Modeling and advanced control of recombinant Zymomonas mobilis fed-batch fermentation

This work presents the development of an unstructured kinetic model incorporating the differing degrees of product, substrate, and pH inhibition on the kinetic rates of ethanol fermentation by recombinant Zymomonas mobilis CP4:pZB5 for growth on two substrates. Product inhibition was observed to start affecting the specific growth rate at an ethanol concentration of 20 g/L and the specific productivity at about 35-40 g/L. Specific growth rate was also shown to be more sensitive to inhibition by lowered pH as well. A model for the inhibition of two competing substrates' cellular uptake via membrane transport is proposed. Inhibition functions and model parameters were determined by fitting experimental data to the model. The model was utilized in a nonlinear model predictive control (NMPC) algorithm to control the product concentration during fed-batch fermentation to offset the inhibitory effects of product inhibition. Using the optimal feeding policy determined online, the volumetric productivity of ethanol was improved 16.6% relative to the equivalent batch operation when the final ethanol concentration was reached.     

Ethanol production in an integrated process of fermentation and ethanol recovery by pervaporation

In ethanol fermentations inhibition of the microorganism by ethanol limits the amount of substrate in the feed that can be converted. In a process high feed concentrations are desirable to minimize the flows. Such high feed concentrations can be realized in integrated processes in which ethanol is recovered from the fermentation broth as it is formed. In this study ethanol recovery by pervaporation was coupled to glucose fermentations by baker's yeast. Pervaporation was carried out with commercial silicone based hollow-fibre membrane modules with relatively high fluxes. Three different types of process configurations with pervaporation were investigated. Two of these configurations also included cell retention by microfiltration, in order to optimize the productivity. In the systems with pervaporation a feed containing 360 kg/m³ glucose could be converted almost completely. This feed concentration is a factor three higher than in a process without ethanol recovery. The productivity was 14 kg/m³ h in a system with pervaporation only, and could be increased to 43 kg/m³ h in the system with all recycle by microfiltration. The kinetic data suggest that accumulation of inhibitory compounds occurs in the integrated system. The integrated process was relatively easy in operation.     

Cell growth and death rates as factors in the long-term performance, modeling, and design of immobilized cell reactors

The viable fraction of immobilized cells in a bioreactor may be critical in predicting long-term or steady-state reactor performance. The assumption of near 100% viable cells in a bioreactor may not be valid for portions of immobilized cell reactors (ICRs) characterized by conditions resulting in appreciable death rates. A mathematical model of an adsorbed cell type ICR is presented in which a steady-state viable cell fraction is predicted, based on the assumptions of no cell accumulation in the reactor and a random loss of cells from the reactor. Data on cell death rates, cell growth rates, and productivity rates as functions of temperature, substrate, and ethanol concentration for the lactose utilizing yeast K. fragillis were incorporated into this model. The steady-state reactor viable cell fraction as predicted by this model is a strong function of both temperature and ethanol concentration. For example, a stable 20% viable fraction of the immobilized cells is predicted in ICR locations experiencing continuous conditions of either 30 g/L ethanol at 40 degrees C, or 95 g/L ethanol at 25 degrees C. Steady-state ICR "plug flow" concentration profiles and column productivities are predicted at three operating temperatures, 20, 30, and 40 degrees C using two different models for ethanol inhibition of productivity. These profiles suggest that the reactor operating temperature should be low if higher outlet ethanol concentrations are desired. Three reactor design strategies are presented to maximize the viable cell fraction and improve long-term ethanol productivity in ICR's: (1) reducing outlet ethanol concentrations, (2) rotating segments of an ICR between high and low ethanol environments, and (3) simultaneous removal of the ethanol produced from the reactor as it is formed.     

