Three-dimensional simulation of grain mixing in three different rotating drum designs for solid-state fermentation

A previously published two-dimensional discrete particle simulation model for radial mixing behavior of various slowly rotating drums for solid-state fermentation (SSF) has been extended to a three-dimensional model that also predicts axial mixing. Radial and axial mixing characteristics were predicted for three different drum designs: (1) without baffles; (2) with straight baffles; and (3) with curved baffles. The axial mixing behavior was studied experimentally with video- and image-analysis techniques. In the drum without baffles and with curved baffles the predicted mixing behavior matched the observed behavior adequately. The predicted axial mixing behavior in the drum with straight baffles was predicted less accurately, and it appeared to be strongly dependent on particle rotation, which was in contrast to the other drum designs. In the drum with curved baffles complete mixing in the radial and axial direction was achieved much faster than in the other designs; that is, it was already achieved after three to four rotations. This drum design may therefore be very well suited to SSF. It is concluded that discrete particle simulations provide valuable detailed knowledge about particle transport processes, and this may help to understand and optimize related heat and mass transfer processes in SSF.     

Heat and water transfer in a rotating drum containing solid substrate particles

In previous work we reported on the simulation of mixing behavior of a slowly rotating drum for solid-state fermentation (SSF) using a discrete particle model. In this investigation the discrete particle model is extended with heat and moisture transfer. Heat transfer is implemented in the model via interparticle contacts and the interparticle heat transfer coefficient is determined experimentally. The model is shown to accurately predict heat transfer and resulting temperature gradients in a mixed wheat grain bed. In addition to heat transfer, the addition and subsequent distribution of water in the substrate bed is also studied. The water is added to the bed via spray nozzles to overcome desiccation of the bed during evaporative cooling. The development of moisture profiles in the bed during spraying and mixing are studied experimentally with a water-soluble fluorescent tracer. Two processes that affect the water distribution are considered in the model: the intraparticle absorption process, and the interparticle transfer of free water. It is found that optimum distribution can be achieved when the free water present at the surface of the grains is quickly distributed in the bed, for example, by fast mixing. Alternatively, a short spraying period, followed by a period of mixing without water addition, can be applied. The discrete particle model developed is used successfully to examine the influence of process operation on the moisture distribution (e.g., fill level and rotation rate). It is concluded that the extended discrete particle model can be used as a powerful predictive tool to derive operating strategies and criteria for design and scale-up for mixed SSF and other processes with granular media.     

Substrate aggregation due to aerial hyphae during discontinuously mixed solid-state fermentation with Aspergillus oryzae: experiments and modeling

Solid-state fermentation (SSF) is prone to process failure due to channeling caused by evaporative cooling and the formation of an interparticle mycelium network. Mixing is needed to break the mycelium network and to avoid such failure. This study presents the first attempt to quantify and predict the effect of mycelium bonds on particle mixing and vice versa. We developed a novel experimental set-up to measure the tensile strength of hyphal bonds in SSF: Aspergillus oryzae was cultivated between two wheat-dough disks and the tensile strength of the aerial mycelium was measured with a texture analyzer. Tensile strength at different incubation times was related to oxygen consumption, to allow a translation to a rotating drum with A. oryzae cultivated on wheat grain. We performed several discontinuously mixed solid-state fermentations in the drum fermentor and measured the number and size of grain-aggregates remaining after the first mixing action. We integrated data on mycelium tensile strength into a previously developed two-dimensional discrete-particle model that calculates forces acting on individual substrate particles and the resulting radial-particle movements. The discrete-particle model predicted the quantity and size of the aggregates remaining after mixing successfully. The results show that the first mixing event in SSF with A. oryzae is needed to break mycelium to avoid aggregate formation in the grain bed, and not to distribute water added to compensate for evaporation losses, or smooth out temperature gradients.     

Discrete particle simulations predicting mixing behavior of solid substrate particles in a rotating drum fermenter.

A soft-sphere discrete particle model was used to simulate mixing behavior of solid substrate particles in a slow rotating drum for solid-state fermentation. In this approach, forces acting on and subsequent motion of individual particles can be predicted. The (2D) simulations were qualitatively and quantitatively validated by mixing experiments using video and image analysis techniques. It was found that the simulations successfully predicted the mixing progress as a function of the degree of filling and size of the drum. It is shown that only relatively large, straight baffles perpendicular to the drum wall (67% of the drum radius) increase the mixing performance of the rotating drum. Considering the different aspects of mixing dealt with in this work, it is concluded that the soft sphere discrete particle model can serve as a valuable tool for investigating mixing of solid substrate particles. Finally, it is expected that this model may evolve into a potential tool for design and scale-up of mixed solid-state fermenters.     

