Mathematical model for a three-phase fluidized bed biofilm reactor in wastewater treatment

A mathematical model for a three phase fluidized bed bioreactor (TFBBR) was proposed to describe oxygen utilization rate, biomass concentration and the removal efficiency of Chemical Oxygen Demand (COD) in wastewater treatment. The model consisted of the biofilm model to describe the oxygen uptake rate and the hydraulic model to describe flow characteristics to cause the oxygen distribution in the reactor. The biofilm model represented the oxygen uptake rate by individual bioparticle and the hydrodynamics of fluids presented an axial dispersion flow with back mixing in the liquid phase and a plug flow in the gas phase. The difference of settling velocity along the column height due to the distributions of size and number of bioparticle was considered. The proposed model was able to predict the biomass concentration and the dissolved oxygen concentration along the column height. The removal efficiency of COD was calculated based on the oxygen consumption amounts that were obtained from the dissolved oxygen concentration. The predicted oxygen concentration by the proposed model agreed reasonably well with experimental measurement in a TFBBR. The effects of various operating parameters on the oxygen concentration were simulated based on the proposed model. The media size and media density affected the performance of a TFBBR. The dissolved oxygen concentration was significantly affected by the superficial liquid velocity but the removal efficiency of COD was significantly affected by the superficial gas velocity. An erratum to this article can be found online at .     

Mathematical modeling of wastewater decolorization in a trickle-bed bioreactor

This work focuses on mathematical modeling of removal of organic dyes from textile industry waste waters by a white-rot fungus Irpex lacteus in a trickle-bed bioreactor. We developed a mathematical model of biomass and decolorization process dynamics. The model comprises mass balances of glucose and the dye in a fungal biofilm and a liquid film. The biofilm is modeled using a spatially two-dimensional domain. The liquid film is considered as homogeneous in the direction normal to the biofilm surface. The biomass growth, decay and the erosion of the biofilm are taken into account. Using experimental data, we identified values of key model parameters: the dye degradation rate constant, biofilm corrugation factor and liquid velocity. Considering the dye degradation rate constant 1×10?? kg m?3 s?1, we found optimal values of the corrugation factor 0.853 and 0.59 and values of the liquid velocity 5.23×10?3?m?s?1 and 6.2×10?3?m?s?1 at initial dye concentrations 0.09433 kg m?3 and 0.05284 kg m?3, respectively. A good agreement between the simulated and experimental data using estimated values of the model parameters was achieved. The model can be used to simulate the performance of laboratory scale trickle-bed bioreactor operated in a batch regime or to estimate values of principal parameters of the bioreactor system.     

Approximated solution of model for three-phase fluidized bed biofilm reactor in wastewater treatment

An approximated analytical solution of mathematical model for the three phase fluidized bed bioreactor (TFBBR) was proposed using the linearization technique to describe oxygen utilization rate in wastewater treatment. The validation of the model was done in comparison with the experimental results. Satisfactory agreement was obtained in the comparison of approximated analytical solution and numerical solution in the oxygen concentration profile of a TFBBR. The approximated solutions for three modes of the liquid phase flow were compared. The proposed model was able to predict the biomass concentration, dissolved oxygen concentration the height of efficient column, and the removal efficiency.     

Development of a helical-ribbon impeller bioreactor for high-density plant cell suspension culture