自絮凝酵母高浓度重复批次乙醇发酵

利用发酵性能优良的自絮凝酵母Saccharomyces cerevisiaeflo,研究开发了重复批次高浓度乙醇发酵系统,以节省下游加工过程的能耗。在终点乙醇浓度达到120g/L左右的条件下,发酵系统的乙醇生产强度达到8.2g/(L·h)。然而实验中发现,随着发酵批次的增多,自絮凝酵母沉降性能逐渐下降,从发酵液中沉降分离所需时间相应延长,导致发酵液中高浓度乙醇对酵母的毒害作用加剧,影响其发酵活性和发酵系统运行的稳定性,发酵装置运行11个批次后无法继续运行。实验结果表明,絮凝能力下降导致的酵母絮凝颗粒尺度减小是其沉降性能下降的主要原因。进一步研究发现,酵母的絮凝能力通过再培养可以恢复。在此基础上对发酵系统操作进行改进,每批发酵结束后可控采出一定比例菌体,调节系统的酵母细胞密度和乙醇生产强度以刺激酵母增殖,保持其絮凝能力。在达到相同发酵终点乙醇浓度条件下,虽然发酵系统的乙醇生产强度降低到4.0g/(L·h),但运行10d后絮凝颗粒酵母尺度趋于稳定,继续运行14d,未发现絮凝颗粒酵母尺度继续下降的现象,系统可以稳定运行。     

Elimination of ethanol inhibition by perstraction

Perstraction (membrane-aided solvent extraction) was utilized for elimination of ethanol inhibition in continuous ethanol fermentation using high sugar concentrate. Hollow fibers for an artificial kidney were used as a permeable membrane, and their capacity to extract ethanol was examined by using several organic solvents. When tri-n-butylphosphate was used as an extractant, a 500 g/L feed glucose medium was successfully fermented by immobilized yeast cells. During this continuous fermentation a high ehtanol productivity of 48 g/h-L-gel was held, and the solvent requirement per consumed glucose was 6 L-solvent/kg-glucose.     

Aeration alleviates ethanol inhibition and glycerol production during fed-batch ethanol fermentation

In this study, we investigated the effects of aeration on ethanol inhibition and glycerol production during fed-batch ethanol fermentation. When aeration was conducted at 0.13, 0.33, and 0.8 vvm, the ethanol productivity, specific ethanol production rate, and ethanol yield in the presence of greater than 100 g/L of ethanol were higher than when aeration was not conducted. In addition, estimation of the parameters (α and β) in a model equation of ethanol inhibition kinetics indicated that aeration alleviated ethanol inhibition against the specific growth rate and the specific ethanol production rate. Specifically, when aeration was conducted, the glycerol yield and specific glycerol production rate decreased approximately 50 and 70%, respectively. Finally, the results of this study indicated that aeration during fed-batch ethanol fermentation may improve the ethanol concentration in the final culture broth, as well as the ethanol productivity.     

Inhibition of ethanol-producing yeast and bacteria by degradation products produced during pre-treatment of biomass

An overview of the different inhibitors formed by pre-treatment of lignocellulosic materials and their inhibition of ethanol production in yeast and bacteria is given. Different high temperature physical pre-treatment methods are available to render the carbohydrates in lignocellulose accessible for ethanol fermentation. The resulting hydrolyzsates contain substances inhibitory to fermentation—depending on both the raw material (biomass) and the pre-treatment applied. An overview of the inhibitory effect on ethanol production by yeast and bacteria is presented. Apart from furans formed by sugar degradation, phenol monomers from lignin degradation are important co-factors in hydrolysate inhibition, and inhibitory effects of these aromatic compounds on different ethanol producing microorganisms is reviewed. The furans and phenols generally inhibited growth and ethanol production rate (Q_EtOH) but not the ethanol yields (Y_EtOH) in Saccharomyces cerevisiae. Within the same phenol functional group (aldehyde, ketone, and acid) the inhibition of volumetric ethanol productivity was found to depend on the amount of methoxyl substituents and hence hydrophobicity (log P). Many pentose-utilizing strains Escherichia coli, Pichia stipititis, and Zymomonas mobilis produce ethanol in concentrated hemicellulose liquors but detoxification by overliming is needed. Thermoanaerobacter mathranii A3M3 can grow on pentoses and produce ethanol in hydrolysate without any need for detoxification.     

