of the medium without impairing lignin peroxidase-producing ability. The use of desalinated water leads not only to the absence of lignin peroxidase production but also to retardation in growth of the fungi, emphasizing the need for a systematic investigation of the culture medium. The experiments were conducted in a 42 l stirred tank reactor and scaled up to 300 l reactor. Constant impeller tip speed and constant gas flow rate are not sufficient criteria for upscaling of this system.     

Production of optically pure L-alanine in batch and continuous stirred tank reactors using immobilized Pseudomonas sp.

A process to obtain optically pure l-alanine has been developed using batch and continuous stirred tank reactors with a new l-aminoacylase-producing bacterium Pseudomonas sp. BA2 immobilized in calcium alginate beads coated with glutaraldehyde. The maximum production of l-alanine in a continuous stirred tank reactor was 11.26 g after 2 days of operation which is higher than that previously reported.     

Degradation of dimethylamine salt of 2,4-dichlorophenoxyacetate by a mixed bacterial culture in stirred tank reactors

Summary An aerated microbiological process was tested in 1.5-l stirred tank reactors for the treatment of dimethylamine salt of 2,4-dichlorophenoxyacetate (2,4-D). A mixed culture was used with the concentration range of 54 to 216 mg 2,4-D/l. The highest concentration was completely depleted within 6 to 8 days of contact time. 2,4-Dichlorophenol, the first intermediate of the degradative pathway, accumulated transiently in the growth medium.     

Estimation of oxygen mass transfer coefficient in stirred tank reactors using artificial neural networks

The estimation of volumetric mass transfer coefficient, k(L)a, in stirred tank reactors using artificial neural networks has been studied. Several operational conditions (N and V(s)), properties of fluid (μ(a)) and geometrical parameters (D and T) have been taken into account. Learning sets of input-output patterns were obtained by k(L)a experimental data in stirred tank reactors of different volumes. The inclusion of prior knowledge as an approach which improves the neural network prediction has been considered. The hybrid model combining a neural network together with an empirical equation provides a better representation of the estimated parameter values. The outputs predicted by the hybrid neural network are compared with experimental data and some correlations previously proposed in the literature for tanks of different sizes.     

Comparison of air-lift and stirred tank reactors for itaconic acid production by Aspergillus terreus

In a 2-l stirred tank reactor (STR), maximum production rate ofitaconic acid was 0.48g/l.h , for an agitation rate of 400 rpm andan aeration rate of 0.5 vvm. In an air-lift reactor (ALR) themaximum production rate was 0.64 g/l.h at an O supply rate of0.41 l O /l. min. Power input per unit volume which gave themaximum production rates for STR and ALR were 1180 and 542 W/m 3,respectively. If O -enriched air was used in place of air for ALR,the corre-sponding power input per unit volume was decreased to 34W/m 3 . ALR requires less power input per unit volume in comparisonwith that of STR whether therefore air or O -enriched air is used.ALR would be a suitable bioreactor for a large production of itaconicacid.     

Biotransformation of β-methyldigitoxin by cell cultures ofDigitalis lanata in airlift and stirred tank reactors

Summary Digitalis lanata cells were grown at dif-ferent dissolved-oxygen (DO) levels in 20-1 airlift reactors. A DO level of 30% saturation (using air for aeration) was found to be optimal for growth and the biotransformation ofβ-methyldigitoxin toβ-methyldigoxin. Product yield was further in-creased by using stirred tank reactors instead of the airlift reactor.     

Biological degradation of 2,4-dichlorophenoxyacetic acid: chloride mass balance in stirred tank reactors

A mass balance was developed for the degradation of 2,4-dichlorophenoxyacetic acid by a mixed culture. Batch culture experiments showed the degradation to be an acid-producing step. Inorganic chloride concentration consistently correlated with the expected value and with base consumption to maintain a constant pH.     

Oxygen transfer in three-phase airlift and stirred tank reactors using silicone oil as transfer vector

The use of organic liquids as vectors to enhance mass transfer has been applied since the 1970s. However, mass transfer in three-phase reactors is only partially understood. This paper aimed to characterize oxygen transfer in three-phase reactors containing air as gas, silicone oil as vector and water as aqueous phase. A mass transfer model that considers separately air/vector, vector/water and air/water oxygen transfers was developed. The model was used to describe oxygen transfer in airlift and stirred tank reactors containing from 0 to 50% of silicone oil. Under the experimental conditions, silicone oil had a positive effect on the overall oxygen transfer. In both reactor designs, the maximum overall oxygen transfer was observed with 10% silicone oil which was increased by 65 and 84% in the airlift and stirred reactor, respectively, compared to reactors operated without silicone oil. The overall transfer increase was mainly due to an enhanced air/water transfer. With 10% silicone oil, the air/water contribution to the overall oxygen transfer was 94.7 and 93.0% for the airlift and stirred reactor, respectively.     

