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.     

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).     

Ethanol fermentation in a magnetically fluidized bed reactor with immobilized Saccharomyces cerevisiae in magnetic particles

Ethanol fermentation by immobilized Saccharomyces cerevisiae cells in magnetic particles was successfully carried out in a magnetically stabilized fluidized bed reactor (MSFBR). These immobilized magnetic particles solidified in a 2 % CaCl(2) solution were stable and had high ethanol fermentation activity. The performance of ethanol fermentation of glucose in the MSFBR was affected by initial particle loading rate, feed sugar concentration and dilution rate. The ethanol theoretical yield, productivity and concentration reached 95.3%, 26.7 g/L h and 66 g/L, respectively, at a particle loading rate of 41% and a feed dilution rate of 0.4 h(-1) with a glucose concentration of 150 g/L when the magnetic field intensity was kept in the range of 85-120 Oe. In order to use this developed MSFBR system for ethanol production from cheap raw materials, cane molasses was used as the main fermentation substrate for continuous ethanol fermentation with the immobilized S. cerevisiae cells in the reactor system. Molasses gave comparative ethanol productivity in comparison with glucose in the MSFBR, and the higher ethanol production was observed in the MSFBR than in a fluidized bed reactor (FBR) without a magnetic field.     

An extension of the pressure-test technique for immobilized biocatalyst preparations

Based on an analysis of variables in the Ergun equation for pressure drop in granular beds, the technique of pressuretesting of immobilized biocatalyst preparations is reexamined from the point of view of evaluation of biocatalyst mechanical properties in packed bed reactors. The variation of biocatalyst particle size in the course of bioreactor performance was found to be a convenient estimate of mechanical strength for the biocatalyst particles. Based on this finding, an extension of the pressure-test technique with particle size analysis was proposed as an opportunity to carry out differential analysis of biocatalyst structure, regardless of time and position. An example of bed destruction is given to support the suggested characterization analysis.     

Evaluation of inverse anaerobic fluidized bed reactor for treating high strength organic wastewater

The aim of this work is to evaluate the feasibility of an inverse fluidized bed reactor for the anaerobic digestion of distillery effluent, with a carrier material that allows low energy requirements for fluidization, providing also a good surface for biomass attachment and development. Inverse fluidization particles having specific gravity less than one are carried out in the reactor. The carrier particles chosen for this study was perlite having specific surface area of 7.010 m2/g and low energy requirements for fluidization. Before starting up the reactor, physical properties of the carrier material were determined. One millimeter diameter perlite particle is found to have a wet specific density of 295 kg/m3. It was used for the treatment of distillery waste and performance studies were carried out for 65 days. Once the down flow anaerobic fluidized bed system reached the steady state, the organic load was increased step wise by reducing hydraulic retention time (HRT) from 2 days to 0.19 day, while maintaining the constant feed of chemical oxygen demand (COD) concentration. Most particles have been covered with a thin biofilm of uniform thickness. This system achieved 84% COD removal at an organic loading rate (OLR) of 35 kg COD/m3/d.     

Kinetics of the acid precipitation of soya protein in a continuous-flow tubular reactor

The acid precipitation of soya protein was studied in a continuous-flow tubular reactor under conditions of turbulent flow. Preliminary batchwise experiments of a semiquantitative nature were also carried out on a bench-scale reactor to better define the parameters affecting precipitate growth. The experiments indicated the dominant growth mechanism to be the aggregation of primary precipitate particles produced by the contacting of the protein and acid streams. The rate of particle growth was observed to rise with an increase in the protein concentration as well as with greater intensity of turbulence. The final mean particle size decreased with increased intensity of turbulence. A theoretical model was set up to simulate the growth of the precipitate particles.     

Racemization of undesired enantiomers: Immobilization of mandelate racemase and application in a fixed bed reactor

Production of optically pure products can be based on simple unselective synthesis of racemic mixtures combined with a subsequent separation of the enantiomers; however, this approach suffers from a 50% yield limitation which can be overcome by racemization of the undesired enantiomer and recycling. Application of biocatalyst for the racemization steps offers an attractive option for high‐yield manufacturing of commercially valuable compounds. Our work focuses on exploiting the potential of racemization with immobilized mandelate racemase. Immobilization of crude mandelate racemase via covalent attachment was optimized for two supports: Eupergit^® CM and CNBr‐activated Sepharose 4 Fast Flow. To allow coupling of enzymatic reaction with enantioselective chromatography, a mobile phase composition compatible with both processes was used in enzymatic reactor. Kinetic parameters obtained analyzing experiments carried out in a batch reactor could be successfully used to predict fixed‐bed reactor performance. The applicability of the immobilized enzyme and the determined kinetic parameters were validated in transient experiments recording responses to pulse injections of R‐mandelic acid. The approach investigated can be used for futher design and optimization of high yield combined resolution processes. The characterized fixed‐bed enzymatic reactor can be integrated e.g. with chromatographic single‐ or multicolumn steps in various configurations.     

