An engineering analysis of rotating sieves for hybridoma cell retention ins stirred tank bioreactors

The use of internal rotating sieves for perfused hybridoma culture offers unique advantages but has been up to now largely empirical. Calculations have been performed on a 15 l spinfilter stirred tank in order to have an idea of hydrodynamic conditions inside and outside the rotating sieve. The large peripheral velocity value, resulting from sieve rotation (compared to axial and radial velocities) is expected to affect strongly sieve surface colonization by cells; this is confirmed by lab scale experiments, showing that cell colonization is prevented providing sieve rotation exceeds a defined value (around 0.6 m.s.1 tip speed); the fluid removal force calculated under these conditions appears to be in the range of 10 pN, similar to the adhesion force already reported for mammalian cells attached to inorganic substrata.     

Bioprocess engineering: now and beyond 2000

Abstract: Bioprocess engineering may be defined as the translation of life-science discoveries into practical products, processes, or systems capable of serving the needs of society. It is a critical link from discovery to commercialization. Current bioprocess engineering is primarily focused on biopharmaceutical products of high dollar value per gram such as erythropoietin or growth hormones. However, other products of current interest include ethanol, amino acids, organic acids, antibiotics, and specialty chemicals. Current challenges for increased use of bioprocesses for producing bulk and semi-bulk chemicals include both technical and infrastructural barriers. Technical barriers are easy to identify and at times can be overcome by engineering improvements or changes brought about radical developments in science (e.g. recombinant DNA). Infrastructural barriers, such as raw-material substitutions or educational limitations are more difficult to define and change. Recently the National Academy of Sciences examined barriers to bioprocess engineering and issued a report entitled: "Putting Biotechnology to Work: Bioprocess Engineering". A key recommendation was the establishment of a coordinated long-range plan of research, development, training and education in bioprocess engineering involving participation by industry, academe and the federal government. The report was the first national analysis devoted entirely to bioprocess engineering and covered new topics such as space bioprocess engineering. Other topics covered by the author include the current state of the US chemical industry and future directions in three promising areas of bioprocess engineering environmental bioprocess engineering, marine bioprocess engineering and microsystem bioprocess engineering.     

Self-cycling fermentation in a stirred tank reactor

Self-cycling fermentations (SCFs) were conducted in a stirred tank apparatus using Bacillus subtilis and Acinetobacter calcoaceticus. The systems were very stable and the experiments lasted through many cycles. The variation of parameters such as biomass and doubling time from cycle to cycle was small. The stirred tank reactor (STR) allowed a much better control of the working volume in the fermentor from cycle to cycle, compared to the cyclone column, and it was not necessary to make periodic corrections.The production of surfactin from B. subtilis was achieved without extending the cycle time. The harvested broth at the end of each cycle was allowed to remain in a secondary vessel, at ambient temperature, before being collected. It is exhaustion of the limiting nutrient which causes an increase in dissolved oxygen (DO). At this point, the computer, which constantly monitors the DO, triggered the harvesting sequence to end the cycle. Thus, the mature culture in the secondary vessel experienced appropriate conditions for the production of the secondary metabolite. Meanwhile, the next batch of cells was being grown in the primary reactor.The response of a gas analyzer on the effluent paralleled that of the DO measurements in the fermentor. These data for oxygen and carbon dioxide exhibited less noise than the DO readings. Either would be a more reliable parameter for feedback control of the SCF because the problem of fouling of the DO probe after extended runs of many cycles would be eliminated. (c) 1993 John Wiley & Sons, Inc.     

Phosphorus removal in aerated stirred tank reactor

The possibility to obtain biological phosphorus removal in strictly aerobic conditions has been investigated. Experiments, carried out in a continuous stirred tank reactor (CSTR), show the feasibility to obtain phosphorus removal without the anaerobic phase. Reactor performance in terms of phosphorus abatement kept always higher then 65% depending on adopted sludge retention time (SRT). In fact increasing SRT from 5 days to 8 days phosphorus removal and reactor performance increase but overcoming this SRT value a decreasing in reactor efficiency was recorded.     

