Continuous ethanol production by a flocculent strain of Zymomonas mobilis

Summary Cell retention and ethanol production using the flocculent bacterium Zymomonas mobilis NRRL B-12526 were studied in three bioreactor configurations. The flocculent growth characteristic of this strain and a special reactor design were combined to achieve relatively high cell concentrations in a continuous bioreactor for the conversion of glucose to ethanol.Research sponsored by the Office of Energy Research, U.S. Department of Energy, under contract W-7405-eng-26 with the Union Carbide Corporation.     

Thermal inducible expression of xylose isomerase and its performance in a hollow fiber bioreactor

Summary TheEscherichia coli xylose isomerase (EC 5.3.1.5) has been expressed under the control of a thermal inverting promotor system (att-nutL-p-att-N block) and its performance in a hollow fiber bioreactor measured. The conversion of xylose to xylulose was inversely proportional to the flow rate and the system operated up to 60°C. The maximum conversion efficiency observed was 19.05% at 55°C.     

High solids fermentation of hydrolysates of wheat starch B in a continuous dynamic immobilized biocatalyst bioreactor

Summary A simple and efficient method of conversion of wheat starch B to ethanol was investigated. Employing a two-stage enzymatic saccharification process, 95% of the wheat starch was converted to fermentable sugars in 40 h. From 140 g/l total sugars in the feed solution, 63.6 g/l ethanol was produced continuously with a residence time of 3.3 h in a continuous dynamic immobilized biocatalyst bioreactor by immobilized cells ofSaccharomyces cerevisiae. The advantages and the application of this bioreactor to continuous alcoholic fermentation of industrial substrates are presented.     

Construction of a non-support bioreactor: optical resolution of 2-(4-chlorophenoxy)propanoic acid in an organic solvent system

Summary A non-support bioreactor, a novel column reactor packed with a free non-supported enzyme was constructed by applying the insolubility of the enzyme in organic solvents. Stereoselective esterification of 2-(4-chlorophenoxy)propanoic acid by lipase OF 360 from Candida cylindracea with n-tetradecanol was selected as a model reaction. Non-supported lipase revealed threefold higher activity than Celite-adsorbed lipase by maintaining high stereoselectivity in a batch reaction. In continuous operation, a non-support bioreactor produced the ester with fourfold higher productivity to that of a column reactor packed with Celite-adsorbed lipase (an adsorbed bioreactor). However, the optical purity of the remaining (S)-acid was low even when the conversion ration was kept at approximately 50%. Lipase recovered from the non-support bioreactor after continuous operation retained the original stereoselectivity in a batch reaction. Therefore, semi-continuous operation was conducted by recycling the substrate solution at a high flow rate. The non-support reactor showed high stereoselectivity and ten times the productivity compared with the adsorbed bioreactor. The reason for this high performance is discussed. Offprint requests to: A. Tanaka     

Ethanol production by immobilized whole cells ofZymomonas mobilis in a continuous flow expanded bed bioreactor and a continuous flow stirred tank bioreactor

Continuous ethanol fermentation by immobilized whole cells ofZymomonas mobilis was investigated in an expanded bed bioreactor and in a continuous stirred tank reactor at glucose concentrations of 100, 150 and 200 g L^–1. The effect of different dilution rates on ethanol production by immobilized whole cells ofZymomonas mobilis was studied in both reactors. The maximum ethanol productivity attained was 21 g L^–1 h^–1 at a dilution rate of 0.36 h^–1 with 150 g glucose L^–1 in the continuous expanded bed bioreactor. The conversion of glucose to ethanol was independent of the glucose concentration in both reactors.     

Preparation of lipophilic alkyl (hydroxy)benzoates by solvent-free lipase-catalyzed esterification and transesterification

Agal-fermentation-based microbio-diesel production was realized through high-cell-density fermentation of Chlorella protothecoides and efficient transesterification process. Cell density achieved was 16.8 g l⁻¹ in 184 h and 51.2 g l⁻¹ in 167 h in a 5-l bioreactor by performing preliminary and improved fed-batch culture strategy, respectively. The lipid content was 57.8, 55.2, and 50.3% of cell dry weight from batch, primary, and improved fed-batch culture in 5-l bioreactor. Transesterification was catalyzed by immobilized lipase, and the conversion rate reached up to 98%. The properties of biodiesel from Chlorella were comparable to conventional diesel fuel and comply with US standard for Biodiesel. In a word, the approach including high-density fermentation of Chlorella and enzymatic transesterification process were set up and proved to be a promising alternative for biodiesel production.     