Adsorptive control of water in esterification with immobilized enzymes: II. fixed-bed reactor behavior

Experimental and theoretical studies are conducted to understand the dynamic behavior of a continuous-flow fixed-bed reactor in which an esterification is catalyzed by an immobilized enzyme in an organic solvent medium. The experimental system consists of a commercial immobilized lipase preparation known as Lipozyme as the biocatalyst, with propionic acid and isoamyl alcohol (dissolved in hexane) as the reaction substrates. A complex dynamic behavior is observed experimentally as a result of the simultaneous occurrence of reaction and adsorption phenomena. Both propionic acid and water are adsorbed by the biocatalyst resulting in lower reaction rates. In addition, an excessive accumulation of water in the reactor leads to a rapid irreversible inactivation of the enzyme. A model based on previously-obtained adsorption isotherms and kinetic expressions, as well as on adsorption rate measurements obtained in this work, is used to predict the concentration and thermodynamic activity of water along the reactor length. The model successfully predicts the dynamic behavior of the reactor and shows that a maximum thermodynamic activity of water occurs at a point at some distance from the reactor entrance. A cation exchange resin in sodium form, packed in the reactor as a selective water adsorbent together with the catalyst particles, is shown to be an effective means for preventing an excessive accumulation of water formed in the reaction. Its use results in longer cycle times and greater productivity. As predicted by the model, the experimental results show that the water adsorbed on the catalyst and on the ion exchange resin can be removed with isoamyl alcohol with no apparent loss in enzyme activity.     

Adsorptive control of water in esterification with immobilized enzymes. Continuous operation in a periodic counter-current reactor

A periodic counter-current adsorptive-reactor system is developed to carry out continuous esterifications in organic solvents with immobilized enzymes. The system comprises a number of fixed-beds distributed between a reaction-adsorption zone and a regeneration zone and operated in a "merry-go-round" sequence. Water formed in the reaction is adsorbed preventing the formation of a free-water phase and deactivation of the biocatalyst. The adsorbed water is, in turn, recovered by desorption in the regeneration zone. The concept is tested experimentally on a laboratory-scale using, as a model, the esterification of isoamyl alcohol and propionic acid in hexane catalyzed by an immobilized lipase. Pure isoamyl alcohol is used as a regenerant to remove excess water from the biocatalyst. In the periodic steady-state, improvements in ester productivity greater than 50% over that achievable with a conventional fixed-bed reactor are demonstrated experimentally with just two beds in a series arrangement. Use of a water-selective adsorbent in conjunction with the biocatalyst provides further improvements by reducing accumulation of water on the enzyme. A mathematical model is also developed to predict the thermodynamic activity of water along the reactor and describe the dynamic behavior of the system. The model, based on independently developed rate and equilibrium parameters, successfully predicts the experimental behavior and provides an effective tool for scale-up and optimization.     

Stirred fluidised-bed reactor developed for low-density biocatalyst supports

Summary A new type of multistage fluidised-bed reactor was constructed to avoid the fluidisation irregularities by slow stirring of the bed. Aminoacylase immobilized on a polyacrylamide type bead polymer was used as biocatalyst for resolution of racemic amino acids. The efficiency was considerably higher than that of a traditional packed-bed reactor.     

Analysis of substrate protection of an immobilized glucose isomerase reactor

The effect of substrate protection on enzyme deactivation was studied in a differential bed and a packed bed reactor using a commercial immobilized glucose isomerase (Swetase, Nagase Co.). Experimental data obtained from differential bed reactor were analyzed based on Briggs-Haldane kinetics in which enzyme deactivation accompanying the protection of substrate was considered. The deactivation constant of the enzyme-substrate complex was found to be about half of that of the free enzyme. The mathematical analysis describing the performance of a packed bed reactor under the considerations of the effects of substrate protection, diffusion resistance, and enzyme deactivation was studied. The system equations for the packed bed reactor were solved using an orthogonal collocation method. The presence of substrate protection and the diffusion effect within the enzyme particles resulted in an axial variation of effectiveness factor, eta(D), along the length of the packed bed. The axial distribution profile of eta(D) was found to be dependent on the operation temperature, Based on the effect of substrate protection, a better substrate feed policy could be theoretically found for promoting productivity in long-term operation. (c) 1993 John Wiley & Sons, Inc.     

