On-line rheological measurements and control in fungal fermentations

A system for on-line rheological measurements and control in filamentous fermentations is presented. The output signals from the control unit can be used in terms of process control. Diluting the broth in a growth controlled feed pattern was found to influence the viscosity of the broth and lead to process improvements. Just diluting the fermentation broth to keep the viscosity below a preset value was seen to give only temporary process improvements. The higher the viscosity, the less effective the viscosity controlled dilutions. The failure to get full control over the viscosity by the dilution techniques used is caused by the large number of factors influencing the rheological properties of an Aspergillus niger culture. The factors shown in this work to influence the rheological properties of the fermentation broth were the biomass concentration, the specific growth rate, mixing qualities (impeller speed and working volume), and the dissolved oxygen concentration. (c) 1992 John Wiley & Sons, Inc.     

Effect of biomass concentration and mycelial morphology on fermentation broth rheology

The effect of biomass concentration and mycelial morphology on fungal fermentation broth rheological properties has been investigated. In previous work it had been shown that commonly used rheological parameters, such as the power law consistency and flow behavior indices, could be correlated successfully with the broth biomass concentration and clump morphological parameters of roughness and compactness. More recent work on a broader range of data showed a correlation between roughness and compactness; consequently, it was not correct to use both of these morphological variables simultaneously in rheological parameter correlations. Furthermore, earlier correlations were only made using clump morphological parameters, as clumps were found to be around 90% of the biomass in batch fermentations. In the present work it was found that the percentage of clumps fell to around 30% to 40% of a sample during the later stages of fed-batch fermentations. No clear relationship between the flow behavior index and biomass concentration was found, at least for those phases of the fermentation in which the viscosities were high enough for the rheology to be characterized by a disk turbine rheometer. The mean value of the flow behavior index was found to be 0.35 +/- 0.1 (standard deviation) throughout both batch and fed-batch fermentations, although some significant deviations from this value were observed early and very late in the fermentations. Correlations for the consistency index, measured using a disk turbine rheometer, were based on the biomass concentration and the mycelial size (represented by the mean projected area or the mean maximum dimension of all the mycelia). These correlations were reasonably successful for both fed-batch and batch fermentations. The correlation using the mean maximum dimension was preferred to that using the mean projected area, as the former is independent of magnification. The proposed correlation is: where K is the consistency index (Pa. s(n>)), C(m) is the biomass concentration as dry cell weight (g L(-1)), and D is the mean maximum dimension (microm). It should be noted that small changes in the exponent on the biomass concentration (alpha) may dramatically affect any predictions. Consequently, caution in the use of this correlation (and that based on mean projected area) is advocated, although its accuracy may be suitable for operational or design purposes.     

Rheological characterization of a fungal fermentation for the production of pneumocandins

The filamentous fungus Glarea lozoyensis produces a novel, pharmaceutically important pneumocandin (B₀) that is used to synthesize a polypeptide, which demonstrates fungicidal activity against clinically relevant pathogens. The scale-up of the pneumocandin fermentation requires an understanding of the rheological properties of the broth and the factors that influence flow behavior. A systematic approach for characterizing the rheological properties using a standard methodology is presented here. An appropriate rheometer was chosen and the effects of shear rate ramping, broth handling, creep and yield testing were examined. The fed-batch fermentation used a soluble production medium that allowed the relationship between biomass and rheological properties to be studied up to the 19-m³ scale. The morphologically heterogeneous broth demonstrated time-dependent shear thinning behavior with thixotropy and a yield stress. The flow curves were described by the power law model, with flow behavior of 0.35-0.4 and consistency index up to 10 Pa.sⁿ. The use of a cup and bob rheometer was preferable to alternative techniques, including turbine and spindle systems defined by Mitschka's technique. The consistency index and flow behavior were shown to have a non-linear relationship with biomass concentrations up to 140 g/L. The consistency index continually increased with biomass during the fermentation, while the flow behavior initially decreased rapidly and then remained at low values for the remainder of the batch cultivation. The consistency index and yield stress were influenced by temperature, osmotic pressure, and pH, while the flow behavior remained independent of these factors.     

