Treatment of screened dairy manure by upflow anaerobic fixed bed reactors packed with waste tyre rubber and a combination of waste tyre rubber and zeolite: effect of the hydraulic retention time

Two laboratory-scale anaerobic fixed bed reactors were evaluated while treating dairy manure at upflow mode and semicontinuous feeding. One reactor was packed with a combination of waste tyre rubber and zeolite (R1) while the other had only waste tyre rubber as a microorganism immobilization support (R2). Effluent quality improved when the hydraulic retention time (HRT) increased from 1.0 to 5.5 days. Higher COD, BOD5, total and volatile solids removal efficiencies were always achieved in the reactor R1. No clogging was observed during the operation period. Methane yield was also a function of the HRT and of the type of support used, and was 12.5% and 40% higher in reactor R1 than in R2 for HRTs of 5.5 and 1.0 days, respectively. The results obtained demonstrated that this type of reactor is capable of operating with dairy manure at a HRT 5 times lower than that used in a conventional reactor.     

Mathematical modeling of maltose hydrolysis in different types of reactor

A commercial enzyme Dextrozyme was tested as catalyst for maltose hydrolysis at two different temperatures: 40 and 65 °C at pH 5.5. Its operational stability was studied in different reactor types: batch, repetitive batch, fed-batch and continuously operated enzyme membrane reactor. Dextrozyme was more active at 65 °C, but operational stability decay was observed during the prolonged use in the reactor at this temperature. The reactor efficiencies were compared according to the volumetric productivity, biocatalyst productivity and enzyme consumption. The best reactor type according to the volumetric productivity for maltose hydrolysis is batch and the best reactor type according to the biocatalyst productivity and enzyme consumption is continuously operated enzyme membrane reactor. The mathematical model developed for the maltose hydrolysis in the different reactors was validated by the experiments at both temperatures. The Michaelis–Menten kinetics describing maltose hydrolysis was used.     

Treatment of coffee waste by slurry-state anaerobic digestion

Slurries containing 20% (w/v) coffee waste solids were treated anaerobically in one- and two-phase thermophilic methane fermentation systems (53°C) with or without pH control. In one-phase methane fermentation using a roller bottle reactor, the maximum gas evolution rate of 0.87 l/l·d was achieved during treatment for 91 d. However, this one-phase methane fermentation did not yield reproducible data. In a two-phase methane fermentation system consisting of a completely stirred tank reactor type (CSTR-type) liquefaction reactor without pH control and an anaerobic fluidized bed type gasification reactor, three-repetitions of treatment were conducted. Each treatment was very stable and the average gas evolution rate per volume of the gasification reactor was about 2.4 l/l·d. Two-repetitions of treatment were then done while controlling pH in the liquefaction at more than 6. The average gas evolution rate per volume of gasification reactor was found to have increased to 10.2 l/l·d, a value which corresponded to 0.84 l/l·d per total volume, including the liquefaction reactor. It was observed that treatment in a two-phase methane fermentation could be repeated in a stable fashion even in the closed system without discharging anything but the coffee waste residues.     

Improved reactor performance and operability in the biotransformation of carveol to carvone using a solid-liquid two-phase partitioning bioreactor

