High-density algal photobioreactors using light-emitting diodes

Lack of high-density algal photobioreactors (PBR) has been a limitation in exploiting the biotechnological potential of algae. Recent developments of highly efficient light-emitting diodes (LED using gallium aluminum arsenide chips) have made the development of a small LED-based PBR possible. We have calculated theoretical values of gas mass transfer requirements and light-intensity requirement to support high-density algal cultures for the 680 nm monochromatic red light from LED as a light source. A prototype PBR has been designed based on these calculations. A cell concentration of more than 2 x 10(9) cells/mL (more than 6.6% v%sol;v), cell doubling times as low as 12 h, and an oxygen production rate as high as 10 mmol oxygen/L culture/h were achieved using on-line ultrafiltration to periodically provide fresh medium. (c) 1994 John Wiley & Sons, Inc.     

The Super-Spinner: A low cost animal cell culture bioreactor for the CO2 incubator

The production of small quantities of monoclonal antibodies and recombinant proteins was carried out using a new low cost production system, the Super Spinner. Into a 1 1 standard Duran^® flask a membrane stirrer equipped with a polypropylene hollow fiber membrane was installed to improve the oxygen supply by bubble-free aeration. The aeration was facilitated by using the CO₂ conditioned incubator gas, which was pumped through the membrane stirrer via a small membrane pump. The maximal oxygen transfer rate (OTR_max) of the Super Spinner was detected. For this purpose one spinner flask was equipped with an oxygen electrode. The OTR_max was measured by the dynamic method. The ratio of membrane length to culture volume was adapted corresponding to the oxygen uptake rate of the cells according to the desired cell density. A balanced nutrient supply resulted in an optimal formation and yield of products.     

High cell density suspension culture of mammalian anchorage independent cells: Oxygen transfer by gas sparging and defoaming with a hydrophobic net

Gas sparging directly into the culture-broth is not done in cell culture, except when the gas flow rate is very small, because much foaming occurs.During screening of defoaming methods, foam was observed to be broken up effectively when it made contact with a net fabricated from hydrophobic materials. Providing a highly efficient oxygen supply to suspension culture was tried using the new defoaming method. In a 5 1 reactor equipped with the foam-eliminating net fabricated with polysiloxane, oxygen was transferred at 21 mmole/l·h equivalent to an about forty-fold higher rate than in conventional surface aeration. This was equivalent to a consumption rate of 1×10⁸ cells/ml, even at a low oxygen gas flow rate of 0.1 cm/s corresponding to a fourth of the gas flow rate when foam leaked through the net.Perfusion culture of rat ascites hepatoma cell JTC-1 was successfully carried out in the 51 scale culture system with the net and a hydrophobic membrane for cell filtration. The viable cell concentration reached 2.7×10⁷ cells/ml after twenty-seven days, in spite of the nutrient-deficient condition of the lower medium exchange rate, that is, a working volume a day, and viability was maintained at more than 90%. In a 1.21 scale culture of mouse-mouse hybridoma cell STK-1, viable cell concentration reached 4×10⁷ cells/ml. These results showed that oxygen transfer by gas sparging with defoaming was useful for high density suspension culture. A foam-breaking mechanism was proposed.Abbreviations Eagle's MEM Eagle's minimal essential medium - Dulbecco's modified Eagle MEM Dulbecco's modified Eagle minimal essential medium     

An investigation of bioreactor performance for the production of recombinant protein in immobilized and suspended Escherichia coli

The performance of packed bed (PBR) and modified bubble tank (MBTR) reactors was compared with respect to recombinant protein (β-galactosidase) production by suspended and immobilized E. coli. The MBTR was superior to the PBR due to easy operation and higher protein production. Gas-liquid mass transfer was not affected by the presence of gel beads, and there were no internal or external oxygen diffusion limitations in either reactor. High substrate concentration, small bead size, low cell densities, and similar values of effective diffusion coefficient of oxygen in water and in alginate may have decreased the internal mass transfer limitations.     

