Why use bubble-column bioreactors?

Among the plethora of bioreactors available for aerobic culture, bubble columns, which are composed of a cylindrical vessel fitted with a gas sparger, are gaining in use. The simple construction of bubble-column reactors makes them easy to maintain. In addition, it is possible to control the degree of shear, uniformly within the reactor, which is critical to the growth of plant and animal cells in particular. This article reviews in detail the hydrodynamic, heat and mass-transfer characteristics of bubble-column bioreactors - parameters that are important for industrial scale-up.     

How scalable and suitable are single-use bioreactors?

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Nonlinear control of bioreactors with input multiplicities—an experimental work

The phrase input multiplicities means that an input variable with more than one value produces the same output value as if there were a single input–single output process. With input multiplicities, the value of the process gain changes as the manipulated variable changes, and beyond a certain input value, the sign of the gain also changes. A conventional PI controller for processes with input multiplicities may give unstable, less economical, or oscillatory responses. In the present work, control problems of a continuous bioreactor exhibiting two input multiplicities in the dilution rate on productivity were experimentally analyzed. A regulatory problem for the evaluation of controllers was taken up, i.e. a step change was made in the feed substrate concentration from 20 to 25 g/l at steady state conduction at lower (0.09386 h⁻¹) and higher (0.2278 h⁻¹) dilution rates for the same productivity of 2.9 g/l h. The nonlinear PI controller gave a more stable and fast response at both input dilution rates. The linear PI controller designed for a lower input dilution rate was stable, with some oscillations at the lower dilution rate, but the response was unstable at a higher dilution rate due to the input multiplicity behaviour of the process. Thus, nonlinear PI controller performance was found to be superior to that of the linear controller, and earlier reported theoretical results have been validated by the present experimental work.     

Continuous production of α,α-trehalose by immobilised fungal trehalose phosphorylase

Immobilisation of trehalose phosphorylase from Schizophyllum commune by adsorption onto anion-exchange materials stabilised the enzyme activity at 30°C by approx. 35-fold. Immobilised and free enzymes showed similar pH-dependence of activity but different inactivation behavior above 30°C. A fixed-bed enzyme reactor produced ,-trehalose at a stable substrate conversion of 80% with a productivity of 2.6 g l–1 h–1 for 72 h. Inhibition of trehalose phosphorylase by phosphate limited the productivity of a direct conversion of starch into ,-trehalose.     

Combined carbon and nitrogen removal from acetonitrile using algal–bacterial bioreactors

When compared with Chlorella vulgaris, Scenedesmus obliquus and Selenastrum capricornutum, C. sorokiniana presented the highest tolerance to acetonitrile and the highest O₂ production capacity. It also supported the fastest acetonitrile biodegradation when mixed with a suitable acetonitrile-degrading bacterial consortium. Consequently, this microalga was tested in symbiosis with the bacterial culture for the continuous biodegradation of acetonitrile at 2 g l^–1 in a stirred tank photobioreactor and in a column photobioreactor under continuous illumination (250 E m^–2 s^–1). Acetonitrile removal rates of up to 2.3 g l^–1 day^–1 and 1.9 g l^–1 day^–1 were achieved in the column photobioreactor and the stirred-tank photobioreactor, respectively, when operated at the shortest retention times tested (0.4 days, 0.6 days, respectively). In addition, when the stirred-tank photobioreactor was operated with a retention time of 3.5 days, the microbial culture was capable of assimilating up to 71% and nitrifying up to 12% of the NH₄⁺ theoretically released through the biodegradation of acetonitrile, thus reducing the need for subsequent nitrogen removal. This study suggests that complete removal of N-organics can be combined with a significant removal of nitrogen by using algal–bacterial systems and that further residual biomass digestion could pay-back part of the operation costs of the treatment plant.     

A bioreaction–diffusion model for growth of marine sponge explants in bioreactors

Marine sponges are sources of high-value bioactives. Engineering aspects of in vitro culture of sponges from cuttings (explants) are poorly understood. This work develops a diffusion-controlled growth model for sponge explants. The model assumes that the explant growth is controlled by diffusive transport of at least some nutrients from the surrounding medium into the explant that generally has a poorly developed aquiferous system for internal irrigation during early stages of growth. Growth is assumed to obey Monod-type kinetics. The model is shown to satisfactorily explain the measured growth behavior of the marine sponge Crambe crambe in two different growth media. In addition, the model is generally consistent with published data for growth of explants of the sponges Disidea avara and Hemimycale columella. The model predicted that nutrient concentration profiles for nutrients, such as dissolved oxygen within the explant, are consistent with data published by independent researchers. In view of the proposed model’s ability to explain available data for growth of several species of sponge explants, diffusive transport does play a controlling role in explant growth at least until a fully developed aquiferous system has become established. According to the model and experimental observations, the instantaneous growth rate depends on the size of the explant and all those factors that influence the diffusion of critical nutrients within the explant. Growth follows a hyperbolic profile that is consistent with the Monod kinetics.     