Modeling of heat and mass transfer for solid state fermentation process in tray bioreactor

A mathematical model is developed to simulate oxygen consumption, heat generation and cell growth in solid state fermentation (SSF). The fungal growth on the solid substrate particles results in the increase of the cell film thickness around the particles. The model incorporates this increase in the biofilm size which leads to decrease in the porosity of the substrate bed and diffusivity of oxygen in the bed. The model also takes into account the effect of steric hindrance limitations in SSF. The growth of cells around single particle and resulting expansion of biofilm around the particle is analyzed for simplified zero and first order oxygen consumption kinetics. Under conditions of zero order kinetics, the model predicts upper limit on cell density. The model simulations for packed bed of solid particles in tray bioreactor show distinct limitations on growth due to simultaneous heat and mass transport phenomena accompanying solid state fermentation process. The extent of limitation due to heat and/or mass transport phenomena is analyzed during different stages of fermentation. It is expected that the model will lead to better understanding of the transport processes in SSF, and therefore, will assist in optimal design of bioreactors for SSF.     

The behavior of kinetic parameters in production of pectinase and xylanase by solid-state fermentation

Solid-state fermentation (SSF) is defined as the growth of microbes without a free-flowing aqueous phase. The feasibility of using a citrus peel for producing pectinase and xylanase via the SSF process by Aspergillus niger F3 was evaluated in a 2 kg bioreactor. Different aeration conditions were tested to optimize the pectinase and xylanase production. The best air flow intensity was 1 V kg M (volumetric air flow per kilogram of medium), which allowed a sufficient amount of O2 for the microorganism growth producing 265 U/g and 65 U/g pectinases and xylanases, respectively. A mathematical model was applied to determine the different kinetic parameters related to SSF. The specific growth rate and biomass oxygen yield decreased during fermentation, whereas an increase in the maintenance coefficient for the different employed carbon sources was concurrently observed.     

Control of carbon dioxide in exhaust air as a method for equal biomass yields at different bed heights in a column fermentor

Summary The rate of aeration of the medium in a solid state fermentation system for biomass production by Schwanniomyces castellii in a large column fermentor was found to influence the gradient of biomass yield at different bed heights. The variations were lower with a higher rate of aeration. These trends were used to formulate a successful strategy to ensure equal biomass yield at all the bed heights by controlling the level of CO₂ at about 2% in exhaust air from the fermentor. Correspondence to: B. K. Lonsane     

Solid-state fermentation in rotating drum bioreactors: operating variables affect performance through their effects on transport phenomena

Aspergillus oryzae ACM 4996 was grown on an artificial gel-based substrate and on steamed wheat bran during solid-state fermentations in 18.7 L rotating drum bioreactors. For gel fermentations fungal growth decreased as rotational speed increased, presumably due to increased shear. For wheat bran fermentations fungal growth improved under agitated compared to static culture conditions, due to superior heat and mass transfer. We conclude that the effects of operational variables on the performance of SSF bioreactors are mediated by their effects on transport phenomena such as mixing, shear, heat transfer, and mass transfer within the substrate bed. In addition, the substrate characteristics affect the need for and the rates of these transport processes. Different transport phenomena may be rate limiting with different substrates. This work improves understanding of the effects of bioreactor operation on SSF performance.     

Numerical simulation and PEPT measurements of a 3D conical helical-blade mixer: a high potential solids mixer for solid-state fermentation

Helical-blade solids mixers have a large potential as bioreactors for solid-state fermentation (SSF). Fundamental knowledge of the flow and mixing behavior is required for robust operation of these mixers. In this study predictions of a discrete particle model were compared to experiments with colored wheat grain particles and positron emission particle tracking (PEPT) measurements. In the discrete particle model individual movements of particles were calculated from interaction forces. It was concluded that the predicted overall flow behavior matched well with the PEPT measurements. Differences between the model predictions and the experiments with wheat grains were found to be due to the assumption that substrate particles were spherical, which was in the model. Model simulations and experiments with spherical green peas confirmed this. The mixing in the helical-blade mixer could be attributed to (1) the transport of particles up and down in the interior of the mixer, and (2) dispersion or micro-mixing of particles in the top region of the mixer. It appeared that the mixing rate scaled linearly with the rotation rate of the blade, although the average particle velocity did not scale proportionally. It may be that the flow behavior changes as a function of the rotation rate (e.g., changing thickness of the top region); further study is required to confirm this. To increase the mixing performance of the mixer, a larger blade or a change in the shape of the mixer (larger top surface/volume ratio) is recommended.     

