Mixing time and oxygen transfer characteristics of double draft tube airlift fermentor

Despite the increasing importance of airlift fermentors, very little published information is available on how the geometric configurations of the draft tubes and the air-sparging system affect the mixing and oxygen transfer characteristics of the fermentor. A 14-L air-lift fermentor was designed and build with a fixed liquid height to diameter ratio of 1.5 utilizing four equally spaced air jets at the bottom. Two jet orifice sizes were used, 1.27 and 3.81 mm i.d., and for each jet size the following four geometric configurations were used: Single inner concentric draft tube, single outer concentric draft tube, two concentric draft tubes, and no draft tubes where the fermentor was operated as a shallow bubble column. It was found that the presence of draft tubes stabilized liquid circulation patterns and gave systemically higher mixing times than those obtained in the absence of draft tubes. In addition, the double draft tube geometry resulted in higher mixing times than the single draft tubes. For the power unit volume range 20 to about 250 W/m³ the larger 3.81-mm orifices gave systemically higher k_L a values than the smaller 1.27-mm i.d. orifices. At 200 W/m³ the use of a single outer draft tube with the 3.81-mm orifices resulted in 94% increase in k_L a values over that obtained with no draft tubes. However, the effect of draft tube geometry on k_L a values when the 1.27-mm orifices were used was not significant. The air bubble formation characteristics at the jet orifices were found to be different, which reflected the differences observed in mass transfer and mixing characteristics. The power economy for oxygen transfer was found to be depend strongly on the orifice size and less on the geometric configuration of draft tubes.     

Development of a new commercial-scale airlift fermentor for rapid growth of yeast

To grow yeast rapidly, it is necessary to supply sufficient oxygen to the yeast and to effectively remove the heat of the fermentation. We succeeded in developing a commercial-scale fermentor for growing a food yeast (Candida utilis) to produce RNA rapidly. This fermentor is an internal-loop airlift type with vertical heat transfer tubes between inner and the outer columns. The volume of the fermentor is 145 m³ (working volume 75 m³). The oxygen transfer rate (OTR) was 9.9 kg-O₂/m³/h using a superficial gas velocity of 30 cm/s based on the outer column. Much of the heat of fermentation and the energy resulting from aeration could be removed effectively by the heat transfer tubes. This unique airlift fermentor was driven at a dilution rate of 0.43 h⁻¹ for about 70 d, with the yeast concentration being maintained at 22.8 kg-dry cell/m³. The yeast production rate was 9.79 kg-dry cell/m³/h. Compared with a traditional stirred-type fermentor, two Vogelbush-type fermentors and another airlift fermentor, our fermentor was far superior with respect to OTR and yeast productivity.     

Efficient acetic acid production by repeated fed-batch fermentation using two fermentors

Summary In acetic acid fermentation, the number of viable cells decrease as the acetic acid concentration increases to more than about 40 g/l, which means that the productivity attainable by conventional fed-batch and repeated fed-batch operations using one fermentor is limited. In this paper, based on a fed-batch experiment using Acetobacter aceti 2096, a mathematical model was developed. The optimization carried out showed the superiority of repeated fed-batch operation using two fermentors. The performance evaluation was made with respect to productivity and product concentration. It was shown to be attractive in practice to use multiple fermentors, in particular for high product concentrations. Experiments were then conducted to ascertain the simulation results. Offprint requests to: T. Kobayashi     

Influence of acetic acid on the growth of Escherichia coli K12 during high-cell-density cultivation in a dialysis reactor

High-cell-density cultivations of Escherichia coli K12 in a dialysis reactor with controlled levels of dissolved oxygen were carried out with different carbon sources: glucose and glycerol. Extremely high cell concentrations of 190 g/l and 180 g/l dry cell weight were obtained in glucose medium and in glycerol medium respectively. Different behaviour was observed in the formation of acetic acid in these cultivations. In glucose medium, acetic acid was formed during the earlier phase of cultivation. However, in glycerol medium, acetic acid formation started later and was particularly rapid at the end of the cultivation. In order to estimate the influence of acetic acid during these high-cell-density cultivations, the inhibitory effect of acetic acid on cell growth was investigated under different culture conditions. It was found that the inhibition of cell growth by acetic acid in the fermentor was much less than that in a shaker culture. On the basis of the results obtained in these investigations of the inhibitory effect of acetic acid, and the mathematical predictions of cell growth in a dialysis reactor, the influence of acetic acid on high-cell-density cultivation is discussed. Received: 20 May 1997 / Received revision: 12 August 1997 / Accepted: 25 August 1997     