Screening of two terrestrial cyanobacteria for biotechnological production processes in shaking flasks,bubble columns,and stirred tank reactors

Terrestrial cyanobacteria are rarely used for biotechnological processes, although they show great potential in terms of value-added substances. Cyanobacteria from arid habitats are of particular interest because they tolerate higher temperatures and feature a different product spectrum compared with their aquatic counterparts. In addition, terrestrial cyanobacteria may represent an interesting source of pharmaceutical products. To investigate the future use of these organisms in biotechnological processes, the growth rates of Trichocoleus sociatus (formerly Microcoleus sociatus) and Nostoc muscorum were examined using three different cultivation systems: shaking flasks, bubble columns, and stirred tank reactors. Parameters including pH, temperature, CO₂ level, and power dissipation were investigated quantitatively in the three systems for their impact on growth rate. The highest growth rate of the terrestrial cyanobacteria could be achieved in a stirred tank reactor under enriched CO₂ concentration. In this system, the growth rate was 1.15 day^-1?±?0.08 (2 % vol.) for T. sociatus and 0.72 day^-1?±?0.22 (5 % vol.) for N. muscorum, based on dry weight. Furthermore, a basic mathematical model was created as an add-on to predict growth rates of terrestrial cyanobacteria based on their dependency on temperature, pH, and substrate concentration, in general. This model was used to estimate growth of N. muscorum in stirred tank reactor experiments with an accuracy of 98.8 % and with 75 % accuracy for T. sociatus.     

Optimization of agitation for production of swainsonine from Metarhizium anisopliae in stirred tank and airlift reactors

The optimal agitation rate for production of swainsonine from Metarhizium anisopliae grown in batch stirred tank reactors (2 to 20 l) was 400 rpm with a mixed hyphal and pelleted morphology where the specific swainsonine production rate was 9×10^–2 mg g^–1 cell dry wt h from 87 to 142 h. Culture of the fungus in a 6-l airlift reactor produced loose pellets and the production of swainsonine started at least 24 h earlier than in the stirred tank reactor. The final yield (5.9 mg swainsonine g^–1 cell dry wt) after 168 h in the airlift reactor was 18% less than those obtained in the stirred tank reactor with an agitation rate of 400 rpm.     

A pilot-scale study of struvite precipitation in a stirred tank reactor: conditions influencing the process

Currently, the two most developed techniques for recovering phosphorus from wastewater consist of the formation of calcium phosphates and struvite (MgNH(4)PO(4).6H(2)O). In this work the influence of the operational conditions on the struvite precipitation process (pH in the reactor, hydraulic retention time, and magnesium:phosphorus, nitrogen:phosphorus, and calcium:magnesium molar ratios) have been studied. Twenty-three experiments with artificial wastewater were performed in a stirred reactor. In order to obtain the pH value maintenance during the crystallization process, a fuzzy logic control has been developed. High phosphorus removal efficiencies were reliably achieved precipitating the struvite as easily dried crystals or as pellets made up of agglomerated crystals.     

Biodegradation of phenol in a continuous process: comparative study of stirred tank and fluidized-bed bioreactors

The paper presents the main results obtained from the study of the biodegradation process of phenol by a pure culture of Pseudomonas putida ATCC 17484. The experimental work was carried out in two different systems: a stirred tank where cells grew as a suspended culture and a fluidized bed where cells were immobilized within calcium alginate gel beads. The influence of the hydraulic residence time (HRT) and organic loading rate on the removal efficiency of phenol was determined for both bioreactors. Also, the stability of the fluidized-bed bioreactor (FBB) in terms of its ability to withstand sudden phenol overdoses is also reported. Experimental values indicated that both bioreactors showed high phenol degradation efficiencies, higher than 90%, even for a phenol loading rate in the influent as high as 4 g phenol/l day. The FBB showed better performance than the suspended-culture bioreactor due to its better control and because it could operate with lower HRT.     

The effect of heavy metals on microbial community structure of a sulfidogenic consortium in anaerobic semi-continuous stirred tank reactors

The effect of heavy metals on community structure of a heavy metal tolerant sulfidogenic consortium was evaluated by using a combination of denaturing gradient gel electrophoresis (DGGE) of 16S rRNA gene and dissimilatory sulfite reductase (dsrB) gene fragments, 16S rRNA gene cloning analysis and fluorescence in situ hybridization (FISH). For this purpose, four anaerobic semi-continuous stirred tank reactors (referred as R1–R4) were run in parallel for 12 weeks at heavy metal loading rates of 1.5, 3, 4.5 and 7.5 mg l^?1 d^?1 each of Cu²⁺, Ni²⁺, Zn²⁺, and Cr⁶⁺, respectively. The abundance ratio of Desulfovibrio vulgaris detected by FISH to total cell counts was consistent with the obtained results of cloning and DGGE. This indicated that D. vulgaris was dominant in all analyzed samples and played a key role in heavy metal removal in R1, R2, and R3. In contrast, after 4 weeks of operation of R4, a distinct biomass loss was observed and no positive hybridized cells were detected by specific probes for the domain Bacteria, sulfate-reducing bacteria and D. vulgris. High removal efficiencies of heavy metals were achieved in R1, R2 and R3 after 12 weeks, whereas the precipitation of heavy metals in R4 was significantly decreased after 4 weeks and almost not observed after 6 weeks of operation. In addition, the anaerobic bacteria, such as Pertrimonas sulfuriphila, Clostridium sp., Citrobacter amalonaticus, and Klebsiella sp., identified from DGGE bands and clone library were hypothesized as heavy metal resistant bacteria at a loading rate of 1.5 mg l^?1 d^?1 of Cu²⁺, Ni²⁺, Zn²⁺, and Cr^6+.