Characterisation of a novel support for biocatalysis in supercritical carbon dioxide

The work presents a characterisation study of Accurel EP100 (polypropylene based hydrophobic granules) as support material for lipase (Lypozyme 10,000 l, from native Rhizomucor miehei) operating as biocatalyst in supercritical CO₂ as solvent. The study involved assay of biocatalytic activity and operational stability as functions of system pressure and temperature. Furthermore, the presence of diffusion limitations was tested, by varying the bed diameter and support particle size. In addition, SEM and Gas Absorption were employed to test the mechanical stability. Results were compared with the commercially available biocatalyst Lipozyme™ IM60.

Pressure did not have a significant effect on the activity or the stability, while temperature had a positive effect on the activity and negative effect on the stability. As expected, an ‘optimum’ value of system water content gave maximum catalytic activity for each biocatalyst. External- and internal-diffusion limitations were both found negligible. The mechanical stability analysis demonstrated little (if any) effect of supercritical carbon dioxide (scCO₂) on the structural integrity of Accurel EP100, although subtle increases in pore volume and surface area were observed.     

Rigorous model for spherical cell-support aggregate

The activity of immobilized cell-support particle aggregates is influenced by physical and biochemical elements, mass transfer, and physiology. Accordingly, the mathematical model discussed in this study is capable of predicting the steady state and transient concentration profiles of the cell mass and substrate, plus the effects of the substrate and product inhibition in an immobilized cell-support aggregate. The overall mathematical model is comprised of material balance equations for the cell mass, major carbon source, dissolved oxygen, and non-biomass products in a bulk suspension along with a single particle model. A smaller bead size and higher substrate concentration at the surface of the particle, resulted in a higher supply of the substrate into the aggregate and consequently a higher biocatalyst activity.     

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.     

Mechanical stability of some immobilised preparations for glucose isomerisation in fixed and agitated bed columns

Immobilised preparations mechanical stability was studied by an analysis of particle disintegration in fixed and agitated beds of laboratory reactors. The analysis was carried out by comparing the particle size distributions obtained for three different states within the overall time-course of operation: The initial state, an intermediate state and the final one. It was found that mechanical stability by both fixed bed operation and paddle mixing was high. Agitation by flat discs was shown to cause intensive particle attrition. The relationships observed are discussed with regard to the flow pattern of the various types of reactors.     

Design of immobilised dextransucrase for fluidised bed application

Immobilisation of dextransucrase from Leuconostoc mesenteroides NRRL B-512F in alginate is optimised for applications in a fluidised bed reactor with high concentrated sugar solutions, in order to allow a continuous formation of defined oligosaccharides as prebiotic isomalto-oligosaccharides. Efficient design of fluidised bed immobilised biocatalyst in high density solutions requires particles with elevated density, high effectiveness and both thermal and mechanical stability. Inert silica flour/sand (Mikrosil 300) as supplement turned out to be best suited for increasing the density up to 1400 kg m(-3) of the alginate beads and generating a stable expanded bed without diffusional restrictions. Kinetic investigations demonstrate that low effectiveness of immobilised enzyme due to close association to dextranpolymers (dextran content of enzyme preparation >90%) is compensated by reducing the particle size and/or by decreasing the dextran content. A low dextran content (5%) is sufficient to immobilise and stabilise the enzyme, thus diffusional limitation is reduced essentially while operational stability is maintained. Fluidisation behaviour and bed expansion proved to be appropriate for the intended application. Both calculated and measured expansion coefficients showed good agreement for different conditions.     

Evaluation of the Kinetic Parameters of Trickle Bed Vapor Phase Bioreactors

The dependence of toluene elimination capacity on its load was determined in five small-scale reactors filled with glass beads carrying biocatalyst cells. With an increase in the operation time, the calculated maximum elimination capacity was shown to increase in parallel with the biomass density in the biocatalyst bed. A fivefold increase in the trickling rate did not affect the reactor performance. A simplified mathematical model for evaluating the minimal required biocatalyst bed volume at a certain loading was developed based on the experimental curve of elimination capacity versus loading.     