Hydroxyethylation of Comenic Acid

A small jar fermentor was developed in order to investigate the effect of oxygen supply on hydrocarbon fermentation. Several indices to oxygen transfer were examined with this small jar fermentor. Conditions for suitable oxygen supply were examined in l-glutamic acid fermentation from hydrocarbon by use of shaking flasks and these small jar fermentors. The data indicated that the rate of oxygen transfer ought to be more than 14.3 × 10^?7 mole/ml·min in order to obtain satisfactory results. The coefficient of oxygen transfer rate (K_La/H) decreased as the fermentation went on, so the supply of oxygen enriched gas mixture was effective to increase the production of l-glutamic acid.     

Aeration-controlled formation of acetic acid in heterolactic fermentations

Summary Controlled aeration ofLeuconostoc mesenteroides was studied as a possible mechanism for control of the formation of acetic acid a metabolite of major influence on the taste of lactic fermented foods. Fermentations were carried out in small scale in a medium in which growth was limited by the buffer capacity only. Ethanol and acetic acid formed during the fermentation were analyzed by rapid head space gas chromatography, and the ratio of the molar concentrations of these two volatiles quantitatively predicted the balance between the formation of acetic acid and lactic acid. The oxygen concentration during the fermentations decreased rapidly to zero, meaning that oxygen transfer was limited by the volumetric oxygen transfer rate,k ₁ aC ^*. A linear correlation between k₁aC^* and the quantity of acetic acid produced was established, and it is suggested that such oxygenated heterolactic fermentation processes should be analyzed as fed-batch fermentations with oxygen as the limiting substrate. Addition of fructose in limited amounts leads to the formation of one half mole of acetic acid for each mole fructose, thus offering an alternative mechanism for controlling acetic acid formation.     

Effect of Pollution Load and Oxygen Availability on Thermophilic Aerobic Continuous Biodegradation of Potato Processing Wastewater

The possibility of enhancing the effectiveness of the biodegradation process of potato wastewater was evaluated. The effect of wastewater pollution load, dilution rate and oxygen supplementation during the thermophilic aerobic continuous utilization process on biodegradation of the main organic pollutants was investigated. Aeration performed using a stirred tank reactor (1.5 vvm, 300 rpm, 55 °C) proved to be not sufficient to provide aerobic conditions. During the continuous process, the amount of oxygen introduced into the wastewater was totally utilized by the microflora. The accumulation and decomposition of the fermentative metabolism products of the Bacillus mixed culture during oxygen limitation and supplementation were analyzed. Under microaerobic conditions (DOT < 1 %), a biosynthesis of acetic acid was observed up to a concentration of 6.5 g/dm³. After chemostat conditions were achieved, the level of acetic acid stabilized at 2.2 g/dm³. The addition of oxygen for aeration allowed a total decomposition of organic acids like acetic and lactic acid (the by‐products were synthesized from partially oxidized substrates) as well as an increase in COD reduction of the wastewater (from 66 % to 79 %). The periodic fortification of aeration with pure oxygen is proposed for critical situations during the continuous wastewater biodegradation when an unexpected inflow of highly polluted wastewater occurs in the system.     

Stoffwechselprodukte von Mikroorganismen

At low iron(III)-concentrations (<10^-5 M) the fungus Aspergillus viridi-nutans Ducker & Thrower excretes desferri-ferricrocin as the main sideramine into the culture medium. While this compound accounts for 95% of the sideramines produced, small amounts of additional sidermines may also be detected. In a search for an inexpensive nutrient medium for optimum production of desferri-ferricrocin, experiments using shake flasks with good aeration were undertaken initially. The best medium conditions were then employed in a fermentor system.In a 20-1 fermentor with intensor system, it was shown that at certain growth rates there was an inverse correlation between rate of growth and rate of sideramine production. A defined nutrient medium of glucose plus acetate as carbon sources, and urea or ammonium acetate as nitrogen sources was used. Two different feeding regimens were used in response to changes of pH or to changes of partial pressure of oxygen in the submerged culture: acetic acid/urea of acetic acid/ammonium acetate additions regulated these conditions. The rate of sideramine production under such feeding achieved a maximum of 20 mg l^-1 h^-1 over a period of several days.