Understanding factors that limit the productivity of suspension-based perfusion cultures operated at high medium renewal rates

One of the key parameters in perfusion culture is the rate of medium replacement (D). Intensifying D results in enhanced provision of nutrients, which can lead to an increase in the viable cell density (X(v)). The daily MAb production of hybridoma cells can thus be increased proportionally without modifying the bioreactor scale, provided that both viable cell yield per perfusion rate (Y(Xv/D)) and specific MAb productivity (q(MAb)) remain constant at higher D. To identify factors prone to limit productivity in perfusion, a detailed kinetic analysis was carried out on a series of cultures operated within a D range of 0.48/4.34 vvd (volumes of medium/reactor volume/day) in two different suspension-based systems. In the Celligen/vortex-flow filter system, significant reductions in Y(Xv/D) and q(MAb) resulting from the use of gas sparging were observed at D > 1.57 vvd (X(v) > 15 x 10(6) cells/mL). Through glucose supplementation, we have shown that the decrease in Y(Xv/D) encountered in presence of sparging was not resulting from increased cellular destruction or reduced cell growth, but rather from glucose limitation. Thus, increases in hydrodynamic shear stress imparted to the culture via intensification of gas sparging resulted in a gradual increase in specific glucose consumption (q(glc)) and lactate production rates (q(lac)), while no variations were observed in glutamine-consumption rates. As a result, while glutamine was the sole limiting-nutrient under non-sparging conditions, both glutamine and glucose became limiting under sparging conditions. Although a reduction in q(MAb) was observed at high-sparging rates, inhibition of MAb synthesis did not result from direct impact of bubbles, but was rather associated with elevated lactate levels (25-30 mM), resulting from shear stress-induced increases in q(lac), q(glc), and Y(lac/glc). Deleterious effects of sparging on Y(Xv/D) and q(MAb) encountered in the Celligen/vortex-flow filter system were eliminated in the sparging-free low-shear environment of the Chemap-HRI/ultrasonic filter system, allowing for the maintenance of up to 37 x 10(6) viable cells/mL. A strategy aimed at reducing requirements for sparging in large-scale perfusion cultures by way of a reduction in the oxygen demand using cellular engineering is discussed.     

The scale-up of plant cell culture: Engineering considerations

The enormous versatility of plants has continued to provide the impetus for the development of plant tissue culture as a commercial production strategy for secondary metabolites. Unfortunately problems with slow growth rates and low products yields, which are generally non-growth associated and intracellular, have made plant cell culture-based processes, with a few exceptions, economically unrealistic. Recent developments in reactor design and control, elicitor technology, molecular biology, and consumer demand for natural products, are fuelling a renaissance in plant cell culture as a production strategy. In this review we address the engineering consequences of the unique characteristics of plant cells on the scale-up of plant cell culture.Abbreviations a gas-liquid interfacial area per volume - C dissolved oxygen concentration - C^* liquid phase oxygen concentration in equilibrium with the partial pressure of oxygen in the bulk gas phase - K_L overall mass transfer coefficient - k_L liquid film mass transfer coefficient - m_O2 cell maintenance coefficient for oxygen - OTR oxygen transfer rate - OUR oxygen uptake rate - pO₂ partial pressure of oxygen - STR stirred-tank reactor - v.v.m. volume of gas fed per unit operating volume of reactor per minute - X biomass concentration - Y_x/O2 biomass yield coefficient for oxygen - specific growth rate     

Errors in measurements of aquatic macrophyte gas exchange due to oxygen storage in internal airspaces

Dissolved oxygen measurements of respiratory and photosynthetic gas exchanges of the aquatic angiosperm Egeria densa Planch. and vesicles of the macroalga Carpophyllum maschalocarpum (Turn.) Grev. were made using a Clark-type oxygen electrode in a well-stirred closed chamber. Comparisons were made of dark—light and light—dark transients and light and dark oxygen exchanges for intact material and the same material with the internal airspaces flooded.For Egeria, there was an apparently greater gas exchange (up to 17% for photosynthesis and 50% for respiration) for infiltrated material. The duration of transient lags following light and dark treatments remained unchanged by infiltration, indicating that the storage error could not be detected from lag duration. The storage error during photosynthesis agreed closely with theoretical predictions based on oxygen solubility, but additional factors contribute to the dark error. Carpophyllum results were unpredictable from solubility calculations as the thick vesicle walls restricted exchange between the internal and external phases, allowing internal oxygen storage only at high external partial pressures.The widespread assumption that short lag phases indicate negligible internal oxygen storage in the gas spaces is questioned on the basis of these results. Solutions to the storage error are proposed.     