Countercurrent multistage fluidized bed reactor for immobilized biocatalysts: III. Hydrodynamic aspects

In Parts I and II of this series we described the modelling, design, and operation of a multistage fluidized bed reactor (MFBR) for immobilized biocatalysts. This article deals with those aspects of the MFBR which are different from single-stage fluidized beds which are operated in batch mode with respect to the solids. The semicontinuous transport of the particles requires perfect mixing of the particles in the reactor compartments, because particles are mainly transported from the bottom of these compartments. A large spread in the physical properties of the biocatalyst particles, especially of both size and density, may cause the particles to segregate into layers with different diameter and/or density. This affects the efficient use of the biocatalyst. The properties of the particles are dependent on the immobilization method. The suitability of different methods for possible future application in the MFBR is therefore compared. Because of segregation, successful use of a biofilm catalyst with a nonuniform thickness of the biofilm is doubtful. Experiments in a small scale reactor (+/- 0.1 m diameter) demonstrated that perfect particle mixing is possible using commercially available biocatalyst particles of uniform density. Co-immobilization of the biocatalyst with glass powder in a gel is a simple and effective method of increasing gel density. High density particles allow high liquid flow rates, and thus an improved external mass transfer can be achieved.The distributor plates, which separate the reactor compartments, must allow unhindered transport of particles. Therefore, the holes in these plates must have a diameter of at least 4.5 times that of the largest particles which are present in the particle mixture used. Furthermore, the plates must be designed such that, when scaling-up the reactor, a uniform liquid distribution over the cross-sectional area of the reactor occurs. Large-scale experiments were not carried out, but published correlations, indicate that particle mixing and a uniform liquid distribution can be accomplished in a large-scale reactor under similar flow conditions.     

Succinic acid fermentation in a stationary-basket bioreactor with a packed bed of immobilized Actinobacillus succinogenes: 1. Influence of internal diffusion on substrate mass transfer and consumption rate

This paper is dedicated to the study on external and internal mass transfers of glucose for succinic fermentation under substrate and product inhibitions using a bioreactor with a stationary basket bed of immobilized Actinobacillus succinogenes cells. By means of the substrate mass balance for a single particle of biocatalysts, considering the Jerusalimsky kinetic model including both inhibitory effects, specific mathematical expressions have been developed for describing the profiles of the substrate concentrations and mass flows in the outer and inner regions of biocatalyst particles, as well as for estimating the influence of internal diffusion on glucose consumption rate. The results indicated that very low values of internal mass flow could be reached in the particles center. The corresponding region was considered biologically inactive, with its extent varying from 0.24% to 44% from the overall volume of each biocatalyst. By immobilization of bacterial cells and use of a basket bed, the rate of glucose consumption is reduced up to 200 times compared with the succinic fermentation system containing free cells.     

Experimental measurement of particle size distribution and voidage in an expanded bed adsorption system

This paper presents an experimental analysis of matrix bead size distribution and voidage variations with axial height in an expanded bed adsorption system. Use of a specially constructed expanded bed with side ports has enabled sampling from within the expanded bed along the vertical axis. Particles removed from within the bed were measured for their size distributions. Residence time distribution studies were used to estimate bed voidage. Measurements of axial and radial particle size distributions and axial voidage distribution have been made at different flow rates. Particle size was found to be radially constant, indicating constant stratification in the column. The particle size was found to decrease with increasing axial height. Voidage increased with axial height from a settled bed value of 0.39 to approaching unity for high liquid velocities and increased at a constant axial position with increased flowrate. This information provides key insight into bed stability and data for the improved modeling of this important unit operation.     

Countercurrent multistage fluidized bed reactor for immobilized biocatalysts: I. Modeling and simulation

For the application of immobilized enzymes, fixed bed reactors are used almost exclusively. Fixed bed reactors have specific disadvantages, especially for processes with a deactivating catalyst. Therefore, we have studied a novel reactor type with continuous transport of the immobilized biocatalyst. Flow of biocatalyst is countercurrent to the substrate solution. Because of a stagewise reactor design, back-mixing of biocatalyst is very limited and transport is nearly plug flow. The reactor operates at a constant flow rate and conversion, due to constant holdup of catalytic activity. The reactor performance is compared with a configuration of fixed bed reactors. For reactions in the first-order regime, enzyme requirements in this new reactor are slightly less than for fixed bed processes. The multistage fluidized bed appears to be an attractive reactor design to use biocatalyst to a low residual activity. However, nonuniformity of the particles might affect plug flow transport of the biocatalyst. A laboratory scale reactor and experiments are described in Part II(1) of this series. Hydrodynamic design aspects of a multistage fluidized bed are discussed in more detail in Part III.(2).     