165. Mitteilung: H.-P. Fiedler, J. Sauerbier: Isolation and quantitative determination of siderochromes. Europ. J. Appl. Microbiol. (in press)     

Co-production of biomass and metabolites by cell retention culture of <Emphasis Type="Italic">Leuconostoc citreum</Emphasis>

Cell retention culture of lactic acid bacterium Leuconostoc citreum was carried out in a fermentor equipped with an internal ceramic filtration system to co-produce biomass and metabolites. The filtration system was composed of porous ceramic filter module with pore size of 0.1 μm and total surface area of 330 cm². High cell density cultivation of L. citreum was achieved within the fermentor, while extracellular metabolites such as mannitol and d-lactic acid were produced through the filter with high productivities. In batch culture of L. citreum using a medium containing 50 g/L of glucose and 100 g/L of fructose, the maximum optical density (OD) monitored at 660 nm was 13 with 65 g/L of mannitol and 38 g/L of lactic acid. In cell retention culture of L. citreum with dilution rate of 0.07 h⁻¹, OD increased to 75, which was 6 times higher than that in batch culture. The concentrations of mannitol and lactic acid increased to 85 and 45 g/L, respectively, and were maintained throughout the cultivation to 105 h. By increasing dilution rate to 0.13 h⁻¹, the productivities of mannitol and lactic acid increased to 8.5 and 4.2 g/L/h, respectively, which were 2.7 to 3 times higher than those in batch culture, suggesting that cell retention culture using internal filtration system is highly effective for co-production of useful cell biomass and various extracellular metabolites.     

Production of poly(3-hydroxybutyrate) from inexpensive substrates

Two inexpensive substrates, starch and whey were used to produce poly(3-hydroxybutyrate) (PHB) in fed-batch cultures of Azotobacter chroococcum and recombinant Escherichia coli, respectively. Oxygen limitation increased PHB contents in both fermentations. In fed-batch culture of A. chroococcum, cell concentration of 54 g l⁻¹ with 46% PHB was obtained with oxygen limitation, whereas 71 g l⁻¹ of cell with 20% PHB was obtained without oxygen limitation. The timing of PHB biosynthesis in recombinant E. coli was controlled using the agitation speed of a stirred tank fermentor. A PHB content of 80% could be obtained with oxygen limitation by increasing the agitation speed up to only 500 rpm.     

Effect of dissolved oxygen concentration on repeated production of gluconic acid by immobilised mycelia of Aspergillus niger

Summary Gluconic acid production from corn starch hydrolysates by immobilised mycelia of Aspergillus niger was studied in a laboratory-scale stirred fermentor at different concentrations of glucose (S ₀) and dissolved oxygen (DO) in the culture broth. Its evolution was simulated quite well by applying the same unstructured model set up in previous experiments using stirred and airlift fermentors. In particular, increasing S ₀ in the range 70–160 g/l, although uninfluential upon the yield coefficient, resulted in an exponential decrease in the gluconic acid formation rate constant. Nevertheless, the greater the oxygen transfer rate used in the fermentor, the smaller the inhibitor effect of the higher concentrations of glucose on gluconate productivity became. This was achieved by enriching the inlet air with pure oxygen so as to maintain the DO level above 75% saturation throughout the fermentation. Offprint requests to: M. Moresi     

High cell density culture of a recombinant Escherichia coli producing penicillin acylase in a membrane cell recycle fermentor

A recombinant Escherichia coli HB101(pPAKS2) producing penicillin acylase was cultured in a membrane cell recycle fermentor. The strain was very stable throughout the whole experiment. The main inhibitory by-product was acetic acid, and cell growth ceased when its concentration was above 14 g/L Cell density could be increased up to 145 g/L dry weight without experiencing by-product inhibition by regulating glucose concentration in the fermentor and by using total membrane recycle. Acetic acid formation was negligible not only when cells were cultured in medium containing no glucose but also when glucose was limited. Dissolved oxygen control as well as glucose limitation was an indispensable condition for minimizing acetic acid formation when the medium contained glucose. Low concentrations of accumulated acetic acid were reused when glucose was limited. Use of highly concentrated medium reduced the membrane surface area required for cell recycle greatly. The recycle fermentor could be operated in various operational modes including partial bleed and repeated recycle culture to give high productivity. Productivity of a repeated recycle system was over 10 times higher than that of a simple batch system.     

