Sustainable, High-Yielding Outdoor Mass Cultures of Chaetoceros muelleri var. subsalsum and Isochrysis galbana in Vertical Plate Reactors

Continuous cultures of Chaetoceros muelleri and Isochrysis galbana were grown outdoors in flat plate-glass reactors in which light-path length (LPL) varied from 5 to 30 cm. High daily productivity (13 to 16 g cell mass per square meter of irradiated reactor surface) for long periods of time was obtained in reactors in which the optical path as well as cell density were optimized. 'Twenty centimeters was the optimal LPL, yielding the highest areal productivity of cell mass (g m^–2d^–1), eicosapentaenoic acid, and docosahexaenoic acid, which was identical with that previously found for polysaccharide production of Porphyridium and not far from the optimal LPL affecting maximal productivity in Nannochloropsis species. Relating the energy impinging on a given reactor surface area to the appropriate number of cells showed that the most efficient light dose per cell, obtained with the 20-cm LPL reactor, was approximately 2.5 times lower than the light dose available per cell in the 5-cm LPL reactor, in which a significant decline in areal cell density accompanied the lowest areal output of cell mass. The most effective harvesting regimen was in the range of 10% to 15% of culture volume harvested daily and replaced with fresh growth medium, resulting in a sustainable culture density of 24 × 10⁶ and 28 × 10⁶ cells/ml of C. muelleri and I. galbana, respectively.     

Development of a hollow-fiber system for large-scale culture of mammalian cells

A flat-bed hollow-fiber cell culture system has been developed which maximizes the utilization of the large fiber surface while diminishing significantly the problems inherent in a cartridge-type reactor. The reactor core consists of a shallow bed of hollow fibers sandwiched between two stainless-steel microporous filter plates through which the media flow is directed normal to the plane of the fiber bed. Reactors with both 930 and 9300 cm² of fiber surface have been successfully constructed and operated. A variety of cells has been grown in these reactors including SV3T3 cells, baby hamster kidney cells, Vero cells, and rhesus money kidney cells, and cell products such as plasminogen activator and migration inhibition factor (MIF) were produced. This system offers an excellent prototype for scaleup design.     

Genetically engineered Escherichia coli FBR5: Part I. Comparison of high cell density bioreactors for enhanced ethanol production from xylose

Five reactor systems (free cell batch, free cell continuous, entrapped cell immobilized, adsorbed cell packed bed, and cell recycle membrane reactors) were compared for ethanol production from xylose using Escherichia coli FBR5. In the free cell batch and free cell continuous reactors (continuous stirred tank reactor‐CSTR) productivities of 0.84 gL^?1 h^?1 and 1.77 gL^?1 h^?1 were achieved, respectively. A cell recycle membrane reactor resulted in the highest productivity of 55.56 gL^?1 h^?1, which is an increase of 66‐fold (e.g., 6614%) over the batch reactor. Calcium alginate gel CSTR resulted in a productivity of 2.04 gL^?1 h^?1 whereas adsorbed cell packed bed reactor resulted in a productivity of 4.39 gL^?1 h^?1. In the five reactor systems, ethanol concentrations ranged from 18.9 to 40.30 gL^?1 with metabolic yields from 0.44 to 0.51. Published 2012 American Institute of Chemical Engineers Biotechnol. Prog., 2012     

Influence of fluorescent coating at rear and front side of a flat panel photobioreactor on algal growth

The focus of this study is the enhancement of microalgae growth rate using spectral conversion of green light. For this purpose, three reactors were considered and fluorescent pigment Rhodamine 6G was dissolved in a thermoplastic acrylic resin, the mixture was then applied on the front side of the first reactor, and on a mirror located at the rear side of the second one. Comparing their maximum specific growth rate (μ _max) of Chlorella sp. to that in the third (uncoated) reactor, the former resulted in an increase up to 15% while the latter in decrease to at least 30%. Also, the rear side coated reactor showed up to 50% increase in biomass productivity rate (P) in early 4 days of experiment. However, this value decreased over time and the uncoated reactor in 12 days exhibited higher biomass productivity rate.     