The long-term effects of ethanol on immobilized cell reactor performance using K. fragilis

The effects of ethanol on reactor performance were studied in a small, 5-cm packed height, "differential" type immobilized cell reactor. Lactose utilizing yeast cells, Kluyveromyces fragilis, were absorbed to a porous adsorbant sponge matrix in a gas continuous reactor. Step changes in the feed ethanol concentration to the column (10-130 g/L) were used to test the reactor response over extended periods of time (about 30-50 h per dosage level) followed by a return to basal zero inlet ethanol feed. Effluent cell density and effluent cell viability were measured at intervals. An inhibitory response in ethanol productivity to feed dosage ethanol levels above 20 g/L was detected almost immediately, with a near steady state response noted within 2.5 h of initiating the dosage. Feed ethanol levels above 50 g/L resulted in a subsequent gradual decrease in reactor productivity over time, which was associated with a decrease in the fraction of viable shed cells in the reactor effluent. The reactor response to a step removal of the ethanol inhibition was also monitored. Quick and complete rebounding of the fermentation rate to the original basal rate was noted following dosage concentrations of under 50 g/L ethanol. Recovery rates slowed following ethanol dosage levels above 50 g/L. Viable shed cell density improved overtime during the slow recovery periods. Growth rates (as determined by shed cell density) were more strongly inhibited than productivity. Growth responded more slowly to changes in ethanol environment as growth rates at 30 h fell to about 40% of the rates measured 7.5 h after initiation of a dosage level. It is concluded that ethanol contributions to cell injury and death (and consequent ICR performance degradation) may be more important than ethanol inhibition of productivity rates in the long-term operation of immobilized cell reactors at ethanol concentrations over 50 g/L.     

Production of high ethanol concentrations from glucose using a vertical rotating immobilized cell reactor of the bacterium zymomonas mobilis

Long-term continuous ethanol production of up to 80 g.l¹ with a volumetric ethanol productivity of 63 g. l^?1. h^?1 was maintained for more than 72 days using a Vertical Rotating Immobilized Cell Reactor of the bacterium Z. mobilis. Continuous production of higher ethanol concentration was unsuccessful due to an inhibition of cell growth by long exposure to high ethanol concentrations. However, ethanol concentration as high as 120g. l^?1 and volumetric ethanol productivity of 13g. l^?1. h^?1 were achieved in a repeated-batch fermentation system using the same bioreactor. By a simple washing operation at the end of each run, immobilized biomass could be effectively regenerated and used to carry out more than 10 successive fermentation cycles.     

Ethanol fermentation in a continuous tower fermentor

A mutant of Saccharomyces cerevisiae, which forms large, multicellular flocs in liquid culture, rapidly fermented media containing high concentrations of glucose (100-180 g/L) in a continuous nonaerated tower fermentor at 30 degrees C. The fermentor operated continuously for seven months. Batch and tower fermentor data were fitted to a kinetic model incorporating linear ethanol inhibition and Monod dependence on glucose. Conversion, ethanol yield, and ethanol productivity were related to the apparent fermentation time for initial glucose concentrations of 130 and 180 g/L. Productivities of 8-12 g ethanol/L h were achieved through the yeast bed giving conversions exceeding 90% of the theoretical yield.     

Ethanol production from starch in a pervaporation membrane bioreactor using Clostridium thermohydrosulfuricum

To attain both high productivity and efficient recovery of ethanol from broth, a membrane bioreactor consisting of a jar fermentor and a pervaporation system was applied to the direct production of ethanol from uncooked starch with a thermophilic anaerobic bacterium, Clostridium thermohydrosulfuricum. From four types of ethanol-selective membranes tested, microporous polytetrafluoroethylene (PTFE) membrane, the pores of which are impregnated with silicone rubber, was chosen for its large flux, high ethanol selectivity, and high stability. During fed-batch fermentation with pervaporation in the membrane bioreactor, ethanol was continuously extracted and concentrated in two traps with concentrations at 5.6%-6.2% (w/w) in trap 1 (20 degrees C) and 27%-32% (w/w) in trap 2 (liquid N(2)), while the ethanol concentration in the broth was maintained at 0.85-0.9% (w/w). Due to the low ethanol concentration in the broth, and the immobilization of bacterial cells by the membrane, the number of viable cells, and, eventually, the ethanol productivity, increased in the membrane bioreactor.     