Analysis of kinetic parameters of gas phase bioreactors

The dependence of toluene elimination capacity on its load was obtained in five small-scale reactors filled with glass beads carrying biocatalyst cells. With increase in operation time the calculated maximal elimination capacity was shown to increase along with biomass density in the biocatalyst bed. Fivefold increase in trickling intensity did not affect the reactor performance. A simplified mathematical model for evaluation of minimal required biocatalyst bed volume at certain loading was developed based on experimental dependence of elimination capacity vs. loading.     

D-Glucose Isomerization using an Immobilized Glucose Isomerase preparation from Streptomyces Thermovulgaris Strain 127

The kinetics of D-glucose isomerization to D-fructose by an original whole-cell immobilized biocatalyst preparation based on Streptomyces thermovulgaris (strain 127) have been studied under various process conditions, substrate concentration, particle size. Two versions of different activity were applied. For the biocatalyst of moderate activity the kinetic constants in the MICHAELIS -MENTEN equation for reversible reaction were determined. Effectiveness factors for both preparations were calculated and compared with other reported data.     

Luffa cylindrica sponges as a thermally and chemically stable support for Aspergillus niger lipase

The use of biopolymer compounds as matrices for enzyme immobilization is currently a focus of increasing interest. In the present work we propose the use of Luffa cylindrica vegetable sponges as a support for the lipase extracted from Aspergillus niger. Effectiveness of immobilization was analyzed using Fourier transform infrared spectroscopy, elemental analysis and the Bradford method. An initial enzyme solution concentration of 1.0 mg/mL and an immobilization time of 12 h were selected as the parameters that produce a system retaining the highest hydrolytic activity (84% of free enzyme). The resulting biocatalyst system also exhibited high thermal and chemical stability, reusability and storage stability, which makes it a candidate for use in a wide range of applications. Kinetic parameters for the native and immobilized lipase were also calculated. The value of the Michaelis–Menten constant for the immobilized lipase (0.47 mM) is higher than for the free enzyme (0.21 mM), which indicates that the adsorbed enzyme exhibits a lower affinity to the substrate than native lipase. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:657–665, 2016     

Torrefaction of sawdust in a fluidized bed reactor

In the present work, stable fluidization of sawdust was achieved in a bench fluidized bed with an inclined orifice distributor without inert bed materials. A solids circulation pattern was established in the bed without the presence of slugging and channeling. The effects of treatment severity and weight loss on the solid product properties were identified. The decomposition of hemicelluloses was found to be responsible for the significant changes of chemical, physical and mechanical properties of the torrefied sawdust, including energy content, particle size distribution and moisture absorption capacity. The hydrophobicity of the torrefied sawdust was improved over the raw sawdust with a reduction of around 40 wt.% in saturated water uptake rate, and enhanced with increasing the treatment severity due to the decomposition of hemicelluloses which are rich in hydroxyl groups. The results in this study provided the basis for torrefaction in fluidized bed reactors.     

Theoretical investigation of axial and local particle size distribution on expanded bed adsorption process

The general rate model was developed and solved to describe protein adsorption in an expanded bed. The model takes into account axial variation of bed porosity, particle size distribution (PSD), external and intraparticle mass transfer, and dispersion in liquid and solid phase. The analysis of the influence of the model parameters on dynamic capacity (DC) was investigated. The simulation results showed that major impact on dynamic capacity is exerted by intraparticle mass transfer (particle diameter and pore diffusivity). The external mass transfer resistance and dispersion parameters have secondary effect on DC. The replacement of axial PSD by the mean particle diameter results in error in calculation of DC, which increases remarkably with the increase of mean particle diameter. The PSD can promote a very slow approaching of plateau concentration by breakthrough curves. It was shown also that axial bed porosity variation could be replaced by average porosity with negligible error for DC calculations.     

A New Rapid On-Line Imaging Method to Determine Particle Size Distribution of Granules

The purpose of this research was to study the feasibility of the new image analysis method in the particle size determination of the granules. The method is capable of forming a three-dimensional topographic image of a sample surface from a digital picture. In the method, a flat granule bed surface was illuminated from three different directions, using the three primary colors (red, green, and blue). One color picture was taken by a digital camera, after which a topographic image of the object surface was constructed. The particle size distribution was then calculated from the image data. The particle size analysis method was tested both off-line and on-line. Off-line particle size measurement results determined by the image analysis method corresponded quite well to those of sieve analysis in the size fraction range 250–1,000 μm. In on-line application, images were successfully retrieved and median granule size trend could be calculated and followed during fluid bed granulations.     