A double helical-ribbon impeller (HRI) bioreactor with a 11-L working volume was developed to grow high-density Catharanthus roseus cell suspensions. The rheological behavior of this suspension was found to be shear-thinning for concentrations higher than 12 to 15 g DW . L(-1). A granulated agar suspension of similar rheological properties was used as a model fluid for these suspensions. Mixing studies revealed that surface baffling and bottom profiling of the bioreactor and impeller speeds of 60 to 150 rpm ensured uniform mixing of suspensions. The HRI power requirement was found to increase singnificantly for agar suspensions higher than 13 g DW . L(-1), in conjunction with the effective viscosity increase. Oxygen transfer studies showed high apparent surface oxygen transfer coefficients (k(L)a approximately 4 to 45 h(-1)) from agar suspensions of 30 g DW . L(-1) to water and for mixing speeds ranging from 120 to 150 rpm. These high surface k(I)a values were ascribed to the flow pattern of this bioreactor configuration combined with surface bubble generation and entrainment in the liquid phase caused by the presence of the surface baffles. High-density C. roseus cell suspension cultures were successfully grown in this bioreactor without gas sparging. Up to 70% oxygen enrichment of the head space was required to ensure sufficient oxygen supply to the cultures so that dissolved oxygen concentration would remain above the critical level (>/=10% air saturation). The best mixing speed was 120 rpm. These cultures grew at the same rate ( approximately 0.4 d(-1)) and attained the same high biomass concentrations ( approximately 25 to 27 g DW . L(-1), 450 to 500 g filtered wet biomass . L(-1), and 92% to 100% settled wet biomass volume) as shake flask cultures. The scale-up potential of this bioreactor configuration is discussed.     

A comparative study of gel entrapped and membrane attached microbial reactors for biodegrading phenol

A comparative study between two reactors, one using microorganisms entrapped in calcium alginate gel, and the other using microorganisms attached on the surface of a membrane (polymeric microporous sheeting, MPS^TM) to biodegrade phenol is performed. Results indicate that the alginate bead bioreactor is efficient at higher phenol concentrations while the membrane bioreactor shows better performance at lower phenol concentrations. This unique response is primarily attributed to the different techniques by which the microorganisms are immobilized in the two reactors.In batch mode, below a starting concentration of 100 ppm phenol, biodegradation rates in the membrane bioreactor are (7.58 to 12.02 mg phenol/h · g dry biomass) atleast 10 times the rates in alginate bead bioreactor (0.74 to 1.32 mg phenol/h · g dry biomass). Biodegradation rates for the two reactors match at a starting concentration of 250 ppm phenol. Above 500 ppm phenol, the rates in the alginate bead bioreactor are (7.3 to 8.1 mg phenol/h · g dry biomass) on an average 5.5 times the corresponding rates in the membrane bioreactor (2.18 to 1.03 mg phenol/h · g dry biomass).In continuous feed mode the steady state degradation rates in the membrane bioreactor are one to two orders of magnitude higher than the alginate bead bioreactor below 150 ppm inlet phenol concentration. At an inlet concentration around 250 ppm phenol the rates are comparable. Above 500 ppm of phenol the rates in the alginate bioreactor are an order of magnitude high than the membrane bioreactor.Due to substrate inhibition, and its inability to sustain a high biomass concentration, the membrane bioreactor shows poor efficiencies at phenol concentrations above 250 ppm. At low phenol concentrations the apparent reaction rates in the alginate bead bioreactor decrease due to the diffusional resistance of the gel matrix, while biodegradation rates in the membrane bioreactor remain high due to essentially no external diffusional resistance.Results indicate that a combined reactor system can be more effective for bioremediation than either separate or attached microbial reactors.     

The biological response of hairy roots to O2 levels in bioreactors

Summary The efficient exchange of gases between roots and their environment is one of the biggest challenges in bioreactor design for transformed root cultures. Gas-phase reactors can alleviate this problem as well as provide a new tool for studying the biological response of roots and other differentiated tissues to changes in the gas phase composition. In our comparison of liquid- and gas-phase reactors, roots grown in liquid (shake flasks or bubble column reactors) are shown to be under hypoxic stress. Roots grown in a gas-phase reactor (nutrient mist), while not hypoxic, produced 50% less biomass. These results suggest that the response of the tissues to gas phase composition are complex and need further study.     