Microbiologic characteristics of a trisectional horizontal biogas tank running on cow manure

The methanogenic activity of manure destructors was investigated at different stages of cattle manure utilization at 35 degrees in a three-section horizontal methane tank manufactured by "Enbom" company (Finland). The association of microorganisms was found to have the highest activity at the last stage of the process, while the least activity was observed in case of fresh manure. A considerable increase of the methanogenic activity in the methane tank was proved by the radioisotopic method and by calculation of the population size of microorganisms from different groups by the series dilution method. Acetic and propionic acids were absent in samples from the third section of the methane tank, while the maximum concentration of the acids was found in the manure storage and in the first section of the methane tank. A significant part of active methanogenic microorganisms was removed with the effluent. Therefore, partial recirculation of the biomass should be used to increase the efficiency of the methane tank.     

Cephalosporin C production in a stirred tank reactor

Summary Cephalosporin C was produced with the moldCephalosporium acremonium in a 20 1 stirred tank reactor with 100 kg/m³ peanut flour in fed-batch operation. The growth and product formation was followed by on-line analysis of the broth composition. The cell concentration was estimated from the RNA-content of the cells. By optimization of the fed-batch operation and by increasing the phosphate content in the broth, a final cephalosporin C concentration of 12 kg/m³ was attained.Nomenclature CPC cephalosphorin C - DAC deacetylcephalosporin C - DAOC deacetoxycephalosporin C - k _L a volumetric mass transfer coefficient - MMBS 2-Hydroxy-4-methylmercaptobutyric acid - PABAH p-Hydroxybenzoicacidhydrazid - RNA ribonucleic acid - RQ respiratory quotient - oxygen transfer rate - CO₂-production rate - t fermentation time     

Mechanistic analysis of xanthan gum production in a stirred tank

The overall effect of agitation on xanthan gum production by Xanthomonas campestris ATCC13951 in a stirred vessel was mechanistically analyzed considering local variation of the specific production rate due to variation of shear stress in the vessel. The whole liquid volume in a fermentor was roughly divided into three regions; the micromixing region around the impeller with high shear stress, the macromixing region dominated by a circulating flow and the stagnant region. The value of the shear rate was first ascertained by experiments in order to obtain a picture of shear rate variation in a radial direction from the impeller, and the equivalence between the volumes of the high shear stress region and micromixing region was confirmed. The shear stress obtained using a correlation between the shear rate at the impeller tip and Reynolds number of Wichterle et al. was used as a representative of the shear stress in the micromixing region, and the shear stress estimated by use of an empirical correlation between the average shear rate in a fermentor and agitation speed derived by Metzner et al. was adopted as a representative of the shear stress in the macromixing region. The information about the circulation time distribution was also used to take into account oxygen deficiency during circulation of liquid elements in the macromixing region, considering that oxygen from the gas phase was supplied mainly in the high shear region. The calculated values of xanthan gum concentrations which were obtained by the proposed simulation method agreed well with the experimental data in the time course of xanthan gum production at various agitation speeds. Experimental results of the relationship between the overall specific production rate and ND (N, agitation speed, and D, impeller diameter) was also verified by the proposed method.     

Interpretation of the gas residence time distributions in large stirred tank reactors

The behaviour of dispersed gas in large aerated stirred tank reactors is modelled by means of a Markov-process, which distinguishes between small recirculation bubbles with stagnant gas content, large rising bubbles with active gas content and exchange of stagnant and active gas contents, the gas exchange region at the impeller. The measurements of the gas residence time distributions (RTDs) in an 1.5 m³ aerated stirred tank reactor with water and Penicillium chrysogenum cultivation medium are interpreted by this model.List of Symbols CPR CO₂ production rate - OTR oxygen transfer rate - PRS pseudo random signal - RTD residence time distribution - V gas volume - recirculation coefficient - mean gas residence time Indices act active gas - ex gas exchange - stagn stagnant gas - tot total gas Dedicated to the 65th birthday of Professor Fritz Wagner.The authors thank Hoechst AG for the strain and the medium components, the GBF for the support of the experiments and H.M. Rüffer thanks the Verband der Chemischen Industrie for a Fond-der-Chemie scholarship.     