Design of a bubble-swawm bioreactor for animal cell culture

A stationary bubble-swarm has been used to aerate a mammalian cell culture bioreactor with an extremely low gas flow rate. Prolonging the residence time of the gas bubbles within the medium improved the efficiency of the gas transfer into the liquid phase and suppressed foam formation. An appropriate field of speed gradients prevented the bubbles from rising to the surface. This aeration method achieves an almost 90% transfer of oxygen supplied by the bubbles. Consequently, it is able to supply cells with oxygen even at high cell densities, while sparging with a gas flow of only 0.22·10^–3–1.45·10^–3 vvm (30–200 ml/h).The reactor design, the oxygen transfer rates and the high efficiency of the system are presented. Two repeated batch cultures of a rat-mouse hybridoma cell line are compared with a surface-aerated spinner culture. The used cell culture medium was serum-free, either with or without BSA and did not contain surfactants or other cell protecting agents. One batch is discussed in detail for oxygen supply, amino acid consumption and specific antibody production.     

Membrane sparger in bubble column,airlift, and combined membrane–ring sparger bioreactors

The bubble column and the two internal loop airlift reactors (riser/downcomer area ratios of 0.11 and 0.58) characterized in this study were equipped with a rubber membrane sparger, which produced small bubbles, giving high mass transfer coefficients. The low mixing intensity in the bubble column was increased by an order of magnitude in the airlift reactors. We designed a novel aeration and mixing system by adding a ring sparger to the membrane sparger in the bubble column and maintained the advantages of both airlift configuration (good mixing properties) and bubble column configuration (efficient aeration, without any internal constructions). The combined membrane–ring sparger system has unique features with respect to the efficiency of utilization of substrate gasses and energy. Model experiments showed that the small bubbles from the membrane sparger do not coalesce with the large bubbles from the ring sparger. If different gases were added through the two spargers it was possible to transfer a hazardous or expensive gas quantitatively to the liquid through the membrane sparger (dual sparging mode). In the combined membrane–ring sparger system the energy input for mixing and mass transfer is divided. Therefore, the energy consumption can be minimized if the flow distribution of air through the membrane and ring sparger is controlled by the oxygen demand and the inhomogeneity of the culture, respectively (split sparging mode). The dual sparging mode was used for mass production of the alga Rhodomonas sp. as the first step in aquatic food chains. Avoiding mechanical parts removes an important risk of malfunction, and a continuous culture could be maintained for more than 8 months. © 1999 John Wiley & Sons, Inc. Biotechnol Bioeng 64: 452–458, 1999.     

A test facility for fritted spargers of production-scale-bioreactors

The production of therapeutic proteins requires qualification of equipment components and appropriate validation procedures for all operations. Since protein productions are typically performed in bioreactors using aerobic cultivation processes air sparging is an essential factor. As recorded in literature, besides ring spargers and open pipe, sinter frits are often used as sparging elements in large scale bioreactors. Due to the manufacturing process these frits have a high lot-to-lot product variability. Experience shows this is a practical problem for use in production processes of therapeutic proteins, hence frits must be tested before they can be employed. The circumstance of checking quality and performance of frits as sparging elements was investigated and various possibilities have been compared. Criteria have been developed in order to evaluate the sparging performance under conditions comparable to those in production bioreactors. The oxygen mass transfer coefficient (k _L a) was chosen as the evaluation criterion. It is well known as an essential performance measure for fermenters in the monoclonal antibody production. Therefore a test rig was constructed able to automatically test frit-spargers with respect to their k _L a-values at various gas throughputs. Performance differences in the percent range could be detected.     

Oxygen transfer from silicone hollow fiber membrane to water

Silicone rubber hollow fiber was able to enrich the oxygen concentration in air by about 30%, and oxygen was transferred sufficiently from the membrane to water. When an aeration tank was filled with hollow fiber to up to 10% of its volume, the oxygen utilization rate, Rr, was about seven times as much as the value in the standard activated sludge method. It is suggested that there is some possibility of improving the efficiency of aerobic wastewater treatment by using this system.     

Enhancement of gas-liquid mass transfer rate of apolar pollutants in the biological waste gas treatment by a dispersed organic solvent

Dispersed water-immiscible solvents are known to enhance oxygen transfer rates in oxygen-limited aerobic fermentations. Here, this technique is applied to improve the mass transfer rate of poorly water-soluble gaseous pollutants during the biological treatment of waste gases. In a stirred-tank reactor, the enhancement of mass transfer rates was studied as a function of the pollutant solubility in water. The solvent used was FC40 (up to 10% v/v) and the model gaseous pollutants were toluene and oxygen (moderately and poorly water-soluble, respectively).