Gas concentration and temperature gradients in a packed bed solid-state fermentor

In solid-state fermentation (SSF), interaction of heat and mass transfer with biochemical reaction (growth associated enzyme production) affects the bioreactor performance. This interaction was earlier observed to cause temperature and gaseous concentration gradients which reduced the effective bed height of the bioreactor. Since forced aeration is known to alleviate this problem, a packed column bioreactor with forced aeration was employed in the present study. Using wheat bran and Aspergillus niger CFTRI 1105, experiments were conducted for the production of the enzyme amyloglucosidase at various air flow rates. Temperatures and gas concentrations were recorded and enzyme activities estimated at different bed heights during the course of SSF. Gas concentration and temperature gradients decreased with increasing air flow rate. The packed column allowed the use of larger bed heights and yielded higher enzyme activities (6,260 Units/gDMB) than trays (345 Units/gDMB). Enzyme activity was affected more by temperature than concentration gradients, and increased with air flow rates.     

Relation between Citric Acid Production and Respiration Rate of Aspergillus niger in Solid‐State Fermentation

Among the organic acids produced industrially, citric acid is the most important in quantitative terms. Solid‐state fermentation (SSF) has been an alternative method for citric acid production using agro‐industrial residues such as cassava bagasse (CB). The use of CB as a substrate can avoid environmental problems caused by its disposal into the environment. This study was developed to verify the influence of the treated bagasse amount, and consequently, the influence of the gelatinization degree of CB starch on citric acid production by SSF in Erlenmeyer flasks, horizontal drums, and trays. The best results were obtained in a horizontal drum bioreactor using 100 % of treated CB. However, trays showed advantages and good perspectives for large‐scale citric acid production due to economic reasons such as energy costs. A kinetic study was also carried out in order to compare citric acid production in glass columns (laboratory scale) and horizontal drum bioreactors (semi‐pilot scale). This study was accomplished in order to follow the influence of aeration on citric acid accumulation. In addition, the production of CO₂ was evaluated as an indirect method of biomass estimation. Citric acid production was higher in glass columns (309.70 g/kg of dry CB) than in HD bioreactors (268.94 g/kg of dry CB). Finally, it was possible to show that citric acid production was favored by a limited biomass production, which occurred with low aeration rates. Biomass production is related to CO₂ production and as a result, a respirometry analysis could be used for biomass estimation.     

Model-based bioreactor selection for large-scale solid-state cultivation of Coniothyrium minitans spores on oats

Non-mixed and mixed SSF reactors were evaluated for their applicability in large-scale spore production of the biocontrol fungus Coniothyrium minitans. The major problem to overcome in large-scale SSF is heat accumulation. Testing various cooling strategies in large-scale bioreactors would be very expensive and time consuming, therefore lab experiments in combination with mathematical simulations were used instead. The metabolic heat production rate, estimated from the oxygen consumption rate of C. minitans on oats in Erlenmeyer flasks, was about 500 Watt per m(3) bed. Conductive cooling in packed-bed reactors was insufficient to cool large reactor volumes (radius > 0.2 m). The poor thermal conductivity of the bed (lambda(b) = 0.1 W m(-2) K(-1)) resulted in steep radial temperature profiles. Adequate temperature control could be achieved with forced aeration, but concomitant water losses lead to significant shrinkage of the oats (30%) and critically low water activities, even though the bed was assumed to be aerated with water saturated air. Mixed systems, however, allowed heat removal without the need of evaporative cooling. Simulations showed that large volumes could be cooled via the wall at low mixing intensities and small temperature driving forces. Experimental studies showed no detrimental effect of mixing on spore production by C. minitans. The spore production yield in a continuously mixed scraped-drum reactor (0.2 rpm) was 5 x 10(12) spores per kg dry oats after 450 hours. Based on the scale-up potential of the mixed system and the absence of detrimental mixing effects it is believed that a mixed bioreactor is superior to a non-mixed system for large-scale production of C. minitans spores.     