In an effort to improve reactor performance and process operability, the microbial biotransformation of (-)-trans-carveol to (R)-(-)-carvone by hydrophobic Rhodococcus erythropolis DCL14 was carried out in a two phase partitioning bioreactor (TPPB) with solid polymer beads acting as the partitioning phase. Previous work had demonstrated that the substrate and product become inhibitory to the organism at elevated aqueous concentrations and the use of an immiscible second phase in the bioreactor was intended to provide a reservoir for substrates to be delivered to the aqueous phase based on the metabolic rate of the cells, while also acting as a sink to uptake the product as it is produced. The biotransformation was previously undertaken in a two liquid phase TPPB with 1-dodecene and with silicone oil as the immiscible second phase and, although improvement in the reactor performance was obtained relative to a single phase system, the hydrophobic nature of the organism caused the formation of severe emulsions leading to significant operational challenges. In the present work, eight types of polymer beads were screened for their suitability for use in a solid-liquid TPPB for this biotransformation. The use of selected solid polymer beads as the second phase completely prevented emulsion formation and therefore improved overall operability of the reactor. Three modes of solid-liquid TPPB operation were considered: the use of a single polymer bead type (styrene/butadiene copolymer) in the reactor, the use of a mixture of polymer beads in the reactor (styrene/butadiene copolymer plus Hytrel(R) 8206), and the use of one type of polymer beads in the reactor (styrene/butadiene copolymer), and another bead type (Hytrel(R) 8206) in an external column through which fermentation medium was recirculated. This last configuration achieved the best reactor performance with 7 times more substrate being added throughout the biotransformation relative to a single aqueous phase benchmark reactor and 2.7 times more substrate being added relative to the best two liquid TPPB case. Carvone was quantitatively recovered from the polymer beads via single stage extraction into methanol, allowing for bead re-use.     

Development of continuous flow type hydrothermal reactor for hemicellulose fraction recovery from corncob

The semi-pilot scale of continuous flow type hydrothermal reactor has been investigated to separate hemicellulose fraction from corncob. We obtained the effective recovery of hemicellulose using tubular type reactor at 200 °C for 10 min. From constituent sugar analysis of corncob, 82.2% of xylan fraction was recovered as mixture of xylose, xylooligosaccharides and higher-xylooligosaccharide which has more than DP 10. During purification of solubilized fraction by hydrothermal reaction such as ultrafiltration and ion exchange resin, higher-xylooligosaccharide was recovered as the precipitate. This precipitate was identified as non-blanched xylan fraction which has from DP 11 to DP 21 mainly. In this system, only a small amount of furfural has been generated. This tubular reactor has a characteristic controllability of thermal history, and seems to be effective for sugar recovery from soft biomass like corncob.     

Bioconversion of waste cellulose by using an attrition bioreactor

A new type of reactor, an attrition bioreactor, was tested to achieve a higher rate and extent of enzymatic saccharification of cellulose than is possible with conventional methods. The reactor consisted of a jacketted stainless-steel vessel with shaft, stirrer, and milling media, which combined the effect of the mechanical action of wet milling with cellulose hydrolysis. The substrates tested were newsprint and white-pine heartwood. The performance of the reactor was excellent. The extent and rate of enzymatic hydrolysis could be markedly improved over other methods. The power consumption of the attrition bioreactor was also measured. The cellulase enzyme deactivation during attrition milling was not significant.     

Continuous alcohol fermentation in an immobilized cell rotating disk reactor

The increasing interest in alcohol fermentation over these last years because of the energy crisis has been demonstrated by an increase in scientific research. After a brief analysis of the main results of the literature in the field of alcohol fermentation reactors, the use of a new type of immobilized cell reactor [the rotating biological surface (RBS) reactor] was studied. As is well known, the RBS reactor is a form of fixed-film reactor and can be described as a dynamic trickling filter. Our experimental apparatus employed a spongy material to trap the yeast cells on the disks. The results of fermentations carried out in the RBS reactor working in batch, in continuous with cell support, and in continuous without cell support have been presented in order to compare the different productivities and to assess the performance of the RBS immobilized cell reactor. An ethanol productivity of 7.1 g/L h was achieved in the RBS-ICR at a dilution rate of 0.3 h(-1), 2.5 times higher than the maximum productivity obtained in the RBS reactor without support at a lower dilution rate. The adoption of a spongy material as a cell immobilizer, combined with the use of the RBS reactor, enhances the particular advantages of both systems.     