Long-term outdoor growth and lipid productivity of Tetraselmis suecica, Dunaliella tertiolecta and Chlorella sp (Chlorophyta) in bag photobioreactors

There has been considerable interest on cultivation of green microalgae (Chlorophyta) as a source of lipid that can alternatively be converted to biodiesel. The ideal microalga characteristics are that it must grow well even under high cell density and under varying outdoor environmental conditions and be able to have a high biomass productivity and contain a high oil content (~25–30 %). The main advantage of Chlorophyta is that their fatty acid profile is suitable for biodiesel conversion. Tetraselmis suecica CS-187 and Chlorella sp. were grown semi-continuously in bag photobioreactors (120 L, W?×?L?=?40?×?380 cm) over a period of 11 months in Melbourne, Victoria, Australia. Monthly biomass productivity of T. suecica CS-187 and Chlorella sp. was strongly correlated to available solar irradiance. The total dry weight productivity of T. suecica and Chlorella sp. was 110 and 140 mg L^?1 d^?1, respectively, with minimum 25 % lipid content for both strains. Both strains were able to tolerate a wide range of shear produced by mixing. Operating cultures at lower cell density resulted in increasing specific growth rates of T. suecica and Chlorella sp. but did not affect their overall biomass productivity. On the other hand, self shading sets the upper limit of operational maximum cell density. Several attempts in cultivating Dunaliella tertiolecta CS-175 under the same climatic conditions were unsuccessful.     

Flow rate and bead size as critical parameters for immobilized-yeast reactors

The productivity of immobilized yeast cell reactors varies with a number of parameters, including flow, amount and growth rate of yeast, bead size and type of medium. Variation of these parameters has a pronounced effect on reaction rate. This paper presents typical ranges for these productivities and demonstrates the patterns of changes that take place when bead size, flow and reaction medium are varied. Saccharomyces cerevisiae cells were immobilized in calcium alginate beads for the production of ethanol. The productivity of immobilized yeast in a batch reactor (0.2 g ethanol/g yeast · h) was only two-thirds that of free cells suspended at an equivalent cell density (0.3 g ethanol/g yeast · h). Different flow rates and bead sizes were used to ‘optimize’ the productivity. The productivity of 3.34 mm beads at a flow rate of 8.8 litre h^?1(superficial velocity: 0.12 cm s^?1) was 95% higher than that at 1.0 l h^?1. Maximum productivities of 0.34, 0.27, 0.22 g/g yeast· h were obtained (at a flow rate of 8.8 l h^?1) for 9.2% yeast-immobilized beads of 3.34, 4.45 and 5.65 mm in diameter, respectively.     

Continuous Asymmetric Reduction Of 4-Oxoisophorone By Thermophilic Bacteria Using A Hollow Fiber Reactor

Continuous asymmetric reduction of 4-oxoisophorone by the thermophilic bacterium Thermomonospora curvata JTS321 was examined using three reactor systems: packed bed, fluidized bed and hollow fiber. T. curvata was immobilized in polyacrylamide-hydrazide gels when used in the packed and fluidized bed reactors. Of the three reactor systems, the highest productivity (964 mg.1^-1.h^-1) was observed in the fluidized bed reactor. However, many cells grew outside of the gel matrix, causing product contamination. The productivity of the hollow fiber reactor was 504 mg.1^-1.h^-1; the problem of cell contamination of the product was avoided, as the molecular cut-off of the hollow fibers (400 000) was of an appropriate size to prevent cell leakage to the product stream. We therefore consider that the hollow fiber reactor is most suitable for continuous microbial conversions.     