Rheological characteristic of a batch cultivation ofAgrobacterium radiobacter

During a batch cultivation on D-glucoseAgrobacterium radiobacter produces an extracellular polysaccharide agrobacteran. The rheological character of the culture broth is non-Newtonian and can be described by a power-law model or by the Hershel-Bulkley equation. Correlations were obtained between the parameters of these equations and the concentration of agrobacteran in the medium. For the given mixing system the rheological properties of the medium can be used to approximately estimate the qualitative changes in the intensity of mixing and to employ these data for regulating mixing during cultivation.     

促溶剂对雷斯青霉发酵液流变特性的影响

目的:促溶剂通常用于甾体生物催化过程以提高底物溶解度,但在发酵液中添加促溶剂对菌体形态及发酵液特性的影响还少有报道。方法:利用旋转流变仪和顺磁分析仪分别对发酵液的流变特性及体积氧传递系数KLa进行监测。结果:无论是否添加促溶剂,发酵液都表现出非牛顿流体力学特性,但添加3%1,2丙二醇后同一时期发酵液稠度系数减小大约17%,而流动指数平均增加8%。结论:添加促溶剂使得发酵液表观黏度减小,体积氧传递系数增大,从而有利于甾体化合物的生物转化。     

Rheological,Mass Transfer,and Mixing Characterization of Cellulase-Producing Trichoderma reesei Suspensions

Steady and dynamic shear measurements are utilized to characterize the rheological behavior of Trichoderma reesei RUT-C30 fungal suspensions during batch growth on xylose (soluble substrate) or cellulose (particulate solid substrate) at three different fermentor impeller speeds (250, 400, and 550 rpm). Biomass concentrations versus time were unimodal on xylose and bimodal on cellulose. This behavior is consistent with relatively rapid, early growth on easily metabolized growth medium components (yeast extract), followed by a second, slower growth phase due to hydrolysis of recalcitrant cellulose by increasing cellulase concentrations. Critical dissolved oxygen (DO) concentration for T. reesei growth on cellulose was found to be 0.073 mmol/L. The DO was kept above this level by supplementing the air feed with pure oxygen, implying that mass transfer limitations were not the cause of bimodal cell growth. Steady shear rheological data showed shear thinning behavior and a yield stress for all broth samples regardless of substrate. Casson and Herschel−Bulkley constitutive equations fit steady shear data well. Dynamic shear measurements on broth suspensions indicated “gel-like” behavior at low strains, with microstructural breakdown at larger displacements. Time variations of the Casson model parameters (yield stress and Casson viscosity) and dynamic moduli (elastic and viscous modulus) followed both cell mass and morphology: a single maximum in all rheological variables resulted when cells were grown on xylose or on cellulose at impeller speeds of 400 or 550 rpm, and dual maxima were observed for cellulose-grown cells at 250 rpm.     

On-line measurement of the substrate concentrations in <Emphasis Type="Italic">Pichia pastoris</Emphasis> fermentations using FT-IR/ATR

The glycerol and methanol concentrations in Pichia pastoris fermentations were measured on-line using Fourier transform infrared spectroscopy and an attenuated total reflection probe. Partial least squares regression was used to obtain calibration models. The models were regressed on synthetic multi-component spectra and semi-synthetic fermentation broth spectra. These were obtained by spectral addition. The accuracy for the on-line measurement of glycerol, given as standard error of prediction (SEP), was determined to 0.68 g/l, and the SEP of methanol was 0.13 g/l. We show how reliable calibration models are obtained relatively effortlessly by replacing extensive sampling from the reactor with simple mathematical manipulations of the model regression spectra.     