Continuous propionic acid fermentation by immobilized Propionibacterium acidipropionici in a novel packed-bed bioreactor

Continuous propionic acid fermentations of lactate by Propionibacterium acidipropionici were studied in spiral wound fibrous bed bioreactors. Cells were imobilized by natural attachment to fiber surfaces and entrapment in the void volume within the fibrous matrix. A high cell density of approximately 37 g/L was attained in the reactor and the reactor productivity was approximately 4 times higher than that from a conventional batch fermentation. The bioreactor was able to operate continuously for 4 months without encountering any clogging, degeneration, or contamination problems. Also, the reactor could accept low-nutrient and low-pH feed without sacrificing much in reactor productivity. This new type of immobilized cell bioreactor is scalable and thus is suitable for industrial production of propionate. (c) 1992 John Wiley & Sons, Inc.     

Identification of bacteria coexisting with anammox bacteria in an upflow column type reactor

Anammox process has attracted considerable attention in the recent years as an alternative to conventional nitrogen removal technologies. In this study, a column type reactor using a novel net type acrylic fiber (Biofix) support material was used for anammox treatment. The Biofix reactor was operated at a temperature of 25°C (peak summer temperature, 31.5°C). During more than 340 days of operation for synthetic wastewater treatment, the nitrogen loading rates of the reactor were increased to 3.6 kg-N/m³/d with TN removal efficiencies reaching 81.3%. When the reactor was used for raw anaerobic sludge digester liquor treatment, an average TN removal efficiency of 72% was obtained with highest removal efficiency of 81.6% at a nitrogen loading rate of 2.2 kg-N/m³/d. Results of extracellular polymeric substances (EPS) quantification revealed that protein was the most abundant component in the granular sludge and was found to be almost twice than that in the sludge attached to the biomass carriers. The anammox granules in the Biofix reactor illustrated a dense morphology substantiated by scanning electron microscopy and EPS results. The results of DNA analyses indicated that the anammox strain KSU-1 might prefer relatively low nutrient levels, while the anammox strain KU2 strain might be better suited at high nutrient concentration. Other types of bacteria were also identified with the potential of consuming dissolved oxygen in the influent and facilitating survival of anammox bacteria under aerobic conditions.     

Microbial community structure of ethanol type fermentation in bio-hydrogen production

Three continuous stirred-tank reactors (CSTRs) were used for H(2) production from molasses wastewater at influent pH of 6.0-6.5 (reactor A), 5.5-6.0 (reactor B), or 4.0-4.5 (reactor C). After operation for 28 days, the microbial community formed ethanol type (C), propionate type (A) and ethanol-butyrate-mixed type (B) fermentation. The H(2) production rate was the highest for ethanol type fermentation, 0.40 l (g VSS)(-1) day(-1) or 0.45 l H(2) (g COD removed)(-1). Microbial community dynamics and diversity were analysed using double-gradient denaturing gradient gel electrophoresis (DG-DGGE). Denaturing gradient gel electrophoresis profiles indicated that the community structures changed quickly in the first 14 days. Phylogenetic analysis indicated that the dominant bacterial groups were low G+C Gram-positive bacteria, Bacteroides, gamma-Proteobacteria and Actinobacteria; alpha-Proteobacteria, beta-Proteobacteria, delta-Proteobacteria and Spirochaetes were also presented as minor groups in the three reactors. H(2)-producing bacteria were affiliated with Ethanoligenens, Acetanaerobacterium, Clostridium, Megasphaera, Citrobacter and Bacteroides. An ethanol-based H(2)-producing bacterium, Ethanoligenens harbinense CGMCC1152, was isolated from reactor C and visualized using fluorescence in situ hybridization (FISH) to be 19% of the eubacteria in reactor C. In addition, isoenzyme activity staining for alcohol dehydrogenase (ADH) supported that the majority of ethanol-producing bacteria were affiliated with Ethanoligenens in the microbial community.     