Lipid productivity and fatty acid composition in Chlorella and Scenepdesmus strains grown in nitrogen-stressed conditions

Thirty Chlorella and 30 Scenedesmus strains grown in nitrogen-stressed conditions (70 mg L^?1 N) were analyzed for biomass accumulation, lipid productivity, protein, and fatty acid (FA) composition. Scenedesmus strains produced more biomass (4.02?±?0.73 g L^?1) after 14 days in culture compared to Chlorella strains (2.57?±?0.12 g L^?1). Protein content decreased and lipid content increased from days 8 to 14 with an increase in triacylglycerol (TAG) accumulation in most strains. By day 14, Scenedesmus strains generally had higher lipid productivity (53.5?±?3.7 mg lipid L^?1 day^?1) than Chlorella strains (35.1?±?2.8 mg lipid L^?1 day^?1) with the lipids consisting mainly of C16–18 TAGs. Scenedesmus strains generally had a more suitable FA profile with higher amounts of saturated fatty acids and monounsaturated fatty acids (MUFAs) and a smaller polyunsaturated fatty acid (PUFA) component. Chlorella strains had a larger PUFA component and smaller MUFA component. The general trend in the FA composition of Chlorella strains was oleic > palmitic > α-linolenic = linoleic > eicosenoic > heptadecenoic > stearic acid. For Scenedesmus strains, the general trend was oleic > palmitic > linoleic > α-linolenic > stearic > eicosenoic > palmitoleic > heptadecenoic acid. The most promising strains with the highest lipid productivity and most suitable FA profiles were Scenedesmus sp. MACC 401, Scenedesmus soli MACC 721, and Scenedesmus ecornis MACC 714. Although Chlorella sp. MACC 519 had lower lipid productivity, the FA profile was good with a lower PUFA component compared to the other Chlorella strains analyzed and a low linolenic acid concentration.     

Characterization of Persistent Virus-Like Particles in Two Acetate-Fed Methanogenic Reactors

The objective of this study was to characterize the morphology, size-distribution, concentration and genome size of virus-like particles (VLPs) in two acetate-fed Methanosaeta-dominated reactors to better understand the possible correlation between viruses and archaeal hosts. The study reactors were dominated by a single genus of acetoclastic methanogen, Methanosaeta, which was present at 6 to 13 times higher than the combined bacterial populations consisting of Proteobacteria, Firmicutes, and Bacteroidetes. Epifluorescent microscopy showed VLPs concentration of 7.1 ± 1.5×10⁷ VLPs/ml and 8.4 ± 4.3×10⁷ VLPs/ml in the two laboratory reactors. Observations of no detectable import of VLPs with the reactor feed combined long operational time since the last inocula were introduced suggests that the VLP populations were actively propagating in the reactors. Transmission electron microscopy images showed VLPs with morphology consistent with Siphoviridae in both reactors, and VLPs with morphologies consistent with Myoviridae in one of the reactors. The morphology, size-distribution and genome size of VLPs were distinct between reactors suggesting that unique viral populations inhabited each reactor, though the hosts of these VLPs remain unclear.     

Extracellular polysaccharide production in outdoor mass cultures of Porphyridium sp. in flat plate glass reactors

This work concerns an attempt to develop large scalecultivation of Porphyridium sp. outdoors. Theimpact on cell growth and production of solublesulphated polysaccharides of light-path length (LP)was studied in flat plate glass reactors outdoors. TheLP of the plate reactors ranged from 1.3–30 cm,corresponding to culture volumes of 3–72 L. The sidewalls of all reactors were covered, ensuring similarilluminated surfaces for all reactors. Maximal daytemperature was maintained at 26 ±1 ^°C.Growth conditions of pH (7.5), stirring (withcompressed air) and mineral nutrients, were optimal.Maximal volumetric concentration of the soluble sulfated polysaccharide (1.32 g L^-1) was obtained in winter with the smallest light-pathreactor (1.3 cm ) at a cell density of 1.37 ×10¹¹cells L^-1. Under these conditions, theviscosity of the culture medium was also highest,being inversely proportional to the culture'slight-path. Highest areal concentration of solublepolysaccharides (60 g m^-2) and areal cell density(3.01 × 10¹²m^-2) was recorded in the 20 cmLP reactor, progressively lower values being obtainedas the light path became shorter. A similar patternwas obtained for the areal productivity ofpolysaccharides, the highest being 4.15 g m^-2day^-1 (considering the total illuminated reactorsurface), produced in the 20-cm LP reactor.The main sugar composition (i.e. xylose, galactose andglucose) of the sulfated polysaccharides was similarin all reactors. As viscosity increased with timeduring culture growth, there was a substantial declinein bacterial population. Cultivation throughout mostof the year provided good evidence that a light pathlength of 20 cm in flat plate reactors under theseconditions is optimal for maximal areal solublepolysaccharide production of Porphyridium sp.     