Influence of biomass accumulation on bed expansion characteristics of a down-flow anaerobic fluidized-bed reactor

This article describes the bed expansion characteristics of a down-flow anaerobic fluidized bed reactor treating a synthetic wastewater. Experiments were carried out in a 0.08 m diameter and 1 m length PVC column. The carrier used was ground perlite (an expanded volcanic rock). Particles characteristics were 0.968 mm in diameter, specific density of 213 kg x m-3 and Umf (minimal fluidization velocity): 2.3 m x h-1. Experimental data of terminal velocities and bed expansion parameters at several biofilm thicknesses were compared to different models predicting the bed expansion of up-flow and down-flow fluidized beds. Measured bed porosities at different liquid superficial velocities for the different biofilm thicknesses were in agreement with the Richardson-Zaki model, when Ut (particle terminal velocity) and n (expansion coefficient) were calculated by linear regression of the experimental data. Terminal velocities of particles at different biofilm thicknesses calculated from experimental bed expansion data, were found to be much smaller than those obtained when Cd (drag coefficient) is determined from the standard drag curve (Lapple and Sheperd, 1940) or with others' correlations (Karamanev and Nikolov, 1992a,b). This difference could be explained by the fact that free-rising particles do not obey Newton's law for free-settling, as proposed by Karamanev and Nikolov (1992a,b) and Karamanev et al. (1996). In the present study, the same free-rising behavior was observed for all particles (densities between 213 and 490 kg x m-3).     

Immobilized cell cross-flow reactor

A cross-current flow reactor was operated using sodium alginate gel entrapped yeast cells under growth conditions. Micron-sized silica, incorporated into the biocatalyst particles (1 mm mean diameter) improved mechanical strength and internal surface adhesion. The process showed decreased productivity and stability at 35 degrees C compared to the normal study done at 30 degrees C. The increased number of cross flows diminish the product inhibition effect. The residence time distribution shows that the cross-flow bioreactor system can be approximated to either a train of backmixed fermentors in series or a plug flow fermentor with moderate axial dispersion.     

Highly enantioselective esterification of racemic ibuprofen in a packed bed reactor using immobilised Rhizomucor miehei lipase

A systematic study of the enantioselective resolution of ibuprofen by commercial Rhizomucor miehei lipase (Lipozyme(R) IM20) has been carried out using isooctane as solvent and butanol as esterificating agent. The main variables controlling the process (temperature, ibuprofen concentration, ratio butanol:ibuprofen) have been studied using an orthogonal full factorial experimental design, in which the selected objective function was enantioselectivity. This strategy has resulted in a polynomial function that describes the process. By optimizing this function, optimal conditions for carrying out the esterification of racemic ibuprofen have been determined. Under these conditions, enantiomeric excess and total conversion values were 93.8% and 49.9%, respectively, and the enantioselectivity was 113 after 112 h of reaction. These conditions have been considered in the design of a continuous reactor to scale up the process. The esterification of ibuprofen was properly described by pseudo first-order kinetics. Thus, a packed bed reactor operating as a plug-flow reactor (PFR) is the most appropriate in terms of minimizing the residence time compared with a continuous stirred tank reactor (CSTR) to achieve the same final conversion. This reactor shows a similar behavior in terms of enantioselectivity, enantiomeric excess, and conversion when compared with batch reactors. A residence-time distribution (RTD) shows that the flow model is essentially a plug flow with a slight nonsymmetrical axial dispersion (Peclet number = 43), which was also corroborated by the model of CSTR in series. The stability of the system (up to 100 h) and the possibility of reutilization of the enzyme (up to four times) lead to consider this reactor as a suitable configuration for scale up of the process.     

A model to describe the performance of the UASB reactor

A dynamic model to describe the performance of the Upflow Anaerobic Sludge Blanket (UASB) reactor was developed. It includes dispersion, advection, and reaction terms, as well as the resistances through which the substrate passes before its biotransformation. The UASB reactor is viewed as several continuous stirred tank reactors connected in series. The good agreement between experimental and simulated results shows that the model is able to predict the performance of the UASB reactor (i.e. substrate concentration, biomass concentration, granule size, and height of the sludge bed).     