Prediction of gas-liquid mass transfer coefficient in sparged stirred tank bioreactors

Oxygen mass transfer in sparged stirred tank bioreactors has been studied. The rate of oxygen mass transfer into a culture in a bioreactor is affected by operational conditions and geometrical parameters as well as the physicochemical properties of the medium (nutrients, substances excreted by the micro-organism, and surface active agents that are often added to the medium) and the presence of the micro-organism. Thus, oxygen mass transfer coefficient values in fermentation broths often differ substantially from values estimated for simple aqueous solutions. The influence of liquid phase physicochemical properties on kLa must be divided into the influence on k(L) and a, because they are affected in different ways. The presence of micro-organisms (cells, bacteria, or yeasts) can affect the mass transfer rate, and thus kLa values, due to the consumption of oxygen for both cell growth and metabolite production. In this work, theoretical equations for kLa prediction, developed for sparged and stirred tanks, taking into account the possible oxygen mass transfer enhancement due to the consumption by biochemical reactions, are proposed. The estimation of kLa is carried out taking into account a strong increase of viscosity broth, changes in surface tension and different oxygen uptake rates (OURs), and the biological enhancement factor, E, is also estimated. These different operational conditions and changes in several variables are performed using different systems and cultures (xanthan aqueous solutions, xanthan production cultures by Xanthomonas campestris, sophorolipids production by Candida bombicola, etc.). Experimental and theoretical results are presented and compared, with very good results.     

Consecutive immobilized enzymatic reactions in continuous stirred tank reactor systems

The performance characteristics of two-enzyme reaction in a continuous stirred tank reactor (CSTR) are analytical investigated in this work. A model is formulated to describe the substrate concentration variations by taking into account the external and internal diffusion resistances. It is found that the reaction system exhibits the characteristics of reaction control or diffusion control depending on the operating conditions. The single CSTR model is also extended to describe the multiple CSTR system. The latter model enables the prediction of the number of CSTRs in series required to achieve a prescribed substrate conversion.     

Photosynthetically oxygenated salicylate biodegradation in a continuous stirred tank photobioreactor

A consortium consisting of a Chlorella sorokiniana strain and a Ralstonia basilensis strain was able to carry out sodium salicylate biodegradation in a continuous stirred tank reactor (CSTR) using exclusively photosynthetic oxygenation. Salicylate biodegradation depended on algal activity, which itself was a function of microalgal concentration, light intensity, and temperature. Biomass recirculation improved the photobioreactor performance by up to 44% but the results showed the existence of an optimal biomass concentration above which dark respiration started to occur and the process efficiency started to decline. The salicylate removal efficiency increased by a factor of 3 when illumination was increased from 50-300 microE/m2.s. In addition, the removal rate of sodium salicylate was shown to be temperature-dependent, increasing from 14 to 27 mg/l.h when the temperature was raised from 26.5 to 31.5 degrees C. Under optimized conditions (300 microE/m2.s, 30 degrees C, 1 g sodium salicylate/l in the feed and biomass recirculation) sodium salicylate was removed at a maximum constant rate of 87 mg/l.h, corresponding to an estimated oxygenation capacity of 77 mg O2/l.h (based on a BOD value of 0.88 g O2/g sodium salicylate for the tested bacterium), which is in the range of the oxygen transfer capacity of large-scale mechanical surface aerators. Thus, although higher degradation rates were attained in the control reactor, the photobioreactor is a cost-efficient process which reduces the cost of aeration and prevents volatilization problems associated with the degradation of toxic volatile organic compounds under aerobic conditions.     

Comparison of the performances of stirred tank and airlift tower loop reactors.