The aerobic growth and product formation of Lactobacillus,Leuconostoc, Brochothrix,and Carnobacterium in batch cultures

Summary The aerobic growth and metabolism of eleven homofermentative and three heterofermentative Lactobacillus strains, three Leuconostoc strains, two Brochothrix thermosphacta strains and two Carnobacterium strains were studied in batch cultures at pH 6.0 and 25°C on a complex substrate containing 10.0 g glucose per litre. All strains, except Carnobacterium divergens 69, grew well aerobically. An oxygen consumption was registered for 18 of the strains—the exceptions being Lactobacillus alimentarius DSM 20249^T, Lactobacillus farciminis DSM 20284^T and Lactobacillus sharpeae DSM 20505^T. The homofermentative lactobacilli showed a maximal oxygen consumption during the stationary growth phase and this was coupled with a low final viable count. Leuconostoc strains, heterofermentative lactobacilli, Brochothrix thermosphacta and Carnobacterium strains showed a maximal oxygen consumption during the exponential growth phase together with a high final viable count. The maximum specific growth rate varied from 0.19 to 0.54 h^-1 while the growth yield varied from 19 to 86 g dry weight per mol glucose consumed. In general, homofermentative lactobacilli produced dl-lactic acid, acetic acid and acetoin. The three heterofermentative lactobacilli produced dl-lactic acid and acetic acid, two strains also produced ethanol Leuconostoc spp. formed d-lactic acid, acetic acid, and ethanol. B. thermosphacta produced acetoin, acetic acid, formic acid, isobutyric acid and isovaleric acid but no lactic acid. Carnobacterium produced l-lactic acid, acetic acid and acetoin. All strains accumulated hydrogen peroxide except L. alimentarius DSM 20249^T, Carnobacterium piscicola 3 and B. thermosphacta.née Blickstad     

Multi-stage biofilm reactor for acetic acid production at high concentration

Summary Continuous production of acetic acid by liquid surface culture ofAcetobacter aceti M7 was investigated using a Multi-Stage Biofilm Reactor (MSBFR) composed of ten shallow flow horizontal reactors of laboratory scale. With varying dilution rate in the range from 0.049 to 0.2 h^–1, the maximum exit acetic acid concentration reached was as high as 98.0 g/l at the lowest dilution rate with step feed of ethanol-rich medium to stages 3, 5, and 7. The production rate (4.3 g/l/h) was rather high considering the inhibitory effect of high acetic acid concentration. This may be ascribed to non-homogeneous distribution of acetic acid concentration in the bioreactor and step feed of ethanol-rich medium.     

Modeling of yeast <Emphasis Type="Italic">Brettanomyces bruxellensis</Emphasis> growth at different acetic acid concentrations under aerobic and anaerobic conditions

Glucose utilization by Brettanomyces bruxellensis at different acetic acid concentrations under aerobic and anaerobic conditions was investigated. The presence of the organic acid disturbs the growth and fermentative activity of the yeast when its concentration exceeds 2 g l⁻¹. A mathematical model is proposed for the kinetic behavior analysis of yeast growing in batch culture. A Matlab algorithm was used for estimation of model parameters, whose confidence intervals were also calculated at a 0.95 probability level using a t-Student distribution for f degrees of freedom. The model successfully simulated the batch kinetics observed at different concentrations of acetic acid under both oxygen conditions.     

Utilizing the tubular bioreactor for continuous recovery of secreted fusion protein from recombinant Escherichia coli

In order to improve the cultivation properties of a traditional continuous stirred tank reactor (CSTR), we introduced a circulation unit made of four inorganic membranes in stainless steel tubes in parallel configuration, the so-called Tubular Bioreactor (TBR). Furthermore, the TBR outlet tube, which has a restriction nozzle at the end, was installed on top of the fermentor vessel, thereby creating a strong jet flow into the reactor and thus improving the mixing and the oxygen transfer rate. The k _La could be increased by approximately 50%. This setup was used for cultivations of recombinant Escherichia coli in a minimal medium and high cell density. More than 50 g dry cell mass/dm³ was obtained. Simultaneously, we have produced an elongated form of human insulin-like growth factor II, which was a secreted fusion protein utilizing the E. coli secretion system based on staphylococcus protein A. The product could be recovered continuously through the TBR-membrane.     