Strategies for penicillin fermentation in tower-loop reactors

Since it has not been possible to produce penicillin in tower-loop reactors with highly viscous filamentous molds of Penicillium chrysogenum which are employed in stirred-tank reactors, a new strategy has been developed to avoid the formation of this morphology and to use the pellet form of the fungi. When employing definite impeller speeds in the subculture in connection with definite inoculum amounts and substrate concentrations in the main culture (bubble column), it is possible to generate a suspension of isolated small pellets, which shows a low broth viscosity up to a sediment content of 45% over the entire fermentation time. Volumetric mass-transfer coefficients k(L)as are by a factor of 4 to 5 higher in these pellet suspensions than in filamentous broths. It was easy to maintain the necessary oxygen supply for penicillin production in these pellet suspensions. Under these conditions the specific penicillin productivities were higher with regard to power input (up to 90%), biomass, and consumed substrate than in the stirred-tank reactors with highly viscous filamentous morphology of the fungi. Under nonoptimized operating conditions the absolute penicillin production in the tower loop was 35% lower than in the stirred-tank reactor due to lower possible biomass concentrations. The separation of the biomass, and therefore the penicillin recovery, is much simpler when employing pellets. It is shown how the particular mass transfer resistances at the gas/liquid and liquid/pellet interfaces and within the pellets change with the pellet diameter. There should be a particular pellet diameter at which penicillin productivity has its maximum. These investigations indicate that the use of tower-loop reactors can, in the future, be an alternative for more economical penicillin production methods.     

Computational fluid dynamics modeling of mass transfer behavior in a bioreactor for hairy root culture. I. Model development and experimental validation

A two-dimensional axisymmetric computational fluid dynamics (CFD) model based on a porous media model and a discrete population balance model was established to investigate the hydrodynamics and mass transfer behavior in an airlift bioreactor for hairy root culture.During the hairy root culture of Echinacea purpurea, liquid and gas velocity, gas holdup, mass transfer rate, as well as oxygen concentration distribution in the airlift bioreactor were simulated by this CFD model. Simulative results indicated that liquid flow and turbulence played a dominant role in oxygen mass transfer in the growth domain of the hairy root culture. The dissolved oxygen concentration in the hairy root clump increased from the bottom to the top of the bioreactor cultured with the hairy roots, which was verified by the experimental detection of dissolved oxygen concentration in the hairy root clump. This methodology provided insight understanding on the complex system of hairy root culture and will help to eventually guide the bioreactor design and process intensification of large-scale hairy root culture.     

Sensitivity analysis of a biofilm model describing a one-stage completely autotrophic nitrogen removal (CANON) process.

A mathematical model for nitrification and anaerobic ammonium oxidation (ANAMMOX) processes in a single biofilm reactor (CANON) was developed. This model describes completely autotrophic conversion of ammonium to dinitrogen gas. Aerobic ammonium and nitrite oxidation were modeled together with ANAMMOX. The sensitivity of kinetic constants and biofilm and process parameters to the process performance was evaluated, and the total effluent concentrations were, in general, found to be insensitive to affinity constants. Increasing the amount of biomass by either increasing biofilm thickness and density or decreasing porosity had no significant influence on the total effluent concentrations, provided that a minimum total biomass was present in the reactor. The ANAMMOX process always occurred in the depth of the biofilm provided that the oxygen concentration was limiting. The optimal dissolved oxygen concentration level at which the maximum nitrogen removal occurred is related to a certain ammonium surface load on the biofilm. An ammonium surface load of 2 g N/m2. d, associated with a dissolved oxygen concentration level of 1.3 g O2/m3 in the bulk liquid and with a minimum biofilm depth of 1 mm seems a proper design condition for the one-stage ammonium removal process. Under this condition, the ammonium removal efficiency is 94% (82% for the total nitrogen removal efficiency) (30 degrees C). Better ammonium removal could be achieved with an increase in the dissolved oxygen concentration level, but this would strongly limit the ANAMMOX process and decrease total nitrogen removal. It can be concluded that a one-stage process is probably not optimal if a good nitrogen effluent is required. A two-stage process like the combined SHARON and ANAMMOX process would be advised for complete nitrogen removal.     