Following a consideration of the prerequisites for reactor comparison and the fundamental differences between stirred tank and airlift tower loop reactors, their performances are compared for the production of secondary metabolites: penicillin V by Penicillium chrysogenum, cephalosporin C by Cephalosporium acremonium, and tetracycline by Streptomyces aureofaciens. In stirred tank reactors, cell mass concentrations, volumetric productivities, and specific power inputs are higher than in airlift tower loop reactors. In the latter, efficiencies of oxygen transfer are higher, and specific productivities with regard to power input, substrate and oxygen consumptions, and yield coefficients of product formation with regard to substrate and oxygen consumptions are considerably higher than in stirred tank reactors. The prerequisites for improved performance are discussed.     

Bioprocess engineering of microalgae to optimize lipid production through nutrient management

Microalgae have been used commercially as a feedstock for the production of high-value compounds, pigments, cosmetics, and nutritional supplements. In addition, because of their rapid growth rates, high photosynthetic efficiency, and high lipid and protein content, commodity products including biodiesel, feed supplements, and polyunsaturated fatty acids derived from algal biomass are of current interest. Since microalgae lack non-photosynthetic structures and float in water, they do not need massive amounts of structural cellulose found in land plants. Thus, under optimal culture conditions, some oleaginous species can allocate up to 70 % of their biomass to lipids. Lipid production and its regulation in microalgae are species-specific and influenced by environmental conditions. Various strategies have been developed to improve lipid productivity and fatty acid composition to meet specific production goals. Manipulation of physiochemical parameters, trophic modes, and nutrient levels, known as process engineering, is a simple approach that leads to desired alterations in the biochemical composition of algal biomass, including lipid quantity and quality. In this paper, we review the effects of manipulating biochemical parameters such as necessary nutrients (C, N, P, S, Fe, and Si), NaCl concentration, and pH of culture medium to optimize lipid content and profile in some algae strains with commercial potential.     

Determination of the average shear rate in a stirred and aerated tank bioreactor

A method for evaluating the average shear rate () in a stirred and aerated tank bioreactor has been proposed for non-Newtonian fluids. The volumetric oxygen transfer coefficient (k _L a) was chosen as the appropriate characteristic parameter to evaluate the average shear rate (). The correlations for the average shear rate as a function of N and rheological properties of the fluid (K and n) were obtained for two airflow rate conditions (ϕ_air). The shear rate values estimated by the proposed methodology lay within the range of the values calculated by classical correlations. The proposed correlations were utilized to predict the during the Streptomyces clavuligerus cultivations carried out at 0.5 vvm and four different rotational impeller speeds. The results show that the values of the average shear rate () varied from 437 to 2,693 s⁻¹ by increasing with N and flow index (n) and decreasing with the fluid consistency index (K).     

Lipase-catalyzed selective synthesis of monolauroyl maltose using continuous stirred tank reactor

Monolauroyl maltose was synthesized by an immobilized lipase that catalyzed condensation of maltose and lauric acid in acetone using a batch reactor or a continuous stirred tank reactor. Mono- and di-lauroyl maltoses were identified by FT-IR, ¹H NMR, ¹³C NMR and MS. Monolauroyl maltose was selectively synthesized in a continuous stirred tank reactor and no diester was detected. The highest concentration of monolauroyl maltose at 28 mmol/l was obtained in 250 ml acetone when maltose was added at 4 g/d and the molar ratio of lauric acid to maltose was fixed at 4:1 at a flow rate of 0.15 ml/min for both influx and effluent without supplement of fresh molecular sieve.     

Disturbance-accommodating control approach applied for the control of a continuous stirred tank reactor

This paper describes an experimental study of linear adaptive control to achieve the monitoring of a continuous stirred tank reactor. The practical control objective was the regulation of the substrate concentration at a pre-specified value in the process effluent despite local changes and/or culture physiology variations. The substrate concentration and the dilution rate have been selected as the controlled and the control variable respectively. The results obtained confirm that this approach offers the possibility to combine simplicity and effectiveness in bioprocess control.