Novel three-phase bioreactor concept for fatty acid alkyl ester production using R. oryzae as whole cell catalyst

A novel three-phase solid–gas–liquid bioreactor (SGLB) concept using gaseous alcohol and liquid rapeseed oil with immersed microorganisms overlying a nutrient agar phase (solid) is proposed for biodiesel (fatty acid alkyl esters, FAAE) production based on the high hydrophobicity and negative surface charge showed by the fungi Rhizopus oryzae. This novel bioreactor was thought to increase oil bioavailability and decrease alcohol toxicity for effective microbial growth, reaching high yields of FAAE production without any pretreatment. High growth rates were reached for R. oryzae using a SGLB simultaneously reaching a high FAAE production yield, up to 50% using methanol and up to 70% using ethanol at 144 h of incubation at 20°C. To compare the effect of gaseous alcohol, the same experiments were carried out in a three-phase solid–liquid–liquid bioreactor (SLLB), where the alcohol was added in liquid phase, showing significant R. oryzae growth but no FAAE formation. This suggests that the inhibitory effect of alcohol is more significant in lipase activity than in R. oryzae growth, and the use of alcohol in gaseous phase may decrease both of them. The experimental procedure using SGLB showed that when R. oryzae is maintained alive, it can catalyze at the same time the hydrolysis, esterification and transesterification of triglycerides from rapeseed oil, but its activity strongly depends on the used growth media. Therefore, the application of gaseous alcohol coupled with R. oryzae as immobilized whole cell catalysts may be a potential alternative to the use of commercial lipases for biodiesel production.