Development of a simultaneous bioreactor system for characterization of gas production kinetics of methanogenic archaea at high pressure

Cultivation of methanogens under high pressure offers a great opportunity in biotechnological processes, one of which is the improvement of the gas‐liquid transfer of substrate gases into the medium broth. This article describes a newly developed simultaneous bioreactor system consisting of four identical cultivation vessels suitable for investigation of microbial activity at pressures up to 50 bar and temperatures up to 145°C. Initial pressure studies at 10 and 50 bar of the autotrophic and hydrogenotrophic methanogens Methanothermobacter marburgensis, Methanobacterium palustre, and Methanobacterium thermaggregans were performed to evaluate the reproducibility of the system as well as to test the productivity of these strains. The strains were compared with respect to gas conversion (%), methane evolution rate (MER) (mmol L^‐1 h^?1), turnover rate (h^?1), and maximum conversion rate (k_min) (bar h^?1). A pressure drop that can be explained by the reaction stoichiometry showed that all tested strains were active under pressurized conditions. Our study sheds light on the production kinetics of methanogenic strains under high‐pressure conditions. In addition, the simultaneous bioreactor system is a suitable first step screening system for analyzing the substrate uptake and/or production kinetics of gas conversion and/or gas production processes for barophilic or barotolerant microbes.     

l-Xylose and l-lyxose production from xylitol using Alcaligenes 701B strain and immobilized l-rhamnose isomerase enzyme

Xylitol was used as a raw material for production of l-xylose and l-lyxose using Alcaligenes 701B strain and immobilized l-rhamnose isomerase enzyme. Alcaligenes 701B converted xylitol to l-xylulose with a yield of 34% in the bioreactor. l-Xylulose was converted to l-xylose and l-lyxose using immobilized l-rhamnose isomerase enzyme. The final equilibrium between l-xylulose, l-xylose and l-lyxose was 53:26:21. The enzyme assays indicated that Alcaligenes 701B strain has an NAD-dependent xylitol dehydrogenase enzyme responsible for l-xylulose production. Furthermore, NAD(P)H-dependent l-xylulose reductase enzyme was active during conversion of xylitol to l-xylulose. The highest l-xylulose production rate corresponded with the highest growth rate. The Alcaligenes 701B strain used d-xylose for biomass growth, but xylitol was used only for l-xylulose production during conversion phase.     

Lignocellulose solubilization and conversion by extremely thermophilic Caldicellulosiruptor bescii improves by maintaining metabolic activity

The extreme thermophile Caldicellulosiruptor bescii solubilizes and metabolizes the carbohydrate content of lignocellulose, a process that ultimately ceases because of biomass recalcitrance, accumulation of fermentation products, inhibition by lignin moieties, and reduction of metabolic activity. Deconstruction of low loadings of lignocellulose (5 g/L), either natural or transgenic, whether unpretreated or subjected to hydrothermal processing, by C. bescii typically results in less than 40% carbohydrate solubilization. Mild alkali pretreatment (up to 0.09 g NaOH/g biomass) improved switchgrass carbohydrate solubilization by C. bescii to over 70% compared to less than 30% for no pretreatment, with two-thirds of the carbohydrate content in the treated switchgrass converted to acetate and lactate. C. bescii grown on high loadings of unpretreated switchgrass (50 g/L) retained in a pH-controlled bioreactor slowly purged (τ = 80 hr) with growth media without a carbon source improved carbohydrate solubilization to over 40% compared to batch culture at 29%. But more significant was the doubling of solubilized carbohydrate conversion to fermentation products, which increased from 40% in batch to over 80% in the purged system, an improvement attributed to maintaining the bioreactor culture in a metabolically active state. This strategy should be considered for optimizing solubilization and conversion of lignocellulose by C. bescii and other lignocellulolytic microorganisms.     