Dynamic modeling and simulation of continuous airlift bioreactors

For dynamic behaviors of continuous airlift bioreactors, a mathematical model based on a tanks-in-series model with backflow has been developed. The equations describing the dynamics of airlift bioreactors are material balances for micro-organism, substrate, dissolved oxygen and oxygen in gas-phase and heat balances. Non-ideal mixing of liquid and gas phases is taken into account using a tanks-in-series model with backflow. The batch operation, startup operation and the consequence of plant failure were simulated and the effects of design and operating parameters for an airlift bioreactor on its dynamic behaviors were discussed. The concentration profiles of micro-organism, substrate, dissolved oxygen and oxygen in gas-phase and the temperature profile in an airlift bioreactors and their dynamics were obtained. The computational results indicate that the transients of a chemostat in the case of bubble column bioreactor are slower compared with those in the case of airlift bioreactor. The proposed simulator is more precise as compared with models published previously in the literature and therefore provides more reliable and rational examination of continuous airlift bioreactor performance.     

Biological degradation of MSW in a methanogenic reactor using treated leachate recirculation

With a methanogenic reactor using treated leachate recirculation, the effects of 12 effective microorganisms (EMs), isolated from Hangzhou Tianzhiling landfill, on the degradation of municipal solid waste (MSW) were investigated. The preliminary experiment indicated that the EMs increased the biodegradability of MSW, enhanced 24% of organic mass effluent from the landfill reactor, and shortened methane production period to about 91 days in the bioreactor landfill system. The total gas production volumes for the landfill only with leachate recirculation, the bioreactor landfill system with and without EMs inoculation were 65.7, 620.9 and 518.6 l, respectively, after 105 days operation. The average methane concentration of the gas formed in the bioreactor landfill system was above 70%. These showed that a combination of EMs and methanogenic reactors using treated leachate recirculation might be a good way to increase the degree of MSW stabilization, and enhance the rate and quality of gas production for energy recovery.     

Biomass retention and performance of anaerobic fixed-film reactors treating acetic acid wastewater

An acetic-acid-based synthetic wastewater of different organic concentrations was successfully treated at 35 degrees C in anaerobic downflow fixed-film reactors operated at high organic loading rates and short hydraulic retention times (HRTs). Substrate removal and methane production rates close to theoretical values of complete volumetric chemical oxygen demand (COD) removal and maximum methane conversion were obtained. A high concentration of biofilm biomass was retained in the reactor. Steady-state biofilm concentration increased with increased organic loading rate and decreased HRTs, reaching a maximum of 8.3 kg VFS/m(3) at a loading rate of 17 kg COD/m(3) day. Biofilm substrate utilization rates of up to 1.6 kg COD/kg VFS day were achieved. Soluble COD utilization rates at various COD concentrations can be described by half-order reaction kinetics.     

Experimental Study of Mass Transfer Phenomena in a Cross Flow Membrane Bioreactor: Aeration and Membrane Separation

Experimental work carried out on wastewater from a wastewater treatment plant (WWTP) showed that in a cross flow membrane bioreactor the gas/liquid transfer is highly dependent on the biomass concentration. In new biological wastewater membrane treatment processes (mostly using deep end membranes), the biomass concentration is usually about 15 g/L, which entails a decrease in the bioreactor aeration capacity by a factor of approximately four compared with clean water. The gas/liquid transfer may therefore become a limiting step in this type of process. To prevent the operating costs of the biological treatment from increasing, it is imperative that the oxygen transfer be optimized. Membrane experiments showed that the permeate flux is highly dependent on the biomass concentration and the tangential velocity in the membrane module.     