Determination of oxygen profiles in biocatalyst particles by means of a combined polarographic oxygen microsensor.

When studying the effect of immobilization of enzymes or whole cells on the conversion of substrate, more information is gained if measurements of substrate inside the biocatalyst particles are possible. With the methods used until now, only measurements outside the particle can be performed. In this article a method for measuring oxygen profiles in a biocatalyst particle under steady state conditions is described. The biocatalyst particle was made of agarose and contained the enzyme L-lactate 2-monooxygenase. This enzyme decarboxylates lactic acid to acetic acid in the presence of oxygen. The experiments were carried out in a flow chamber with the use of a micromanipulator and a stereomicroscope. The data were sampled by means of a computer. Four different profiles were measured using four different enzyme concentrations. The measured oxygen profiles were reproducible and the signal was very stable. It was also possible to measure the boundary layer around the particle. With the use of the oxygen microsensor, measurements in a biocatalyst particle could be performed accurately, giving way for model validation.     

Immobilization of yeast cells in PVA particles for beer fermentation

In this study, the potential of application of non-aggressive LentiKat^® technique for brewer's yeast immobilization on polyvinyl alcohol was assessed. High cell loads of about 10⁹ cells/ml were achieved by this procedure and immobilization procedure had no adverse effect on cell viability. The stability and activity of obtained immobilized biocatalyst was tested in the growth studies and fermentations. Immobilized cells exhibited high fermentation activity in both, laboratory and pilot-scale fermentations. In three successive gas-lift reactor fermentations the apparent attenuation of around 80% was reached after only 2 days, indicating good potential of immobilized cells for development of continuous primary beer fermentation. LentiKat^® particles showed high mechanical and fermentative stability, since they endured 30 days of operating time during 6-month period without significant change of cell activity, particle shape and particle size.     

Particle Size, Moisture, and Fluidization Variations Described by Indirect In-line Physical Measurements of Fluid Bed Granulation

The aim of this study was to evaluate an instrumentation system for a bench scale fluid bed granulator to determine the parameters expressing the changing conditions during the spraying phase of a fluid bed process. The study focused mainly on four in-line measurements (dependent variables): fluidization parameter (calculated by inlet air flow rate and rotor speed), pressure difference over the upper filters, pressure difference over the granules (lower filter), and temperature of the fluidizing mass. In-line particle size measured by the spatial filtering technique was an essential predictor variable. Other physical process measurements of the automated granulation system, 25 direct and 12 derived parameters, were also utilized for multivariate modeling. The correlation and partial least squares analyses revealed significant relationships between various process parameters highlighting the particle size, moisture, and fluidization effect. Fluidization parameter and pressure difference over upper filters were found to correlate with in-line particle size and therefore could be used as estimates of particle size during granulation. The pressure difference over the granules and the temperature of the fluidizing mass expressed the moisture conditions of wet granulation. The instrumentation system evaluated here is an invaluable aid to gaining more control for fluid bed processing to obtain repeatable granules for further processing.     

Continuous sucrose hydrolysis by an immobilized whole yeast cell biocatalyst

An immobilized biocatalyst with invertase activity prepared by immobilization of whole yeast cells without use of any insoluble carrier was tested in tubular fixed-bed reactors from the point of view of possible application for continuous full-scale sucrose hydrolysis. At inlet sucrose concentration above 60% (w/w) and reaction temperature 60–70°C, total sucrose hydrolysis was achieved at a flow rate of 0.6–1.5 bed volumes per hour. At a flow rate about 10 bed volumes per hour, the conversion was still 0.5. The specific productivity of the biocatalyst was 3–25 h⁻¹; the productivity of the reactor was 1–9 kg l⁻¹ h⁻¹. The half-life of the biocatalyst invertase activity was 815 h at 70°C. The specific pressure drop over the biocatalyst bed was less than 23 kPa m⁻¹. The biocatalyst was proved to be fully capable of continuous sucrose hydrolysis in fixed-bed reactors.