Influence of magnetostimulation therapy on rheological properties of blood in neurological patients

ABSTRACT

The aim of the study is to test the influence of in vivo magnetostimulation on the rheological properties of blood in neurological patients. Blood circulation in the body depends both on the mechanical properties of the circulatory system and on the physical and physicochemical properties of blood. The main factors influencing the rheological properties of blood are as follows: hematocrit, plasma viscosity, whole-blood viscosity, red cells aggregability, deformability, and the ability of red cells to orient in the flow. The blood samples were collected from neurological patients with pain. Blood samples were collected twice from each patient, that is, before the magnetostimulation and immediately after the therapy. For each blood sample, the hematocrit value was measured using the standard method. Plasma viscosity and whole-blood viscosity were measured by means of a rotary-oscillating rheometer Contraves LS40. Magnetic field was generated by the instrument Viofor JPS® and the magnetostimulation treatments were performed using M1P2 and M1P3 programs. The analysis of the results included estimation of the hematocrit value (Hct), plasma viscosity (η_p), whole-blood viscosity and rheological parameters of Quemada’s model: k₀, k_∞, γ′_c. Plasma viscosity values were obtained from the shear rate dependence of shear stress using the linear regression method. The results obtained in the study suggest that the blood rheological properties change in accord with applied magnetostimulation program.     

Construction and application a vane system in a rotational rheometer for determination of the rheological properties of <Emphasis Type="Italic">Monascus ruber</Emphasis> CCT 3802

The objectives of this work were the construction and adaptation of a vane system in a rotational rheometer; calibration of vane system using a mineral oil, and determination of rheological properties of the broth fermentation of Monascus ruber CCT 3802 at high cell density. Batch fermentation was carried out with glucose as the sole carbon source in a Bioflo III bioreactor. The consistency index (K) and flow behavior index (n) of the broth fermentation of M. ruber were characterized at different biomass concentrations and were adequately described by a power law model. The K and n values were significantly affected by biomass concentrations. K values ranged from 0.375 to 11.002 Pa s ⁿ when evaluated at biomass concentrations from 25.67 to 63.20 g L⁻¹. The pseudoplastic behavior was confirmed by values of n that ranged between 0.157 and 0.254. Simple empirical correlations have been proposed to quantify the dependence of the power law terms on fungal biomass concentration.     

Gas chromatography and gateway sensors for on-line state estimation of complex fermentations (butanol-acetone fermentation)

A fermentation system has been designed to demonstrate the use of gas chromatography (GC) for on-line monitoring of the butanol-acetone and other complex saccharolytic fermentations. Tangential flow ultrafiltration was used to sterilely and continuously obtain a cell-free filtrate from the fermentation broth for on-line GC analysis of butanol, butyrate, acetate, acetone, ethanol, and acetoin. The liquid injection system consists of a phosphoric acid contactor, a slider-type injection valve, and a heater to address the difficulties (ghosting) encountered in the analysis of carboxylic acids. The fermentation headspace gas was also analyzed by on-line GC for nitrogen and carbon dioxide, while hydrogen was measured by difference. Raw chromatographic data were analyzed by a chromatography data system. Both raw and processed data were transmitted to a VAX 11/750 computer for further processing (using the fermentation equation) and archiving. The fermentation equation, which has recently been derived and tested on completed fermentation data, was also found to be valid during transient fermentations and thus useful as a gateway sensor for calculating various fermentation parameters on-line. Such parameters include glucose concentration and gas composition, as well as a number of unobservable parameters (such as Y(ATP), excess ATP, and NAD reduced by FdH(2)), which characterize the state of the fermentation.     

Estimation of the rheology of glucoamylase fermentation broth from the biomass concentration and shear conditions

Fermentation broths from nine Aspergillus awamori cultivations, carried out under different agitation and aeration conditions and distinct initial substrate concentrations, were characterized using a continuous on-line rheometer. A single correlation between the consistency index (K) and the biomass concentration (X), including the agitation (N) and aeration (Q) conditions fitted the experimental data reasonably well, showing that the shear conditions imposed on the broth influence in a significant way the mycelial morphology and, therefore, the broth rheology.     