Development of a strategy to control the dissolved concentrations of oxygen and carbon dioxide at constant shear in a plant cell bioreactor

To examine the effects of volatile components on plant cell growth, a bioreactor control system was developed to simultaneously control the dissolved concentrations of both oxygen and carbon dioxide. The first step in this work was to develop a mathematical model to account for gas-liquid mass transfer; biological utilization and production of O(2) and CO(2); and the series of chemical reactions of CO(2) in water. Using this model and dynamic measurements for dissolved O(2) and CO(2), it was observed that (1) both absorption and desorption of a volatile component could be described by a single mass transfer coefficient, K(l)a, and (2) K(l)a values for oxygen and carbon dioxide transfer were directly proportional. The second step of this work was to employ the mathematical model in an adaptive feed-forward strategy to control the dissolved O(2) and CO(2) concentrations by manipulating the inlet gas composition to the bioreactor. This strategy allowed dissolved concentrations to be controlled without the need for changing either the total gas flow rate or agitator speed. Adaptive control was required because the volumetric rates of O(2) and CO(2) consumption and production vary with time during long term operation and therefore these rates must be continually updated. As the final step, we demonstrated that this control strategy was capable of controlling the dissolved gas concentrations in both short- and long-term studies involving the cultivation of Catharanthus roseus plant cells.     

Ajmalicine production by cell cultures of Catharanthus roseus: from shake flask to bioreactor

The productivity of a cell culture for the production of a secondary metabolite is defined by three factors: specific growth rate, specific product formation rate, and biomass concentration during production. The effect of scaling-up from shake flask to bioreactor on growth and production and the effect of increasing the biomass concentration were investigated for the production of ajmalicine by Catharanthus roseus cell suspensions. Growth of biomass was not affected by the type of culture vessel. Growth, carbohydrate storage, glucose and oxygen consumption, and the carbon dioxide production could be predicted rather well by a structured model with the internal phosphate and the external glucose concentration as the controlling factors. The production of ajmalicine on production medium in a shake flask was not reproduced in a bioreactor. The production could be restored by creating a gas regime in the bioreactor comparable to that in a shake flask. Increasing the biomass concentration both in a shake flask and in a stirred fermenter decreased the ajmalicine production rate. This effect could be removed partly by controlling the oxygen concentration in the more dense culture at 85% air saturation.     

Rigorous Approach to Modeling of a Continuous Aerobic Membrane Bioreactor

A rigorous approach to mathematical modeling of a continuous aerobic membrane bioreactor (MBR) for the treatment of wastewater is reported. The idea is to apply the activated sludge model ASM3 to the special configuration of a membrane bioreactor. Therefore, the biochemical processes modeled by the ASM3 were implemented together with mass balances typical of a MBR running at constant TSS. The model parameters were adapted to the properties of an artificial wastewater by using a global search algorithm. The model could be validated by comparing effluent chemical oxygen demand (COD), sludge production and CO₂ concentration in the exhaust to the experimental data.     

Improvement of Panax notoginseng cell culture for production of ginseng saponin and polysaccharide by high density cultivation in pneumatically agitated bioreactors

A Panax notoginseng cell culture was successfully scaled up from shake flask to 1.0-L bubble column reactor and concentric-tube airlift reactor. High-density bioreactor batch cultivation was carried out using a modified MS medium. The maximum cell density in batch cultures reached 20.1, 21.0 and 24.1 g/L in the shake flask, bubble column and airlift reactors, respectively, and their corresponding biomass productivity was 950, 1140 and 1350 mg/(L x d) for each. The productivity of ginseng saponin was 70, 96 and 99 mg/(L x d) in the flask, bubble column and airlift reactors, respectively; and the polysaccharide productivity reached 104, 119 and 151 mg/(L x d) for each. Furthermore, a fed-batch cultivation strategy was developed on the basis of specific oxygen uptake rate (SOUR), i.e., sucrose feeding before a sharp decrease of SOUR, and the highest cell density of 29.7 g/L was successfully achieved in the airlift bioreactor on day 17 with a very high biomass productivity of 1520 mg/(L x d). The concentrations of ginseng saponin and polysaccharide reached about 2.1 and 3.0 g/L, respectively, and their productivity was 106 (saponin) and 158 mg/(L x d) (polysaccharide). This work successfully demonstrated the high-density bioreactor cultivation of P. notoginseng cells in pneumatically agitated bioreactors and the reproduction of the shake flask culture results in bioreactors. The cell density, biomass productivity, production titer and productivity of both ginseng saponin and polysaccharide obtained here were the highest that have been reported on a reactor scale for all the ginseng species.     