Microlitre/millilitre shaken bioreactors in fermentative and biotransformation processes – a review

The use of small-scale vessels (below 100?mL) as tools for the characterization of fermentative and biotransformation processes is an emergent approach, which may provide a wide array of data with significant time and cost savings. These result from the reduced reagent requirements and the possibility of simultaneously carrying out the evaluation of multiple operational parameters and assessing their individual or combined effect in the process. Furthermore, it is envisaged that such data will provide the basis for a rational scale-up of the systems evaluated. This requires an engineering approach, which has been integrated with the development of microscale technology. This review comprises recent findings related to the use and characterization of Erlenmeyer type flasks, test tubes and microtiter plates as bioreactors.     

The stereospecific bioconversion of α-aminopropionitrile to L-alanine by an immobilised bacterium isolated from soil

Summary Bacterial isolate APN grew on -aminoacetonitrile and -amino propionitrile (-APN) converting the -aminonitriles to glycine and alanine, respectively. The nitrilase had an apparent Km for -APN of 34mM in whole cells and 21mM when immobilised. The alanine formed from APN was 87% in the L-form and was produced for 45 days after immobilisation in alginate.     

Production of recombinant β-galactosidase in bioreactors by fed-batch culture using DO-stat and linear control

β-Galactosidase enzymes continue to play an important role in food and pharmaceutical industries. These enzymes hydrolyze lactose in its constituent monosaccharides, glucose and galactose. The industrial use of enzymes presents an increase in process costs reflecting in higher final product value. An alternative to enhance processes’ productivity and yield would be the use of recombinant enzymes and their large-scale fed-batch production. The overexpression of recombinant β-galactosidase from Kluyveromyces sp. was carried out in 2-L bioreactors using Escherichia coli strain BL21 (DE3) as host. Effect of induction time on recombinant enzyme expression was studied by adding 1?mM isopropyl thiogalactoside (IPTG) at 12?h, 18?h and 24?h of cultivation. Glucose feeding strategies were compared employing feedback-controlled DO-stat and ascendant linear pump feeding in bioreactor fed-batch cultivations. Linear feeding strategy with IPTG addition at 18?h of cultivation resulted in approximately 20?g/L and 17,745?U/L of biomass and β-galactosidase activity, respectively. On the other hand, although the feedback-controlled DO-stat feeding strategy induced at 12?h of cultivation led to lower final biomass of 18?g/L, it presented an approximately 2.5 increase in enzymatic activity, resulting in 42,367?U/L, and most importantly it led to the most prominent specific enzymatic activity of approximately 40?U/mg_protein. Comparing to previous results, these results suggest that the DO-stat feeding is a promising strategy for recombinant β-galactosidase enzyme production.     

How do immobilised cell-adhesive Arg–Gly–Asp-containing peptides behave at the PAA brush surface?

Bio-engineered surfaces that aim to induce normal cell behaviour in vitro need to ‘mimic’ the extracellular matrix in a way that allows cell adhesion. In this computational work, several model cell-binding peptides with a minimal cell-adhesive Arg–Gly–Asp sequence are investigated in the bulk as well as immobilised on a soft surface. For this reason, a combination of density functional theory and all-atom MD simulations is applied. The major goal of the modelling is to characterise the accessibility of the cell-recognition motif on the functionalised soft polymer surface. As a reference system, the behaviour of three peptide sequences is preliminarily studied in explicit water simulations. From the analysis of the MD trajectories, the solvent accessible surface area, the distribution of water molecules around peptide groups, the secondary structure and the thermodynamics of hydration are evaluated. Furthermore, each peptide is immobilised on the surface of a homopolymer poly(acrylic acid) brush. During MD simulations, all three peptides approach closely toward PAA brush, and their surface accessibility is characterised. Although the peptides are adsorbed onto the brush, they are not hidden by the polymer strands, with RGD unit accessible on the surface and available for guided cell adhesion.     

Determination of CO₂ sensitivity of micro-organisms in shaken bioreactors. II. Novel online monitoring method

In the present study, a new online monitoring method for the determination of the CO? sensitivity of micro-organisms, based on the values of the respiration factors [OTR (oxygen transfer rate) and CTR (carbon dioxide transfer rate)], obtained by using the RAMOS (respiratory activity monitoring system) device considering a variety of aeration rates in the measuring flask, is investigated. Based on the data of the OTR, obtained by RAMOS under a variety of specific aeration rates, the proposed new method was developed as an online monitoring method for CO? sensitivity of micro-organisms in shaken bioreactors. A maximum accumulated CO? concentration of 12% was derived in applied methods, provided that the cultivation system is carried out under optimal conditions. Additionally, to predict these conditions, an unsteady-state gas transfer model in shaken bioreactors would be very advantageous. The data of OTR obtained using the RAMOS device were analysed and recalculated by a programme considering the calibration factor (Cf). The major advantage of the new method is the possibility to determine the metabolic activity, regardless of manual sampling.     