Application of microwave discharge for the synthesis of TiB2 and BN nano- and microcrystals in a mixture of Ti-B powders in a nitrogen atmosphere

Synthesis of titanium diboride and boron nitride nano- and microcrystals by means of a pulsed microwave discharge in a mixture of Ti-B powders in a nitrogen atmosphere is considered. For this purpose, a new type of reactor with a free surface of the powder mixture was used. The reactor design permits free expansion of the reaction products into the reactor volume and their deposition on the reactor walls. Conditions for the synthesis of TiB₂ and BN compounds were studied as functions of the energy input in the discharge, the powder component ratio, the rate of the nitrogen flow through the reactor, and the structure and phase composition of the compounds deposited on the reactor walls. The synthesis of boron nitride and titanium diboride in crystal structures is proven. An important role in the process of synthesis is played by the heating of the mixture due to the titanium diboride synthesis reaction, its behavior in the bulk of the reactor, and the titanium concentration in the powder mixture. It is also found that, as the number of discharges in the bulk of the reactor increases, a dust cloud forms. The luminescence of this cloud indicates that the initiated discharge proceeds not only on the powder surface and in the powder bulk, but also in the reactor volume.     

A new method of autotrophic denitrification with spent sulfidic caustic as substrate and alkalinity source

A new method based on sulfide utilizing autotrophic denitrification was adopted to remove nitrate from wastewater and to reuse spent sulfidic caustic containing high sulfide and alkalinity levels. The experiments were performed using a bench-scale upflow anoxic hybrid growth reactor (UAHGR) and an upflow anoxic suspended growth reactor (UASGR) to characterize the stoichiometric relationship between sulfur and nitrate in the process as well as the performance of the reactors. The level of nitrate removal from the UAHGR and UASGR were maintained at over 90% at a nitrate loading rate ranging from 0.15∼0.40 kgNO₃ ⁻/m³·d and no significant nitrite accumulation was observed in either reactor. Although the influent pH values were higher than the optimum range of autotrophic denitrification at 8.7∼10.1, the effluent pH was stable at 7.2∼7.9 due to the production of hydrogen ions during operation. The stoichiometric ratio of sulfate production to nitrate removal was 1.5∼2.1 mgSO₄ ²⁻/mgNO₃ ⁻ in both reactors. A comparison of the reactor performance revealed that the chemical parameters of the UAHGR operation corresponded to a plug flow like type reactor while the chemical parameters of the UASGR operation corresponded to a completely stirred tank reactor like type reactor. UAHGR did not require sludge recycling due to the packed media while UASGR required 300∼700% sludge recycling. Therefore, spent sulfidic caustic could be used in the sulfur utilizing autotrophic denitrification processes as substrate and alkalinity sources.     

Solid-phase distribution in an airlift reactor with an enlarged degassing zone

The distribution of the solid-phase in an airlift reactor of the concentric draught tube type, with an enlarged degassing zone, has been determined. Samples were taken at eight points of the reactor for various airflow rates, solids loading and density. Hold-up of solids varied considerably within the reactor. The highest value, for all tested experimental conditions, was obtained immediately above the top of the riser and the lowest value near the wall of the degassing zone. © Rapid Science Ltd, 1998     

Kinetics of the enzymatic hydrolysis of cellulose: 2. A mathematical model for the process in a plug-flow column reactor

The kinetics of enzymatic cellulose hydrolysis in a plug-flow column reactor catalysed by cellulases [see 1,4-(1,3;1,4)-β-d-glucan 4-glucanohydrolase, EC 3.2.1.4] from Trichoderma longibrachiatum adsorbed on cellulose surface have been studied. The maximum substrate conversion achieved was 90–94%. The possibility of enzyme recovery for a reactor of this type is discussed. A mathematical model for enzymatic cellulose hydrolysis in a plug-flow column reactor has been developed. The model allows for the component composition of the cellulase complex, adsorption of cellulases on the substrate surface, inhibition by reaction products, changes in cellulose reactivity and the inactivation of enzymes in the course of hydrolysis. The model affords a reliable prediction of the kinetics of d-glucose and cellobiose formation from cellulose in a column reactor as well as the degree of substrate conversion and reactor productivity with various amounts of adsorbed enzymes and at various flow rates.     