Lipid productivity and fatty acid composition-guided selection of Chlorella strains isolated from Malaysia for biodiesel production

The need to develop biomass-based domestic production of high-energy liquid fuels (biodiesel) for transportation can potentially be addressed by exploring microalgae with high lipid content. Selecting the strains with adequate oil yield and quality is of fundamental importance for a cost-efficient biofuel feedstock production based on microalgae. This work evaluated 29 strains of Chlorella isolated from Malaysia as feedstock for biodiesel based on volumetric lipid productivity and fatty acid profiles. Phylogenetic studies based on 18S rRNA gene revealed that majority of the strains belong to true Chlorella followed by Parachlorella. The strains were similarly separated into two groups based on fatty acid composition. Of the 18 true Chlorella strains, Chlorella UMACC187 had the highest palmitic acid (C16:0) content (71.3?±?4.2 % total fatty acids, TFA) followed by UMACC84 (70.1?±?0.7 %TFA), UMACC283 (63.8?±?0.7 %TFA), and UMACC001 (60.3?±?4.0 %TFA). Lipid productivity of the strains at exponential phase ranged from 34.53 to 230.38 mg L^?1 day^?1, with Chlorella UMACC050 attaining the highest lipid productivity. This study demonstrated that Chlorella UMACC050 is a promising candidate for biodiesel feedstock production.     

Contaminated bacterial effects and qPCR application to monitor a specific bacterium in <Emphasis Type="Italic">Chlorella</Emphasis> sp. KR-1 culture

To investigate the effects of bacteria contaminated in microalgal cultivation, several bacteria were isolated from four photobioreactors for Chlorella sp. KR-1 culture. A total of twenty-one bacterial strains isolated from the reactors and identified by 16S rRNA gene sequencing. Six bacteria, which were found from more than two reactors of the four photobioreactors, were introduced into co-culturing experiments with Chlorella sp. KR-1. Then, the bacterial influences on the productivity of microalgal biomass and lipids were assessed in the photoautotrophic- and mixotrophic microalgal cultivation by comparing them with axenic culture of Chlorella sp. KR-1. The results showed that both biomass and lipid production were significantly enhanced under mixotrophic conditions compared to photoautotropic conditions. However, an excess ratio (more than 10%) of bacterial cells to microalgal cells at the initial stage of mixotrophic cultivation has limited the growth of Chlorella sp. KR-1 because of the relatively fast growth of bacteria, especially under mixotrophic conditions. Moreover, it was proven that the strong biofilm formability of Sphingomonas sp. MB6 is the responsible strain to cause the biomass aggregation observed during the early stage of co-culture. The high abundance of Sphingomonas sp. MB6 during early cultivation period shown by qPCR results was also well corresponded with the period shown a strong biofilm formation, which suggested the applicability of qPCR to monitor a specific bacterial group in a microalgal culture.     

Ethanol production by whole cell immobilization using lignocellulosic materials as solid matrix

Amongst four carriers used, rice-straw was found to be superior in terms of ethanol production. The maximum productivity (17.84 gl⁻¹ h⁻¹) corresponded to a dilution rate of 0.39 h⁻¹, the ethanol concentration being 45.80 gl⁻¹. A multistage rhomboidal bioreactor was found to partially overcome the disruption effect caused by the generation of a large volume of carbon dioxide in the column. Increases in productivity of about 12.55% and 3.6%, respectively, were achieved using rhomboidal and tapered bioreactors as compared to the cylindrical bioreactor. It was observed that the generation time of cells, in both the immobilized and free states, was around 2.5 h. The ethanol yield (Y_p/s) in the lower part of the reactor was less in comparison with other zones, where the substrate utilization efficiency was relatively higher.     