Model for on-line moisture-content control during solid-state fermentation

In this study we describe a model that estimates the extracellular (nonfungal) and overall water contents of wheat grains during solid-state fermentation (SSF) with Aspergillus oryzae, using on-line measurements of oxygen, carbon dioxide, and water vapor in the gas phase. The model uses elemental balances to predict substrate dry matter losses from carbon dioxide measurements, and metabolic water production, water used in starch hydrolysis, and water incorporated in new biomass from oxygen measurements. Water losses caused by evaporation were calculated from water vapor measurements. Model parameters were determined using an experimental membrane-based model system, which mimicked the growth of A. oryzae on the wheat grains and permitted direct measurement of the fungal biomass dry weight and wet weight. The measured water content of the biomass depended heavily on the moisture content of the solid substrate and was significantly lower than the estimated values reported in the literature. The model accurately predicted the measured overall water content of fermenting solid substrate during fermentations performed in a 1.5-L scraped drum reactor and in a 35-L horizontal paddle mixer, and is therefore considered validated. The model can be used to calculate the water addition required to control the extracellular water content in a mixed solid-state bioreactor for cultivation of A. oryzae on wheat.     

Effect of oxygen and carbon dioxide on germination and growth ofRhizopus oligosporus on model media and soya beans

 The microcolony technique enables the effects of several atmospheric conditions on fungal growth to be studied by measuring the radius of the colony, while excluding effects of those conditions on germination of the sporangiospores. Various concentrations of oxygen and carbon dioxide in the gas environment were found to influence growth of Rhizopus oligosporus on malt extract/soya peptone/agar. The maximum radial growth rate was 1.48 mm/h and the maximum specific growth rate was 0.109 h^-1 at 30 °C. Oxygen became limiting below 1% (v/v), but growth remained possible at levels of 0.001% oxygen. Carbon dioxide stimulated growth at limiting oxygen levels. The specific growth rate increased from 0.043 h^-1 at 0.5% (v/v) oxygen and 0% (v/v) carbon dioxide to 0.096 h^-1 at 0.5% (v/v) oxygen and 5% (v/v) carbon dioxide. A mixture of 0.5% (v/v) oxygen and 35% (v/v) carbon dioxide inhibited growth. Delay of sporangiospore germination due to low (less than 0.001%) amounts of oxygen was not observed with the techniques used. Fungal activity in a rotating drum fermentor was more strongly affected by low levels of oxygen than was biomass formation on model media. High concentrations of carbon dioxide inhibited growth in the rotating drum fermentor at non-limiting levels of oxygen. It is concluded that aeration and heat removal are both essential aspects of optimization of large-scale solid-substrate bioreactors with Rh. oligosporus. Received: 5 August 1994/Received revision: 14 November 1994/Accepted: 5 December 1994     

Influence of mold growth on the pressure drop in aerated solid state fermentors

The measurement of pressure drop(DeltaP) across an aerated fermentation bed is proposed as alternative on-line sensor for the qualitative and, in some cases, quantitative, macroscopic changes in a static solid state fermentor. An increase in the DeltaP is correlated with the evolution of the different phases of Aspergillus niger growth: germination, vegetative growth, limitation, and sporulation, we observed in the microscope. For the case where the support is not modified during the fermentation and the water content remains constant, i.e., a synthetic resin (Amberlite IRA-900), the gas phase permeability of the bed is directly related to the biomass content. For example, the permeability of the bed is reduced to 5% of the initial value when biomass attains 21 mg dry biomass/g dry support. Biomass was appropriately predicted from the DeltaP measurements in an independent test. Experiments with different initial sucrose solution concentrations showed that biomass could not be produced beyond a certain level (21.5 mg dry biomass/g dry support) which suggests steric limitations. For the case of wheat bran and cane bagasse, the increase in DeltaP was related qualitatively to the evolution in the growth and the morphology of the mold . (c) 1993 Wiley & Sons, Inc.     