Bioactive metabolite production and stress-related hormones in Devil’s claw cell suspension cultures grown in bioreactors

In a previous report, we showed that cell cultures of Harpagophytum procumbens, a South African plant with high medicinal value, accumulate high amounts of anti-inflammatory phenylethanoid glycosides during cultivation in shake-flasks. The aim of the present study was to transfer the phenylethanoid biosynthetic process to a 3-L stirred tank reactor and a 1-L glass-column bioreactor (operated with pulsed aeration). We found that, with stepwise increases in aeration, the stirred tank reactor yielded similar productivities of verbascoside (the major phenylethanoid glycoside in the cells) to those reported for shake-flask cultures (55.68 vs. 54.78 mg verbascoside/L/day, respectively). Transfer in the pulse-aerated column reactor resulted in 165.42 mg verbascoside/L/day, one of the highest yields reported to date. Further, to evaluate the physiological status of the suspended cells in the bioreactors cultures, we examined their hormone levels and compared them to those of cells in shake-flask cultures. While indole-3-acetic acid levels did not differ significantly between the bioreactor and shake-flask cultures, there were considerable differences in their levels of abscisic, jasmonic, and salicylic acids. These results are discussed with respect to relative stress levels in the different cultivation systems.     

Submerged culture production of chitinase by Trichoderma harzianum in stirred tank bioreactors – the influence of agitator speed

The chitinase fermentation process utilizing chitin as the sole carbon source was investigated in a stirred tank bioreactor. Agitator speed of 224 rpm was found to be most suitable for cell growth as well as for chitinase production. Chitinase yield decreased rapidly at higher agitator speed, while decrease in cell yield at higher agitator speed was not rapid. Probably, mass transfer limitation was predominant in the fermentation process at lower agitator speed. Higher agitator speed appears to reduce chitinase production.     

Effect of oil concentration and residence time on the biodegradation of α-pinene vapours in two-liquid phase suspended-growth bioreactors

Recently, research on the use of binary aqueous-organic liquid phase systems for the treatment of polluted air has significantly increased. This paper reports the removal of α-pinene from a waste air stream in a continuous stirred tank bioreactor (CSTB), using either a single-liquid aqueous phase or a mixed aqueous-organic liquid phase. The influence of gas flow rate, load and pollutant concentration was evaluated as well as the effect of the organic to aqueous phase ratio. Continuous experiments were carried out at different inlet α-pinene concentrations, ranging between 0.03 and 25.1 g m?3 and at four different flow rates, corresponding to residence times (RTs) of 120 s, 60 s, 36 s and 26 s. The maximum elimination capacities (ECs) reached in the CSTB were 382 g m?3 h?1 (without silicone oil) and 608 g m?3 h?1 (with 5%v/v silicone oil), corresponding to a 1.6-fold improvement using an aqueous-organic liquid phase. During shock-loads experiments, the performance and stability of the CSTB were enhanced with 5% silicone oil, quickly recovering almost 100% removal efficiency (RE), when pre-shock conditions were restored. The addition of silicone oil acted as a buffer for high α-pinene loads, showing a more stable behaviour in the case of two-liquid-phase systems.     

Solvent damage during immobilised cell catalysis and its avoidance: studies of 11α-hydroxylation of progesterone by Aspergillus ochraceus

Summary The tolerance towards conventional organic solvents of the progesterone 11-hydroxylase system in alginate immobilised Aspergillus ochraceus has been examined. Though greater than that for the enzyme system in free cells it is still too limited for practical use. Substitution of natural oils gave a more stable catalyst system. The activity versus a free cell catalyst was not attractive in short term use, but may be over the longer term.     

A nonlinear three-compartiment model for the administration of 2′,3′-dideoxycytidine by using red blood cells as bioreactors

A non-linear three-compartment model is proposed to describe a new strategy for the administration of 2′,3′-dideoxycytidine (ddCyd) in the treatment of HIV infections. The drug is injected after having been encapsulated in a non-diffusible form (ddCMP) into erythrocytes. Nummerical solutions show that by this treatment the highest ddCyd blood concentration is strongly reduced and in turn its toxicity, while long-lasting therapeutic effect is assured. The model is compared with experimental data in vitro.