Very high gravity ethanol fermentation by flocculating yeast under redox potential-controlled conditions

ABSTRACT: BACKGROUND: Very high gravity (VHG) fermentation using medium in excess of 250 g/L sugars for more than 15 % (v) ethanol can save energy consumption, not only for ethanol distillation, but also for distillage treatment; however, stuck fermentation with prolonged fermentation time and more sugars unfermented is the biggest challenge. Controlling redox potential (ORP) during VHG fermentation benefits biomass accumulation and improvement of yeast cell viability that is affected by osmotic pressure and ethanol inhibition, enhancing ethanol productivity and yield, the most important techno-economic aspect of fuel ethanol production. RESULTS: Batch fermentation was performed under different ORP conditions using the flocculating yeast and media containing glucose of 201 [PLUS-MINUS SIGN] 3.1, 252 [PLUS-MINUS SIGN] 2.9 and 298 [PLUS-MINUS SIGN] 3.8 g/L. Compared with ethanol fermentation by non-flocculating yeast, different ORP profiles were observed with the flocculating yeast due to the morphological change associated with the flocculation of yeast cells. When ORP was controlled at [MINUS SIGN]100 mV, ethanol fermentation with the high gravity (HG) media containing glucose of 201 [PLUS-MINUS SIGN] 3.1 and 252 [PLUS-MINUS SIGN] 2.9 g/L was completed at 32 and 56 h, respectively, producing 93.0 [PLUS-MINUS SIGN] 1.3 and 120.0 [PLUS-MINUS SIGN] 1.8 g/L ethanol, correspondingly. In contrast, there were 24.0 [PLUS-MINUS SIGN] 0.4 and 17.0 [PLUS-MINUS SIGN] 0.3 g/L glucose remained unfermented without ORP control. As high as 131.0 [PLUS-MINUS SIGN] 1.8 g/L ethanol was produced at 72 h when ORP was controlled at [MINUS SIGN]150 mV for the VHG fermentation with medium containing 298 [PLUS-MINUS SIGN] 3.8 g/L glucose, since yeast cell viability was improved more significantly. CONCLUSIONS: No lag phase was observed during ethanol fermentation with the flocculating yeast, and the implementation of ORP control improved ethanol productivity and yield. When ORP was controlled at [MINUS SIGN]150 mV, more reducing power was available for yeast cells to survive, which in turn improved their viability and VHG ethanol fermentation performance. On the other hand, controlling ORP at [MINUS SIGN]100 mV stimulated yeast growth and enhanced ethanol production under the HG conditions. Moreover, the ORP profile detected during ethanol fermentation with the flocculating yeast was less fluctuated, indicating that yeast flocculation could attenuate the ORP fluctuation observed during ethanol fermentation with non-flocculating yeast.     

Germplasm evaluation of Kenaf (Hibiscus cannabinus) for alternative biomass for cellulosic ethanol production

Kenaf (Hibiscus cannabinus) is an annual fiber crop grown mainly in India and China. This crop is becoming a new bio‐based energy source because of its fast growth rate, excellent CO₂ absorption ability, and large productivity per unit area. In this study, we evaluated 10 different cultivars of kenaf for their potential as biomass for cellulosic ethanol production. First, kenaf samples were hydrolyzed using dilute sulfuric acid, which is the most simple and cost‐effective pretreatment method. Next, simultaneous saccharification and fermentation (SSF) of the hydrolysates were performed by wild‐type and engineered xylose‐fermenting yeast strains. The results of compositional analysis of the biomass, the hydrolysates, and the fermented products suggested that ethanol yield and productivity were significantly affected by a type of kenaf cultivars, which was not predictable based on the biomass compositions. Also, the ethanol production was maximized when the xylose fraction was utilized by engineered yeast under the control of pH to avoid acetate inhibition. Considering the sugar compositions and their fermentability, kenaf can be a promising energy‐dedicated crop for cellulosic ethanol production.     