The overall volumetric mass transfer coefficient from the gas to the bulk liquid (k_la_gl) was measured under nonsteady-state conditions in the absence of micro-organisms. It was found to be essentially constant for the solvent volume fractions tested and for both toluene and oxygen. Using the values of k_la_gl and the partition coefficient gas/liquid (m_gl), the enhancement of the mass transfer rate by solvent addition could be predicted theoretically. A good agreement between the theoretical evaluation and the experimental results from experiments in the presence of biological consumption was observed. An enhancement of the mass transfer rate by a factor of 1.1 was found for toluene using a dispersion containing 10% (v/v) FC40 while the oxygen transfer rate increased by a factor of two at the same solvent volume fraction. It was further demonstrated theoretically for other gaseous compounds that the addition of solvent has a more pronounced effect on the enhancement of the transfer rate in the case of poorly water-soluble compounds compared to moderately water-soluble ones.     

Substrate consumption rates for hydrogen production by Rhodobacter sphaeroides in a column photobioreactor

The effect of -malic acid and sodium glutamate, which serve as the carbon and nitrogen source, respectively, on hydrogen production by Rhodobacter sphaeroides O.U.001 has been investigated in a batch water jacketed glass column photobioreactor (PBR), which has an inner volume of 400 ml. The PBR was operated at different carbon to nitrogen ratios at 32°C with a tungsten lamp at a light intensity of 200 W m⁻². Carbon to nitrogen ratio was found to be an important parameter for bio-hydrogen production. Moreover, hydrogen gas production was dependent on certain threshold concentrations of sodium glutamate. -malic acid consumption was found to be first order with respect to -malic acid concentration, whereas sodium glutamate consumption was found to be second order with respect to glutamate concentration. It was concluded that there is a close relationship between the hydrogen production rate and substrate consumption rates. A kinetic model is developed, which relates hydrogen gas production per amount of biomass, -malic acid, and sodium glutamate concentrations.     

Effects of stirring and sparging on cultured hybridoma cells

The response of hybridoma cells to fluid shear caused by stirring and sparging has been investigated in a 2-L turbine-agitated bioreactor. Viable cell count, lactate dehydrogenase (LDH) release, and antibody secretion were measured over the course of batch culture experiments under varied conditions of stirring and gas sparging. The effectiveness of Pluronic F68 as a protective agent in sparged cultures was also studied. Growth was found to be unaffected by stirring of the culture under surface aerated conditions, but gas sparging had a significant detrimental effect on growth and antibody production. The effect of sparging was reduced when cultures were supplemented with Pluronic at a level of 0.4% (w/v). Experimental data were analyzed through formulation of models for LDH release and antibody production. Rates of cell lysis could be estimated by correlating extracellular LDH levels through the model for LDH release. The lysis rate estimated for sparged conditions was sufficiently large to approximately account for the observed decrease in the specific growth rate of the culture. The presence of Pluronic apparently interfered with the LDH release mechanism, so precise estimation of lysis rates under these conditions was not possible. Sparging was found not to have a detrimental effect on antibody production in cultures without Pluronic added. Specific antibody production rates in cultures supplemented with Pluronic were about 25% higher than in sparged cultures without Pluronic added.     

Enhancing oxygen transfer in surface-aerated bioreactors by stable foams.

To enhance oxygen transfer in surface-aeration bioreactors, stabilized foams were generated to increase the gas-liquid interfacial area by slowly introducing coarse bubbles into media containing fetal bovine serum. The bubble sparging rates were so low (i.e., 20 and 50 mL/h) that the contribution to oxygen transfer from these bubbles was due to foaming instead of bubbling. Furthermore, no physical cell damage caused by bubble sparging was observed. Oxygen transfer coefficients, kLa, in the bioreactors were measured in cell-free media. Without the foam-stabilizing agent (i.e., serum), no appreciable change in kLa was observed due to the bubble sparging. On the other hand, with serum, kLa increased with increasing serum content and bubble sparging rate and corresponded well with the degree of foaming. With 10% fetal bovine serum and a bubble sparging rate of 50 mL/h, kLa increased approximately 90% compared with no foaming. The enhancing effect of foam on oxygen transfer in surface aeration bioreactors has been further demonstrated with hybridoma cultures simultaneously grown in three identical bioreactors with and without stabilized foams.     