The morphological variability within a population of coffee somatic embryos produced in a bioreactor affects the regeneration and the development of plants in the nursery

A 1-liter bioreactor was used to obtain approximatively 800 Coffea arabica somatic embryos, 86% of which reached the `germinated' stage but with morphological heterogeneity. The population was sub-divided into three categories according to cotyledon area: 'small', 'medium' and 'large', that amounted to 32%, 36% and 4.5%, respectively. The effect of embryo morphology on plantlet conversion after direct sowing in soil and on plant development in the nursery was investigated. Somatic embryos with large cotyledons had only a 25% plantlet conversion rate, whereas somatic embryos with small to medium-sized cotyledons had conversion rates of 47% and 63%, respectively. The vigour of the aerial and root systems of regenerated plantlets at the end of the plant conversion stage was also affected as the embryos with small, medium and large cotyledon mostly regenerated small plantlets (0.5–1.5 cm), medium plantlets (1.5–2.5 cm) and large plantlets (2.5–5 cm), respectively. When transplanted in plastic bags, these 3 populations of plantlets exhibited distinct development rates. They had an initial slow growth phase, which was much longer for the small plantlets, followed by a rapid growth phase. After 40 weeks in the nursery, an analysis of the growth parameters of aerial and radical systems showed that the vigour of the plants was strongly related to the vigour of the plantlets transplanted. The heterogeneity of somatic embryos in the bioreactor affected both the plant conversion efficiency in soil and the plant growth in nursery, where it mainly resulted in retarded growth, primarily in plantlets derived from the somatic embryos with small cotyledons.     

Fermentative bioconversion in a horizontal rotating tubular bioreactor

The performance of a horizontal rotating tubular bioreactor (HRTB) was investigated with a biological system under non-sterile conditions. A spontaneously developed microbial culture was cultivated in a simple glucose/yeast extract medium. A fermentative bioconversion was examined by different combinations of process parameters (bioreactor rotation speed 5–30 min⁻¹ and medium inflow rate 1–10 l h⁻¹). Bioconversion dynamics in HRTB was monitored by withdrawing the samples from five positions along the bioreactor. Investigation in HRTB showed a rapid and an efficient glucose conversion into different products of metabolism. Glucose consumption rate along the HRTB depended on medium inflow rate, while bioreactor rotation speed did not have a significant influence. Complete glucose conversion in HRTB was observed at inflow rates of up to 6.5 l h⁻¹. The pH gradient along the HRTB was detected at higher medium inflow rates (6.5 and 10 l h⁻¹), but did not significantly influence substrate conversion efficiency. A discussion of its potential use and a comparison of HRTB with other bioreactors are also presented.     

大肠杆菌高密度发酵表达4-羟基苯乙酸酯3-羟化酶及咖啡酸的高效生物合成

来源于大肠杆菌的4-羟基苯乙酸酯3-羟化酶(4-hydroxyphenylacetate 3-hydroxylase,4HPA3H)可以催化对香豆酸生物合成咖啡酸。为了实现4HPA3H的扩大生产和咖啡酸的高效生物合成,首先构建过表达4HPA3H的大肠杆菌工程菌,其次使用5 L发酵罐进行高密度发酵生产4HPA3H,再而优化采用工程菌株进行全细胞催化产咖啡酸的条件。最终实现了在5 L发酵罐中发酵,工程菌株生物量达到干重34.80 g/L。通过使用5 L发酵罐作为生物反应器进行全细胞催化,经过6 h的催化可产生18.74 g/L (0.85 g/(L·OD₆₀₀))咖啡酸,摩尔转化率为78.81%,是目前文献报道4HPA3H以对香豆酸为底物合成咖啡酸的最高水平。初步实现了高密度培养大肠杆菌表达4HPA3H并高效生物合成咖啡酸,为工业化生产奠定了基础。     

High ethanol productivities using small Ca-alginate beads of immobilized cells of Zymomonas mobilis

Summary Zymomonas mobilis cells were immobilized into small 1 mm diameter beads of Ca-alginate in order to minimize mass transfer limitations and maximize immobilized cell activity. A combination of small bead size with a high cell concentration of 58 g dry wt. cell per lit. bead volume resulted in high ethanol productivities using a newly designed packed bed bioreactor system. Steady-state dilution rates ranging from 0.4 h^-1 to 3.9 h^-1 were run resulting in a maximum productivity of 102 g ethanol/l/h for an inlet substrate concentration of 100 g glu/l and 87% conversion. The bioreactor was run continuously at a fixed dilution rate for 384 h and short intermittent treatment of the beads with CaCl₂ temporarily increased ethanol productivity to a maximum of 116 g ethanol/l/h.     