Continuous ethanol production by immobilized yeast reactor coupled with membrane pervaporation unit

A system comprised of an immobilized yeast reactor producing ethanol, with a membrane pervaporation module for continuously removing and concentrating the produced ethanol, was developed. The combined system consisted of two integrated circulation loops: In one the sugar-containing medium is circulated through the membrane pervaporation module. The two loops were interconnected in a way allowing for separate parameter optimization (e.g., flow rate, temperature, pH) for each loop.The fermentation unit was 2.0 L bioreactor with five equal segments, packed with 5-mm beads of immobilized yeasts. The bead matrix was a crosslinked polyacrylamide hydrazide gel coated with calcium alginate. The fast circulation loop of the bioreactor allowed for efficient liberation of CO(2) at the top of the immobilized yeast reactor. Continuous operation of the uncoupled reactor for over 50 days with inflowing defined medium or dilute molasses at a residence time of 1.25 h yielded ethanol at a rate of about 10 g/L h.The pervaporation unit was constructed from four 60-cm-long tubular membranes of silicone composite on a polysulfone support. The output from the fermentor was circulated through the inside of the tubes of a unit with a total surface area of 800 cm(2), having an average flux of 150 mL/h, and selectivities to ethanol vs. water up to 7. A vacuum of 30 mb was applied to the outside of the tubes, removing 20-30 g of ethanol per hour, which was collected in condensors. The continuous removal of ethanol, avoiding inhibition of the fermentation process, resulted in an improved productivity and allowed the use of high sugar concentrations (40% wt/vol) offering the potential of a compact system with reduced stillage.The combined system of ethanol production and removal enabled an operative steady state at which the liquid volume of the system, and the concentrations of ethanol within the reactor ( 4% wt/vol), as well as within the flux crossing the pervaporation membrane (17%-20% wt/vol) were kept constant. At the steady state, a 40% wt/vol sugar solution could be continuously added to the fermentor when 12%-20% wt/vol clear ethanol solution was continuously removed by the pervaporation unit. Membrane fouling was reversed by short washing steps, and continuous step operation was maintained by working with two different modules that were interchanged. In this manner, long term continuous operation (over 40 days) was achieved with a productivity of 20-30 g/L h, representing over a twofold increase relative to the continuously operated reactor uncoupled from the membrane and a fivefold increase in comparison with the value obtained fro a corresponding batch fermentation.     

Kinetics of ethanol production by baker's yeast in an integrated process of fermentation and microfiltration

The productivity of a fermentation is proportional to the biomass concentration. The productivity can therefore be increased by retention of the cells in the fermentor. In this study microfiltration was used for cell retention in a fermentation of glucose to ethanol by baker's yeast. Compared to a system without cell retention the productivity could be increased 12-fold to 55 kg/m³ h at a biomass concentration of 135 kg/m³. Maximal ethanol concentrations of 76 kg/m³ were obtained at conditions of growth. At zero growth conditions in the integrated system the ethanol concentration could be increased to about 115 kg/m³, and could be produced for at least 10 hours. The fermentation results in the integrated system could be described reasonably well with a mathematical model based on a different linear inhibition kinetics for growth and substrate consumption.     