Rheology and Hydrodynamic Properties of Tolypocladium inflatum Fermentation Broth and Its Simulation

A physico-chemical, two phase simulated pseudoplastic fermentation (SPF) broth was investigated in which Solka Floc cellulose fibre was used to simulate the filamentous biomass, and a mixture of 0.1% (w/v) carboxymethyl cellulose (CMC) and 0.15 M aqueous sodium chloride was used to simulate the liquid fraction of the fermentation broth. An investigation of the rheological behaviour and hydrodynamic properties of the SPF broth was carried out, and compared to both a fungal Tolypocladium inflatum fermentation broth and a CMC solution in a 50 L stirred tank bioreactor equipped with conventional Rushton turbines. The experimental data confirmed the ability of the two phase SPF broth to mimic both the T. inflatum broth bulk rheology as well as the mixing and mass transfer behaviour. In contrast, using a homogeneous CMC solution with a similar bulk rheology to simulate the fermentation resulted in a significant underestimation of the mass transfer and mixing times. The presence of the solid phase and its microstructure in the SPF broth appear to play a significant role in gas holdup and bubble size, thus leading to the different behaviours. The SPF broth seems to be a more accurate simulation fluid that can be used to predict the bioreactor mixing and mass transfer performance in filamentous fermentations, in comparison with CMC solutions used in some previous studies.     

Rheological characterization of culture broth containing the exopolysaccharide PS-EDIV from Sphingomonas pituitosa

Sphingomonas pituitosa excretes the capsular exopolysaccharide PS-EDIV into the culture broth augmenting considerably its fluid viscosity. Since this change particularly affects key processes like mixing and transport during the microbial production, this work was aimed at the rheological characterization of the polymer-containing culture broth of S. pituitosa. The study included investigations on basic properties of the culture broth, but also on the dependence of the biomass–polymer-solution properties on different physicochemical post-cultivation treatment steps like variations of temperature, pH-value or concentration of salts. The essential result is the characterization of the viscoelastic behavior of the culture broth, which was more gel-like than sol-like and exhibited slight elastic properties. This rheological behavior showed that the PS-EDIV culture broth formed non-Newtonian fluids, indicating that it is a pseudoplastic biopolymer, with yield stress appearance and exhibits thixotropic properties. Rheograms were fitted to the Herschel–Bulkley model. The amplitude sweep revealed a deformation of 21% as the limiting value of the linear viscoelastic interval. Furthermore, the PS-EDIV culture broth showed a high viscosity which was strongly influenced by salt type and concentration but weakly influenced by temperature and pH-value within the investigated experimental boundaries.     

Rheological study of genipin cross-linked chitosan hydrogels

This paper reports the rheological behavior of chitosan solutions that have been cross-linked with different amounts of genipin, at body temperature and physiological pH. The effect of the cross-linker loading on the rheological properties of hydrogels has been evaluated. The oscillatory time sweep method was used to monitor the dynamic viscoelastic parameters during in situ (i.e., in the rheometer) gelation experiments, enabling the determination of the gelation time. The stress and frequency sweeps were employed to measure G' of the cured hydrogels. It was found that the solutions of chitosan cross-linked with genipin, under physiological conditions, could form relatively strong elastic gels when compared to those of pure chitosan. Moreover, the gelation time obtained from the crossover of G' and G' was in excellent agreement with the value obtained from the Winter-Chambon criterion. A significant reduction on this parameter was achieved even at low genipin concentrations. This behavior suggests that these formulations are able to be produced in situ and thus constitute promising matrices for cells and bioactive molecule encapsulations.     

Physicochemical and Rheological Characterization of Gum Tragacanth Exudates from Six Species of Iranian <Emphasis Type="Italic">Astragalus</Emphasis>

The flow behavior of six species of Iranian gum tragacanth dispersions was investigated at different temperatures and ionic strengths, within a concentration range (0.05–1.5% w/w) using a controlled shear rate rheometer. The steady shear measurements showed that all of the gum dispersions had shear-thinning natures. The power law model was used to describe the rheological properties of dispersions and Arrhenius model was used to evaluate the temperature effect. Composition analysis, surface tension measurement, particle size analysis, and color measurement of all the species were also carried out. The results indicated that the six species of gum tragacanth being studied in this paper exhibited significantly different physicochemical properties. Therefore, various species of gum tragacanth can be used instead of different hydrocolloids in a wide range of applications.     