Cycle characteristics in a temporary immersion bioreactor affect regeneration,morphology, water and mineral status of coffee (<Emphasis Type="Italic">Coffea arabica</Emphasis>) somatic embryos

Mass regeneration of Coffea arabica L. somatic embryos using a temporary immersion bioreactor was improved by optimizing the immersion cycles, i.e. both the duration and the frequency of immersions. It was demonstrated that increasing the frequency of short immersions (1 min immersions every 24, 12 and 4 h) stimulated embryo production (480, 2,094 and 3,081 embryos/1-l bioreactor, respectively) and improved quality (60, 79 and 85 of torpedo shaped embryos, respectively). On the other hand, an increase in the immersion duration (1, 5 and 15 min) inhibited embryo regeneration (from 2,094 to 428 embryos per 1-l bioreactor) and negatively affected their morphological quality (from 79 to 49 torpedo-shaped embryos) and the conversion of embryos into plants (from 70 to 33). A 15 min immersion duration applied every 4 h produced hyperhydric symptoms in 90 of the embryos. Hyperhydric embryos were characterized by higher fresh weight and water content, more negative values for water potential and higher K⁺ content when compared to normal torpedo-shaped embryos. Micrographs showed structural problems in the globular stage, such as the existence of an irregular epidermis and an absence of reserves. Whatever the immersion cycle used, the somatic embryos exhibited water and mineral characteristics very different from those of their zygotic counterparts. The use of 1 min immersions every 4 h led to the production of the largest quantities of torpedo-shaped embryos without hyperhydricity that succeeded in regenerating plants (75 conversion).     

Heterogeneous biofilm activity in a segregated anaerobic fluidized bed bioreactor

Bed segregation in a fluidized bed bioreactor profoundly influenced biofilm thickness and microbial activities of the biofilm along the bed height. Bioparticles coated with a thin biofilm, observed at the bottom of the reactor, had a higher specific activity in propylene glycol and n-propanol degradation than in thick biofilms developed at the top of the reactor. Although no significant difference was observed in specific activity for propionate and acetate along the reactor flow axis, more total propionate and acetate conversion occurred in regions of thicker biofilm accumulation.     

Mass multiplication of protocorm-like bodies using bioreactor system and subsequent plant regeneration in Phalaenopsis

Protocorm-like bodies (PLBs) formed on leaf segmentsin vitro were used as explants for bioreactor cultures. Continuous immersion cultures (air lift column and air lift-balloon bioreactor), and temporary immersion cultures (with or without charcoal filter attached) were used for the culture of PLB sections. A temporary immersion culture with charcoal filter attached was most suitable for PLB culture. About 18,000 PLBs were harvested from 20 g of inoculum (∼1000 PLB sections) in 2 l Hyponex medium after 8 weeks of incubation. Aeration in a bioreactor at 0.5 or 2.0 volume of air per volume of medium min⁻¹ (vvm) yielded similar levels of biomass production. PLBs grown in bioreactors were cultured on solid Murashige and Skoog, Vacin and Went, Knudson C, Lindemann and Hyponex media. Hyponex medium was found to be suitable for conversion of PLBs into plantlets and 83% of PLBs transformed into plantlets on this medium. The feasibility of using PLBs for large-scale micropropagation was evaluated for scaled-up liquid cultures in bioreactors, rate of proliferation, and regeneration. This revised version was published online in June 2006 with corrections to the Cover Date.     