On-line estimation of sugar concentration for control of fed-batch fermentation of lignocellulosic hydrolyzates by Saccharomyces cerevisiae

A feed control strategy, based on estimated sugar concentrations, was developed with the purpose of avoiding severe inhibition of the yeast Saccharomyces cerevisiae during fermentation of spruce hydrolyzate. The sum of the fermentable hexose sugars, glucose and mannose, was estimated from on-line measurements of carbon dioxide evolution rate and biomass concentration by use of a simple stoichiometric model. The feed rate of the hydrolyzate was controlled to maintain constant sugar concentration during fed-batch fermentation, and the effect of different set-point concentrations was investigated using both untreated and detoxified hydrolyzates. The fed-batch cultivations were evaluated with respect to cellular physiology in terms of the specific ethanol productivities, ethanol yields, and viability of the yeast. The simple stoichiometric model used resulted in a good agreement between estimated sugar concentrations and off-line determinations of sugar concentrations. Furthermore, the control strategy used made it possible to maintain a constant sugar concentration without major oscillations in the feed rate or the sugar concentration. For untreated hydrolyzates the average ethanol productivity could be increased by more than 130% compared to batch fermentation. The average ethanol productivity was increased from 0.12 to 0.28 g/g h. The productivity also increased for detoxified hydrolyzates, where an increase of 16% was found (from 0.50 to 0.58 g/g h).     

串联填充管式反应系统中高浓度乙醇连续发酵

在一套由搅拌罐和管式反应器串联而成的组合式反应系统中,利用酿酒酵母进行连续发酵生产高浓度乙醇。后续管式反应器内通过装填聚氨酯颗粒和木块对酵母细胞进行吸附固定化,在乙醇抑制造成细胞活性大幅降低的情况下,通过大幅提高细胞浓度保证发酵效率,在稀释速率0.02h^-1和280g/L葡萄糖的条件下,系统的终点乙醇浓度为15.4 % (v/v)。研究表明在一定稀释速率之下,应该通过增加反应器的级数来降低稀释速率,以达到提高终点乙醇浓度,如简单地降低进料速率则可能增加整个系统所受的乙醇抑制,对提高终点乙醇浓度效果不显著。     

Simultaneous saccharification and co-fermentation of glucose and xylose in steam-pretreated corn stover at high fiber content with Saccharomyces cerevisiae TMB3400

The two main sugars in the agricultural by-product corn stover are glucose and xylose. Co-fermentation of glucose and xylose at high content of water-insoluble solids (WIS) without detoxification is a prerequisite to obtain high ethanol concentration and to reduce production costs. A recombinant strain of Saccharomyces cerevisiae, TMB3400, was used in simultaneous saccharification and fermentation (SSF) of whole pretreated slurry of corn stover at high WIS. TMB3400 co-fermented glucose and xylose with relatively high ethanol yields giving high final ethanol concentration. The ethanol productivity increased with increasing concentration of pretreatment hydrolysate in the yeast production medium and when SSF was performed in a fed-batch mode.     

Batch fermentation kinetics of sugar beet molasses by Zymomonas mobilis

A new osmotolerant mutant strain of Zymomonas mobilis was successfully used for ethanol production from beet molasses. Addition of magnesium sulfate to hydrolyzed molasses allowed repeated growth without the need of yeast extract addition. The kinetics and yields parameters of fermentation on media with different molasses concentrations were calculated. The anabolic parameters (specific growth rate, mu, and biomass yield, Y(X/S)) were inhibited at elevated molasses concentrations while the catabolic parameters (specific ethanol productivity, q(p), and ethanol yield, Y(p/s)) were not significantly affected. In addition to ethanol and substrate inhibition, osmotic pressure effects can explain the observed results.     

Ethanol inhibition of yeast growth and fermentation: Differences in the magnitude and complexity of the effect

Summary The effect of ethanol on yeast growth and fermentation has been studied in two strains, NCYC479 (a commercial saké yeast) and 5D-cyc (a laboratory haploid strain). The effect of ethanol on growth was similar in the two strains. It showed complex kinetics which resulted from both the inhibition of the growth rate itself and also a reduction in cell viability. The growth and viability effects had different inhibition constants. Ethanol was less inhibitory toward fermentation than toward growth. Fermentation in the saké yeast was more ethanol tolerant than in the laboratory strain. The inhibition kinetics for fermentation were less complex than those for growth and followed the classical noncompetitive pattern.