Oxygen uptake rate regulation during cell growth phase for improving avermectin B<Subscript>1a</Subscript> batch fermentation on a pilot scale (2 m<Superscript>3</Superscript>)

Avermectin B_1a batch fermentation of Streptomyces avermitilis in a 2 m³ fermentor was investigated by oxygen uptake rate (OUR) regulation during cell growth phase. OUR was controlled by adjusting of aeration and agitation. Result showed that OUR strongly affected cell growth and antibiotics production. Avermectin B_1a biosynthesis could be effectively enhanced when OUR was stably regulated at an appropriate level in batch fermentation of S. avermitilis. Avermectin B_1a yield reached 5568 ± 111 mg/l by controlling maximal OUR between 15 and 20 mmol/l/h during cell growth phase, which was increased by 21.8% compared with the control (maximal OUR above 20 mmol/l/h). The stimulation effect on avermectin B_1a production could be attributed to the improved supply of propionic acid and acetic acid, the precursors of avermectin B_1a, in the cells. Hence, this OUR control method during cell growth phase may be a simple and applicable way to improve industrial production of avermectin.     

Effect of the oxygen supply on pattern of growth and corrinoid and organic acid production of Propionibacterium shermanii

Propionibacterium shermanii CDB 10014 is able to grow even at high oxygen transfer rates (24.0 mmol O₂ l⁻¹ h⁻¹), in contrast to reports in the specialised literature, where all Propionibacteria are considered oxygen-sensitive microorganisms. Propionic acid is the main product in anaerobiosis. The presence of oxygen in the system leads to an inhibition of propionic acid production while acetic acid formation is enhanced. At high oxygen supply rates no propionic acid is produced and acetic acid is the main product. Lactic acid is also produced in reasonable quantities (2.7 g l⁻¹). The growth rate (μ_max) is higher in anaerobiosis (0.19 h⁻¹) than in aerobiosis (0.12–0.15 h⁻¹). The cell yield is higher in aerobiosis (0.18–0.22 g g⁻¹) than in anaerobiosis (0.14 g g⁻¹) suggesting the oxidative metabolism of glucose by Propionibacterium shermanii CDB 10014. No corrinoid production was detected at oxygen transfer rates of more than 13.6 mmol l⁻¹ h⁻¹. Received: 10 September 1997 / Received revision: 6 January 1998 / Accepted: 9 January 1998     

A kinetic study of acetic acid production by liquid-surface cultures of Acetobacter aceti

Summary The kinetics of acetic acid production by liquid-surface cultures of Acetobacter aceti strain M7 was investigated. Specific rates of acetic acid production (q _pf , g acetic acid/ cm² microbial film per hour), ethanol consumption and oxygen uptake were estimated on the basis of liquid-surface area: these were virtually constant, irrespective of the thickness of the microbial film. The effect of acetic acid concentration (P) on q _pf was found to be expressed from a series of experiments, as follows: q _pf = 0.0227(1-P/93)^2.204. A simple mathematical model was proposed to describe quantitatively the acetic acid production rate as a function of specific surface area and dilution rate. The mathematical model could reasonably well approximate to experimental data in the literature. The oxygen transfer rate through the air-liquid interface of a reactor in the presence of a microbial film was 3.6 times larger than that in the absence of the microbial film. Offprint requests to: K. Toda     

Characterization of anaerobic microbial culture with high acidogenic activity

The mixed cultures which were used were isolated from municipal sludge digesters, and the production of organic acids (acetic, propionic, butyric, etc.) from carbohydrates was tested. The behavior of the reference population (culture R) obtained directly from the sewage treatment plant, is compared to that obtained after three months in a plug-flow reactor (Gradostat fermentor) without pH control (culture A) and after six months with pH control (culture B). For culture B, the specific rate of acid production is related to the cell growth rate by (1/X)r_p= 17 µ + 1.6 with a maximal acid concentration of 40 g/liter. The batch culture yields are improved from 0.36g/g for the initial culture (R) to 0.72 g/g for culture B after six months in continuous culture, and 0.8 g/g in plug-flow continuous culture. The productivity of organic acids reaches 1.7 g/liter·hr. It is suggested that the acidogenic fermentation, the first step of methanogenesis, is a potential process to produce acetic, propionic, and butyric acids.