Continuous malolactic fermentation by Oenococcus Oeni entrapped in LentiKats

A continuous process to deacidify apple juices and cider was developed by entrapping Oenococcus oeni in LentiKats, a new polyvinyl alcohol hydrogel. For a residence time of 0.55 h, malic acid was completely converted into lactic acid when the LentiKats bioreactor was fed with apple juice at pH 4.46 and 3.95 and thirty three percent of initial malic acid (6.7 g l^–1) was converted when the initial apple juice pH was 2.30. The optimal malolactic activity of this bioreactor was obtained at 30°C and a 50% reduction in malic acid conversion was measured between 15°C and 20°C, at a residence time of 0.3 h. The LentiKats bioreactor gave better performance than continuous reactor with Oenococcus oeni immobilised in alginate beads (specific malic acid consumption increased by a factor of 4.6) due to the increase of the ratio external surface to volume, allowing better mass transfer.     

Large-scale plantlets conversion from cotyledonary somatic embryos of Kalopanax septemlobus tree using bioreactor cultures

A suitable bioreactor system for large scale embryo-to-plantlets conversion of Kalopanax septemlobus was established. In temporary immersion with net (TIN) bioreactor, 85% of embryos successfully produced plantlets whereas in continuous immersion with net (CIN) bioreactor, only conversion rate of 29.3% was obtained. Embryos cultured in TIN bioreactor produced more vigorous plantlets in terms of fresh weight, height, root length, roots and leaves quantity. In CIN bioreactor, Kalopanax plantlets showed high malondialdehyde (MDA) content and increased activities of reactive oxygen species (ROS)-processing enzymes, such as ascorbate peroxidase (APX) and glutathione reductase (GR) indicating the occurrence of oxidative stress. However, superoxide dismutase (SOD) and catalase (CAT) showed similar activities in plantlets grown in different bioreactors. Kalopanax plantlets grown in both TIN and CIN bioreactors were harvested and transferred to greenhouse for their acclimatization. Plantlets grown in CIN bioreactor exhibited low survival rate (75.8%) compared to those grown in TIN bioreactor (100%). MDA content decreased with progression of acclimatization indicating a decrease in oxidative stress. However, MDA level in CIN derived plantlets was higher than TIN derived plantlets. In TIN derived plantlets, an increase in SOD and GR activities were observed after 1 week and thereafter decreased. CAT activity decreased while APX activity started to increase after 1 week of acclimatization. The results indicated that Kalopanax plantlets were able to overcome oxidative stress mainly through SOD activity. However, levels of antioxidant enzyme activities were higher in CIN derived plantlets than TIN derived plantlets. Kalopanax plantlets obtained from TIN bioreactor performed better during the acclimatization phase and showed higher survival rate than material obtained on CIN bioreactor or conventional culture systems.     

Bioreactor for solid-state cultivation of <Emphasis Type="Italic">Phlebiopsis gigantea</Emphasis>

Phlebiopsis gigantea fungus used in biological control of root rot is currently cultivated commercially in disposable, sterilizable plastic bags. A novel packed bed bioreactor was designed for cultivating P. gigantea and compared to the plastic bag method and to a tray bioreactor. The spore viability of 5.4 × 10⁶ c.f.u./g obtained with the packed bed bioreactor was of the same order of magnitude as the viabilities obtained with the other cultivation methods. Furthermore, the packed bed bioreactor was less time and space consuming and easier to operate than the tray bioreactor.     

“Organized stress” for robust scale-up of intensified production process with fed-batch seed bioreactor

Process intensification has been widely used for many years in the mammalian biomanufacturing industry to increase productivity, agility and flexibility while reducing production costs. The most commonly used intensified processes are operated using a perfusion or fed-batch seed bioreactor enabling a higher than usual seeding density in the fed-batch production bioreactor. Hence, as part of the growth phase is shifted to the seed bioreactor, there is a lower split ratio, which increases the criticality of the seed bioreactor and could impact production performance. Therefore, such intensified processes should be designed and characterized for robust process scale-up. This research work is focused on intensified processes with high seeding density inoculated from seed bioreactor in fed-batch mode. The impact of the feeding strategy and specific power input (P/V) in the seed bioreactor and on the production step with two different cell lines (CL1 and CL2) producing two different monoclonal antibodies was investigated. Cell culture performance in the production bioreactor has been improved due to more stressful conditions for the cells in the seed bioreactor and the impact of the production bioreactor P/V on the production performance was limited. This is the first reported study highlighting a positive impact of cellular stress in seed bioreactors on intensified production bioreactor with the introduction of the “organized stress” concept.