Growth characteristics of ultrahigh-density microalgal cultures

The physiological characteristics of cultures of very high cell mass (e.g. 10 g cell mass/L), termed “ultrahigh cell density cultures” is reviewed. A close relationship was found between the length of the optical path (OP) in flat-plate reactors and the optimal cell density of the culture as well as its areal (g m⁻² day⁻¹) productivity. Cell-growth inhibition (GI) unfolds, as culture density surpasses a certain threshold. If it is constantly relieved, a 1.0 cm OP reactor could produceca. 50% more than reactors with longer OP,e.g. 5 or 10 cm. This unique effect, discovered by Hu et al. [3], is explained in terms of the relationships between the frequency of the light-dark cycle (L-D cycle), cells undergo in their travel between the light and dark volumes in the reactor, and the turnover time of the photosynthetic center (PC). In long OP reactors (5 cm and above) the L-D cycle time may be orders of magnitude longer than the PC turnover time, resulting in a light regime in which the cells are exposed along the L-D cycle, to long, wasteful dark periods. In contrast, in reactors with an OP ofca. 1.0 cm, the L-D cycle frequency approaches the PC turnover time resulting in a significant reduction of the wasteful dark exposure time, thereby inducing a surge in photosynthetic efficiency. Presently, the major difficulty in mass cultivation of ultrahigh-density culture (UHDC) concerns cell grwoth inhibition in the culture, the exact nature of which is awaiting detailed investigation.     

Effect of starch addition on the biological conversion and microbial community in a methanol-fed UASB reactor during long-term continuous operation

The effect of starch addition on the microbial composition and the biological conversion was investigated using two upflow anaerobic sludge bracket (UASB) reactors treating methanolic wastewater: one reactor was operated with starch addition, and another reactor was operated without starch addition. Approximately 300 days of operation were performed at 30 kg COD/m³/d, and then, the organic load of the reactors was gradually increased to 120 kg COD/m³/d. Successful operation was achieved at 30 kg COD/m³/d in both reactors; however, the methanol-fed reactor did not perform well at 120 kg COD/m³/d while the methanol-starch-fed reactor did. The granule analysis revealed the granule developed further only in the methanol-starch-fed reactor. The results of the microbial community analysis revealed more Methanosaeta cells were present in the methanol-starch-fed reactor, suggesting the degradation of starch produced acetate as an intermediate, which stimulated the growth of Methanosaeta cells responsible for the extension of granules.     

Concentric-tube airlift bioreactors

Gas holdup investigations were performed in three concentric-tube airlift reactors of different scales of operation (RIMP: 0.070 m³; RIS-1: 2.5 m³; RIS-2: 5.2 m³; nominal volumes). The influences of the top and bottom clearances and the flow resistances at the downcomer entrance were studied using tap water as liquid phase and air as gaseous phase, at atmospheric pressure. It was found that the gas holdup in the individual zone of the reactor: riser, downcomer and gas-separator, as well as that in the overall reactor is affected by the analyzed geometrical parameters in different ways, depending on their effects on liquid circulation velocity. Gas holdup was satisfactorily correlated with Fr, Ga, bottom spatial ratio (B), top spatial ratio (T), gas separation ratio (Y) and downcomer flow resistance ratio (A _d /A _R ). Correlations are presented for gas holdup in riser, downcomer, gas separator and for the total gas holdup in the reactor. All the above stressed the importance of the geometry in dynamic behaviour of airlift reactors.     