Sedimentological evolution in an UASB treating SYNTHES, a new representative synthetic sewage, at low loading rates

The changes in the sedimentological attributes of the sludge bed in an upflow anaerobic sludge blanket (UASB) reactor fed with a low-strength wastewater mimicking raw domestic sewage were assessed in this study. The reactor was inoculated with 250 ml of granular sludge from a full-scale UASB reactor. The organic loading rate (OLR) varied from 1 to 2 g COD/ld. During the half-year long study, the reactor was operated at hydraulic retention times (HRTs) of 4.8 and 10 h, at 33 degrees C. Sludge sedimentology showed that the original granular sludge experienced serious instability and disintegration, leading to a much finer final grain assemblage, mainly due to substrate transfer limitation and cell starvation at the interior of larger granules. With time, the size uniformity tended to decrease, sphericity tended to increase, the skewness of the granule size distribution became negative, and the kurtosis became peaked and leptokurtic. In spite of the observed size reduction, reactor efficiency increased to a CODtotal removal of 96%. Biomass (sludge) yield was 0.012 g VS/g COD removed. The CH4 content of the biogas was high (up to 96%). This study thus highlights the treatment of a new type of wastewater with the deployment of the UASB reactor. It also reports the evolutionary trend of the biomass particle size distribution, making reference to a classic sedimentological appraisal.     

Using a thread type of alginate gel particles as cell-immobilised support and some concept of packed bed fermenter design

A thread type of gel particles was studied for yeast-cell immobilisation, instead of the commonly used bead type. There was a better mass transfer of the gel particles using a thinner thread. In comparison with the bead type, the thread type has better shape structure in view of the packed-bed reactor design . At the same time, a continuous beer fermentation, using immobilised yeast in the thread type of gel particles, was carried out in a packed bed column fermenter. The study demonstrated that, the beer fermentation can be accelerated up to the hydraulic residence time of 1 day.     

Reactor design for the ABE fermentation using cells of Clostridium acetobutylicum immobilized by adsorption onto bonechar

Cells of Clostridium acetobutylicum were immobilized by adsorption onto bonechar. and used for the production of solvents (ABE fermentation) from whey permeate. When the process was performed in packed bed reactors operated in a vertical or inclined mode, solvent productivities approximating 6 kg/(m³h) were obtained. However, the systems suffered from blockage due to excess biomass production and gas hold-up. These problems were less apparent when a partially-packed bed reactor was operated in the horizontal mode. A fluidized bed reactor proved to be the most stable of the systems investigated, and a productivity of 4.8 kg/(m³h) was maintained over a period of 2000 h of operation. The results demonstrate that this type of reactor may have a useful future role in the ABE fermentation.     

Countercurrent multistage fluidized bed reactor for immobilized biocatalysts: II. Operation of a laboratory-scale reactor

In Part I of this series,(1) we derived a model and made simulations for a multistage fluidized bed reactor (MFBR). It was concluded that the MFBR can be an attractive alternative for a fixed bed reactor when operated with a deactivating biocatalyst. In Part II of this series, the design of a laboratory-scale MFBR and its evaluation to investigate the practical feasibility of this reactor type, will be described. Experiments with a duration as long as 10 days were carried out successfully using immobilized glucose isomerase as a model reaction system. The results predicted by the model are in good agreement with the measured glucose concentration and biocatalyst activity gradients, indicating perfect mixing of the particles in the reactor compartments.The diameters of the biocatalyst particles used in the experiments showed a large spread, with the largest being 1.7 times the smallest. Therefore, an additional check was carried out, to make sure that the particles were not segregating according to size. Particles withdrawn from the reactor compartments were investigated using an image analyzer. Histograms of particle size distribution do not indicate segregation and it is concluded that the particles used have been mixed completely within the compartments. As a result, transport of biocatalyst is nearly plug flow.