A multikinetic model approach to predict gluconic acid production in an airlift bioreactor

This paper uses a multikinetic approach to predict gluconic acid (GA) production performance in a 4.5 L airlift bioreactor (ALBR). The mathematical model consists of a set of simultaneous firstorder ordinary differential equations obtained from material balances of cell biomass, GA, glucose, and dissolved oxygen. Multikinetic models, namely, logistic and contois equations constitute kinetic part of the main model. The main model also takes into account the hydrodynamic and mass transfer parameters. These equations were solved using ODE solver of MATLAB v6.5 software. The mathematical model was validated with the experimental data available in the literature and is used to predict the effect of change in initial biomass and air sparging rate on the GA production. It is concluded that the mathematical model incorporated with multikinetic approach would be more efficient to predict the change in operating parameters on overall bioprocess of GA production in an ALBR.     

Membrane process for biological treatment of contaminated gas streams

A hollow fiber membrane bioreactor was investigated for control of air emissions of biodegradable volatile organic compounds (VOCs). In the membrane bioreactor, gases containing VOCs pass through the lumen of microporous hydrophobic hollow fiber membranes. Soluble compounds diffuse through the membrane pores and partition into a VOC degrading biofilm. The hollow fiber membranes serve as a support for the microbial population and provide a large surface area for VOC and oxygen mass transfer. Experiments were performed to investigate the effects of toluene loading rate, gas residence time, and liquid phase turbulence on toluene removal in a laboratory-scale membrane bioreactor. Initial acclimation of the microbial culture to toluene occurred over a period of nine days, after which a 70% removal efficiency was achieved at an inlet toluene concentration of 200 ppm and a gas residence time of 1.8 s (elimination capacity of 20 g m-3 min-1). At higher toluene loading rates, a maximum elimination capacity of 42 g m-3 min-1 was observed. In the absence of a biofilm (abiotic operation), mass transfer rates were found to increase with increasing liquid recirculation rates. Abiotic mass transfer coefficients could be estimated using a correlation of dimensionless parameters developed for heat transfer. Liquid phase recirculation rate had no effect on toluene removal when the biofilm was present, however. Three models of the reactor were created: a numeric model, a first-order flat sheet model, and a zero-order flat sheet model. Only the numeric model fit the data well, although removal predicted as a function of gas residence time disagreed slightly with that observed. A modification in the model to account for membrane phase resistance resulted in an underprediction of removal. Sensitivity analysis of the numeric model indicated that removal was a strong function of the liquid phase biomass density and biofilm diffusion coefficient, with diffusion rates below 10(-9) m2 s-1 resulting in decreased removal rates.     

深红红螺菌吸氢酶缺失突变株在管式光合反应器中的产氢

本研究设计了一种2 L分体式管式光合反应器, 并研究了深红红螺菌(Rhodospirillum rubrum)吸氢酶缺失突变株在该反应器中分别利用人工光源(持续光照与光暗交替)和自然光的产氢规律。结果表明在人工光照条件下R. rubrum的产氢可维持5 d, 持续光照和光暗交替条件下(12 h: 12 h)的氢产量可分别达到5752 mL/PBR ± 158 mL/PBR和5012 mL/PBR ± 202 mL/PBR; 自然光条件下, 最适产氢光照强度为30000 Lux~40000 Lux; 在此光照条件下, R. rubrum产氢可维持6 d~ 10 d, 最高氢产量可达到2800 mL/PBR。尽管利用自然光的氢产量比利用人工光源氢产量低, 但是利用自然光的产氢比较经济, 并且该光合产氢系统操作简单, 该工艺有望开发为低成本的光合细菌产氢技术。     

Characterization and improvement of oxygen transfer in pilot plant external air-lift bioreactor for mycelial biomass production

The oxygen transfer dynamics in a pilot plant external air-lift bioreactor (EALB) during the cultivation of mycelial biomass were characterized with respect to hydrodynamic parameters of gas holdup (), oxygen transfer coefficient (K_La) and superficial gas velocity (U _g), and dissolved oxygen (DO). An increased flow rate of air supply was required to meet the increased oxygen demand with mycelial biomass growth. Consequently, an increase in air flow rate led to an increase in , K_La and the DO level. The enhancement of oxygen transfer rate in the cultivated broth system, however, was limited with highly increased viscosity of the mycelial broth. An increase in air flow rate from 1.25 to 2.00 v/v/m resulted in a low increment of oxygen transfer. The newly designed pilot plant EALB with two air spargers significantly improved processing reliability, aeration rate and K_La. The pilot plant EALB process, operated under a top pressure from 0 to 1.0 bars, also demonstrated a significant improvement of oxygenation efficiency by more than 20% in DO and K_La. The performance of the two sparger EALB process under top pressure demonstrated an efficient and economical aerobic system with fast mycelial growth and high biomass productivity in mycelial biomass production and wastewater treatment.