Nutrient removal from high strength nitrate containing industrial wastewater using <Emphasis Type="Italic">Chlorella</Emphasis> sp. strain ACUF_802

the research aim of this study was to characterize an isolated native strain of Chlorella sp. ACUF_802, well adapted to a high nitrate concentration environment and to investigate its potential to nitrate and phosphate removal from industrial wastewaters with the minimal addition of chemical reagents and energy. The isolated strain was identified and evaluated for its capability to support biomass growth and nutrient removal from synthetic wastewater in batch tests using different concentrations of carbon and nitrogen, different carbon sources and N:P ratios. The strain was isolated via the plating method from the settler of a pilot scale moving bed biofilm reactor performing a nitrification process. The strain was identified using molecular analysis with rDNA primers. Using sodium bicarbonate as carbon source, the batch productivity (71.43 mg L^?1 day^?1) of the strain Chlorella sp. ACUF_802 was calculated with a logistic model and compared to the values reported in the literature. Assays on the effect of the N:P ratio indicated that the productivity was increased 36% when the N:P ratio was close to 1 (111.96 mg L^?1 day^?1), but for a complete phosphorus removal a 5:1 N:P ratio with nitrate concentrations ≤125 mg?L^?1 is recommended. The isolated microalgae strain Chlorella sp. ACUF_802 showed versatility to grow in the synthetic industrial wastewaters tested and can be considered as an appropriate organism for nitrogen removal from industrial wastewaters in the presence of an organic or inorganic carbon source.     

Rifamycin B production by Nocardia mediterranei immobilized in a dual hollow fibre bioreactor

Continuous production of rifamycin B was studied using Nocardia mediterranei (ATCC 21789) immobilized in a dual hollow fibre bioreactor designed for cultivating aerobic cells. In the reactor operation the volumetric productivity based on the volume occupied by the immobilized cells was 108 mg l⁻¹ h⁻¹ when air was used for aeration and was 143 mg l⁻¹ h⁻¹ with pure oxygen. These corresponded to 22 and 30-fold increases over the productivity of the comparable batch system. These high productivities were due to the high cell mass density of 550 g l⁻¹. However, the specific productivity of the cell was 30–40% of that in the shake flask culture. As the residence time of medium in the reactor increased, pH of effluent rose to an alkaline region that was outside its optimum condition (pH 6.5–7.0) and the yield and productivity decreased.     

Ethanol production by immobilized whole cells ofZymomonas mobilis in a continuous flow expanded bed bioreactor and a continuous flow stirred tank bioreactor

Continuous ethanol fermentation by immobilized whole cells ofZymomonas mobilis was investigated in an expanded bed bioreactor and in a continuous stirred tank reactor at glucose concentrations of 100, 150 and 200 g L^–1. The effect of different dilution rates on ethanol production by immobilized whole cells ofZymomonas mobilis was studied in both reactors. The maximum ethanol productivity attained was 21 g L^–1 h^–1 at a dilution rate of 0.36 h^–1 with 150 g glucose L^–1 in the continuous expanded bed bioreactor. The conversion of glucose to ethanol was independent of the glucose concentration in both reactors.     

Scale-up and application of a cyclone reactor for fermentation processes

A cyclone reactor for microbial fermentation processes was developed with high oxygen transfer capabilities. Three geometrically similar cyclone reactors with 0.5?l, 2.5?l and 15?l liquid volume, respectively, were characterized with respect to oxygen mass transfer, mixing time and residence time distribution. Semi-empirically correlations for prediction of oxygen mass transfer and mixing times were identified for scale-up of cyclone reactors. A volumetric oxygen mass transfer coefficient k _L a of 1.0?s^?1 (available oxygen transfer rate with air: 29?kg?m^?3?h^?1) was achieved with the cyclone reactor at a volumetric power input of 40?kW?m^?3 and an aeration gas flow rate of 0.2?s^?1. Continuous methanol controlled production of formate dehydrogenase (FDH) with Candida boidinii in a 15?l cyclone reactor resulted in more than 100% improvement in dry cell mass concentration (64.5?g?l^?1) and in about 100% improvement in FDH space-time yield (300?U?l^?1?h^?1) compared to steady state results of a continuous stirred tank reactor.