Correlation of Aspergillus niger broth rheological properties with biomass concentration and the shape of mycelial aggregates

Aspergillus niger was grown in a 7-L chemostat at biomass levels of 7 to 9 gL(-1); dilution rates of 0.03, 0.05, 0.075, and 0.009 h(-1); and dissolved oxygen tensions of 7%, 12%, and 40% of air saturation. Broth rheological measurements were made on-line, while off-line image analysis was used to measure mycelial morphology, including characterization of mycelial aggregates (clumps). Under all conditions, more than 87% of the hyphase were in clumps, the shape of which determined the rheological characteristics of the broth. In particular, the power law consistency index could be correlated with the biomass concentration and the roughness factor of the clumps, which describes their hairiness. A decrease in specific growth rate decreased roughness, possibly due to changes in the amount of clump breakup. However, decreases of roughness with increasing dissolved oxygen tension might rather imply some effect on hyphal-hyphal interactions within the clumps. (c) 1993 John Wiley & Sons, Inc.     

Fermentation broth rheology during dextran production by Leuconostoc mesenteroides B512(F) as a possible tool for control

Dextran is a polysaccharide produced commercially by Leuconostoc mesenteroides B512(F) growing on excess sucrose. The high viscosity of the resulting broth makes process analysis and control extremely difficult. In an attempt to overcome this the broth rheology was monitored with time and correlated with other process variables. It was determined that the viscosity and pseudo-plasticity increase through most of the fermentation, but then go through a sharp maximum immediately prior to completion of dextran synthesis and sucrose consumption. This was attributed to release of dextran molecules from the cell wall, reducing the size of polymer aggregates in solution. As such, the change in rheology provides a marker for the completion of the fermentation. The analysis requires no pretreatment of the broth, and it is envisaged that an on-line viscometer, determining apparent broth viscosity at a single shear rate, could be used for process monitoring and control. This would enable early detection of operating upsets, as well as avoid errors introduced by manual sampling and analysis, ans permit the optimum point at which to harvest the broth to be selected more precisely. Correspondence to: C. Webb     

Substrate inhibition kinetics: Phenol degradation by Pseudomonas putida

A pure culture of Pseudoinonas putida was grown in both a batch and continuous culture using phenol as the limiting substrate. Of two substrate inhibition models examined, the Haldane function was found to statistically best describe the kinetics. The applicable kinetic constants were either measured (μ_M, K_I) or estimated (K_S) from the experimental data. Particularly in the continuous culture, wall growth was found to exert significant effects on the broth biomass concentration and phenol conversion, both of which decreased with increasing amounts of wall growth. These effects are opposite to those predicted by wall growth models and to experimental results of others using mixed culture (activated sludge) systems.     

Multivariate models for prediction of rheological characteristics of filamentous fermentation broth from the size distribution

The main purpose of this article is to demonstrate that principal component analysis (PCA) and partial least squares regression (PLSR) can be used to extract information from particle size distribution data and predict rheological properties. Samples from commercially relevant Aspergillus oryzae fermentations conducted in 550 L pilot scale tanks were characterized with respect to particle size distribution, biomass concentration, and rheological properties. The rheological properties were described using the Herschel-Bulkley model. Estimation of all three parameters in the Herschel-Bulkley model (yield stress (tau(y)), consistency index (K), and flow behavior index (n)) resulted in a large standard deviation of the parameter estimates. The flow behavior index was not found to be correlated with any of the other measured variables and previous studies have suggested a constant value of the flow behavior index in filamentous fermentations. It was therefore chosen to fix this parameter to the average value thereby decreasing the standard deviation of the estimates of the remaining rheological parameters significantly. Using a PLSR model, a reasonable prediction of apparent viscosity (micro(app)), yield stress (tau(y)), and consistency index (K), could be made from the size distributions, biomass concentration, and process information. This provides a predictive method with a high predictive power for the rheology of fermentation broth, and with the advantages over previous models that tau(y) and K can be predicted as well as micro(app). Validation on an independent test set yielded a root mean square error of 1.21 Pa for tau(y), 0.209 Pa s(n) for K, and 0.0288 Pa s for micro(app), corresponding to R(2) = 0.95, R(2) = 0.94, and R(2) = 0.95 respectively.