An integral dynamic model for the UASB reactor

In this article a dynamic model of a continuous working UASB reactor is described. It results from the integration of the fluid flow pattern in the reactor, the kinetic behavior of the bacteria (where inhibition and limitation were taken into account), and the mass transport phenomena between different compartments and different phases. The mathematical equations underlying the model and describing the important mechanisms were programmed and prepared for computations and simulations by computer. The settler efficiency has to be over 99% to prevent the reactor from wash-out. When the settler efficiency is over 99%, the total sludge content of the reactor increases steadily, so the reactor is hardly ever in a steady state. This implies dynamic modeling. The model is able to predict the various observable and nonobservable or difficult to observe state variables, e.g., the sludge bed height, the sludge blanket concentration, the short-circuiting flows over bed and blanket, and the effluent COD concentration as a function of the hydrodynamic load, COD load, pH, and settler efficiency. The optimal pH value is between 6.0 and 8.0; fatty acid shock loadings are difficult to handle outside this optimal pH range.     

Continuous immobilized cell reactor for amide hydrolysis

Summary This article deals with continuous hydrolysis of acrylamide into acrylic acid using the wild-typeBrevibacterium sp. R312 which can hydrolyze all water-soluble amides into their corresponding acids. Biotransformation has been carried out in a fluidized bed reactor specially designed to obtain good contact conditions between cells entrapped into small calcium alginate beads (2–3 mm) and low-concentration acrylamide solutions (10–40g·l^–1). Different flow rates, biocatalyst loads and substrate concentrations have been investigated. Kinetic constants for the immobilized enzyme have been identified. It appears that the Michaelis constant does not change with operating conditions and remains roughly equal to the value obtained for free cells. In contrast, the maximum rate of hydrolysis is considerably decreased, as if only cells on the outskirts of beads were involved in the transformation. On the whole it is proved that corynebacteria cells could be usefully used for the bioconversion of amides in a continuous immobilized cell reactor; the higher the solid hold-up and/or the smaller the beads, the more efficient the biological transformation.     

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.     

Continuous hydrolysis of oil by immobilized lipase in a countercurrent reactor

Lipase from Pseudomonas fluorescens biotype I was immobilized by adsorption of anion exchange resin using glutaraldehyde to enhance the adsorption. The activity yield of the immobilized lipase was very low (below 1%) when lipase activity was measured using emulsion substrate. The activity yield was 10-70% when lipase activity was measured using non-emulsion substrate. Countercurrent reactors for hydrolysis of oil using non-emulsion substrate were studied. A fluidized bed reactor was found to be superior to a fixed bed one since in a fixed bed reactor the separation rate of the two layers was slow and the flow rate of the reactor had to be slower than the separation rate. A fluidized bed reactor system equipped with settling compartments and stirring compartments was devised. Continuous lipolysis at 60 degrees C and continuous separation of oily product and water soluble product were performed. After continuous operation for more than 3 months, 70% of the initial activity of the immobilized lipase was observed at the end of the reaction.     

Effects of solid-phase mass transfer on the performance of a stirred anaerobic sequencing batch reactor containing immobilized biomass

This work reports on experiments for an anaerobic sequencing batch reactor containing immobilized biomass which aimed at verifying the effects of solid-phase mass transfer on the reactor's overall performance. Four experiments were carried out at 30 degrees C with cubic polyurethane foam particles previously inoculated with anaerobic biomass. Different solid-phase mass transfer conditions were reached in each experiment by varying the size of the bioparticle from 0.5 to 3.0 cm. The reactor was fed with a low-strength synthetic wastewater containing protein, carbohydrates and lipid and the effects of mass transfer were evaluated through dynamic substrate concentration profiles during 8-hour batch cycles. A modified first-order kinetic model provided a good representation of the behavior of the dynamic concentration profiles. The solid-phase mass transfer was found to slightly affect the concentration of effluent organic matter expressed as chemical oxygen demand (COD). The concentration of residual effluent substrate increased as the size of the bioparticle was increased. The cycle time was not affected as the size of the bioparticle was increased from 0.5 to 2.0 cm. However, it was found that the cycle time in a reactor with 3.0-cm cubic particles should be higher than that required in systems with smaller particles. The apparent first-order kinetic parameter was estimated as 0.59+/-0.01 h(-1) for experiments with bioparticle sizes ranging from 0.5 to 2.0 cm, while a value of 0.48 h(-1) was obtained in the experiment with 3.0-cm bioparticles.