Effect of oxygen fluctuations on recombinant Escherichia coli fermentation

Escherichia coli DH5alpha, carrying the pUC19 plasmid for the lacZ fragment of beta-galactosidase and ampicillin resistance, was grown in a batch fermentor under conditions of fluctuating oxygen supply. A Monte Carlo method was used to control the on/off supply of air to simulate circulation of cells in a large fermentor. Rapid changes in oxygen supply reduced the rates of oxygen uptake the carbon dioxide release and prolonged the active second growth phase in batch culture, compared to growth with continuous aeration. Amplification of the plasmid was observed during the stationary phase when air supplied continuously, but not during the Monte Carlo experiments.     

Effect of operating conditions on solid substrate fermentation

In this work the effects of environmental parameters on the performance of solid substrate fermentation (SSF) for protein production are studied. These parameters are (i) air flow rate, (ii) inlet air relative humidity, (iii) inlet air temperature, and (iv) the heat transfer coefficient between the outer wall of the fermentor and the air in the incubator. The air flow is supplied to effect cooling of the fermented mass by evaporation of water. A dynamic model is developed, which permits estimation of biomass content, total dry matter, moisture content, and temperature of the fermented matter. The model includes the effects of temperature and moisture content on both the maximum specific growth rate and the maximum attainable biomass content. The results of the simulation are compared with actual experimental data and show good agreement with them. The most important conclusions are that (i) the evaporative cooling of the biomass is very effective for temperature control and (ii) the air flow rate and the heat transfer coefficient have strong effects but they affect the biomass morphology and are not controllable easily. Also, a simple technique for the determination of the optimum temperature and moisture content profile for cell protein production is applied. The simulated biomass production increases considerably employing the optimum temperature and moisture content profiles. The ultimate goal is to implement the determined effects of the environmental parameters on the SSF biomass production and the temperature and moisture variation profiles to effectively control the SSF and optimize the biomass production. (c) 1993 John Wiley & Sons, Inc.     

Evaluation of the effect of process variables on the fatty acid profile of single cell oil produced by Mortierella using solid-state fermentation

This article reviews some of the aspects of single cell oil (SCO) production using solid-state fermentation (SSF) by fungi of the genus Mortierella. This article provides an overview of the advantages of SSF for SCO formation by the aforementioned fungus and demonstrates that the content of the polyunsaturated fatty acids (PUFA) depend on the type of fermentation media and culture conditions. Process variables that influence lipid accumulation by Mortierella spp. and the profile of the fatty acids are discussed, including incubation temperature, time, aeration, growth phase of the mycelium, particle size of the substrate, carbon to nitrogen ratio, initial moisture content and pH as well as supplementation of the substrate with nitrogen and oil. Finally, the article highlights future research trends for the scaled-up production of PUFAs in SSF.     

Effect of PO2 on growth and physiological characteristics of Candida utilis in a multistage tower fermentor

The effect of increasing the partial pressure of oxygen in the aeration gas on growth and physiological activity of the yeast Candida utilis in a multistage tower fermentor was studied. The measurements were made at steady states of continuous culture for single values of dilution rate, temperature, and pH in all stages of the fermentor and with one given ethanol concentration in the growth medium feed. The partial pressure of oxygen in the gas phase was changed in the range from 165 to 310 torr. The results revealed the existence of the upper critical value of the partial oxygen pressure in the gas phase. It was demonstrated that the upper critical value of PO ₂ influences not only the growth rate, biomass yield, and productivity but also the cell physiology resulting in changes of respiration activity and activity of alcohol and aldehyde dehydrogenases.     

Stability of expanded beds during the application of crude feedstock

Expanded bed adsorption is an integrated technology that allows the introduction of a particle containing feedstock without the risk of blocking the bed. Provided a perfectly classified fluidized bed (termed expanded bed) is formed in the crude feed, a sorption performance comparable to packed beds is found. During the application of biomass containing samples to stable expanded beds an increase in bed expansion due to the higher density and viscosity of the feed is encountered. In this article it is investigated whether the expanded bed condition is also fulfilled during the transition in bed expansion from lower to higher density (i.e., from an equilibration buffer to a biomass containing feedstock). Residence time distribution analyses were performed by using model systems and a yeast suspension during this transition phase. It is shown that in systems in which the biomass does not interact with the fluidized stationary phase, the perfectly classified fluidization is maintained also during this transition phase regardless of the type of feedstock. Additional bed expansion takes place in an "ordered" manner without compromising bed stability. In case of biomass/adsorbent interactions, a deterioration in bed stability is found directly when the crude feed is loaded.