The anion-exchange substrate shuttle process: A new approach to two-stage biomethanation of organic and toxic wastes

A novel biomethanation process configuration is described which uses improved biocatalysts to enhance the productivity and stability of waste biomethanation systems. The design facilitates the maintenance of acetogenic and methanogenic bacteria under optimum substrate concentrations far above their K(s) values in a two-stage biomethanation system with closed loop reactors. Volatile fatty acid anions (VFA anions) are provided as substrates for the methanogenic stage by using an anion exchange unit coupled to the acidogenic stage. The slow growing and sensitive acetogenic and methanogenic bacteria are protected from oxygen, cationic pollutants, toxins, and microbial contamination by use of the substrate shuttle process. Due to the closed loop process configuration, washout of the ecoengineered biocatalysts is excluded. The modular system configuration allows industrial mass production of the system components. The new biomethanation process enhances both the BTU content of the gas and the methane production over state-of-the-art anaerobic digestor bioreactor concepts.     

Biodegradation of wastewater pollutants by activated sludge encapsulated inside calcium-alginate beads in a tubular packed bed reactor

The wastewater treatment plants produce large quantities of biomass (sludge) that require about one-third of the total inversion and operation plant costs for their treatment. By the microorganisms immobilization it is possible to handle high cell concentration in the reactor, increasing its efficiency, reducing the loss of biomass and the wash out is avoided. Moreover, there is no cell growth then the sludge production is reduced. In this study, the COD removal and VSS variation were modeled in a tubular reactor with activated sludge immobilized in Ca-alginate. Moreover, two aspects that are commonly not considered in the performance of the actual reactors of this kind were introduced; the performance in non-steady state and the dispersion effect. The model was calibrated with an actual wastewater taken out from a Mexican wastewater treatment plant. The results of the performance of the tubular bioreactor at different scenarios (i.e., different residence time and VSS in the reactor) are presented. With longer residence times and higher VSS concentration in the Ca-alginate beads in the tubular bioreactor it is possible to increase the time operation of the bioreactor and to treat higher volumes of wastewater. During the process, the sludge generation was drastically reduced and it is possible to remove nitrogen form the wastewater making this process more attractive.     

BTEX-Contaminated Gas Treatment in a Shallow, Sparged, Suspended-Growth Bioreactor

Treatment of a gas contaminated with a mixture of benzene, toluene, ethylbenzene, and o-xylene (BTEX) compounds in a 40-cm-deep laboratory-scale bioreactor containing suspended biomass was investigated. Gas treatment efficiency was not significantly impacted by different BTEX mixtures, and approximately 99% removal was achieved for volumetric loadings of 11 to 18 mg-BTEX/L-reactor volume/hr (specific biomass loadings of 0.27 to 0.83 g-BTEX/g-VSS/d; inlet concentrations of total BTEX of 2.3 to 4.3 mg/L) and operational solids retention times (SRTs) of 1.7, 2.7, and 9.2 days. Maximum specific biodegradation rates of the reactor biomass increased as the reactor SRTs decreased. Under specific loadings greater than 1 g-BTEX/g-VSS/d the gas treatment became biokinetically limited, such that BTEX and unidentified BTEX metabolites accumulated in the bioreactor liquid over time. BTEX gas-liquid mass transfer was sufficient in the 40-cm-deep sparged liquid reactor to provide high BTEX treatment efficiency.