Continuous Stirred Tank Fermentor Research Articles

Application of mathematical modelling for investigating oxygen transfer energy requirement and process design of an aerobic continuous stirred tank fermenter

Fermentation kinetic and oxygen transfer modelling coupled with energy analysis was applied to investigate how key input design variables influenced fermenter size, feed substrate requirement, wasted substrate and aeration system electrical energy requirement. The study showed that trade-offs and compromises are required to select the values of key input variables that can produce superior process designs in terms of the output variables. For example, reducing steady-state oxygen concentration reduced aeration system energy requirements and associated carbon footprint but increased fermenter size and associated cost. Mathematical modelling can assist in more precisely zoning in quantitatively on the selection of design input variable values that can produce a best compromise between conflicting design output variables. Mathematical modelling can also highlight design sensitivities. For example, if the steady-state sugar concentration is reduced below a certain value, then this can lead to an exponential increase in fermenter volume and associated cost, thus it is prudent to operate on the conservative side of this value.

An age-structured population balance model for microbial dynamics

This work presents an age-structured population balance model (ASPBM) for a bioprocess in a continuous stirred-tank fermentor. It relates the macroscopic properties and dynamic behavior of biomass to the operational parameters and microscopic properties of cells. Population dynamics is governed by two time- and age-dependent density functions for living and dead cells, accounting for the influence of substrate and dissolved oxygen concentrations on cell division, aging and death processes. The ASPBM described biomass and substrate oscillations in aerobic continuous cultures as experimentally observed. It is noteworthy that a small data set consisting of nonsegregated measurements was sufficient to adjust a complex segregated mathematical model.

Exploration and exploitation of bifurcation/chaotic behavior of a continuous fermentor for the production of ethanol

A four-dimensional model for the anaerobic fermentation process, developed and used earlier to simulate the oscillatory behavior of an experimental continuous stirred tank fermentor is utilized in the present investigation to explore the static/dynamic bifurcation and chaotic behavior of this fermentor, which is shown to be quite rich. The present investigation is a prelude to the experimental exploration of bifurcation and chaos in a membrane fermentor. Dynamic bifurcation (periodic attractors) as well as period doubling sequences leading to different types of periodic and chaotic attractors have been uncovered. It is fundamentally and practically important to discover the fact that in some cases, periodic and chaotic attractors have higher ethanol yield and production rate than the corresponding steady states.

A catalytic multistage fixed-bed tower bioreactor in an industrial-scale pilot plant for alcohol production

This article describes the development of an industrial-scale, multistage fixed-bed tower (MFBT) bioreactor using the promoter mineral kissiris for industrial alcohol production using free cells. Specifically, we examined the parameters needed to maintain operational stability from batch to batch for long periods. Pilot plant operations used one- and two-stage fixed-bed, 7000-L bioreactors. Likewise a 100,000-L, multistage fixed-bed tower system containing layered kissiris confirmed the laboratory results. Compared with a continuous stirred tank fermentor (CSTF) with recycle, a 30% reduction of energy demand and 10%-20% of the production costs are obtained. The latter are attributed to the increased ethanol concentration and alcohol productivity. (c) 1996 John Wiley & Sons, Inc.

Evaluation of sensors for the control of a continuous ethanol fermentation

A method is presented for the evaluation of sensors used in the control of continuous fermentations. Simulations of open-loop response to input disturbance provided a starting point for the choice of sensor type. This was evaluated quantitatively through a sensitivity ratio. It was shown that in the case of ethanol fermentation, there existed three regions where different sensors could be used for the process control depending on the inlet sugar concentration. Sugar sensors were preferable above an inlet sugar concentration of 50 kg/m3, while ethanol sensors were preferable below 25 kg/m3. In the intermediate region, sugar and ethanol sensors demonstrated equally good performance. A controllability study of a continuous ethanol fermentation was also made. A single-stage continuous stirred-tank fermentor was simulated operating at a dilution rate of 0.1 1/h and inlet glucose concentration of 160 kg/m3. The outlet glucose concentration was controlled with a PI controller. Mean square error of the controller input signal during the first five hours after introducing input disturbance was taken as a measure of the controllability. This was studied in the relation to the two key sensor characteristics, sampling time and accuracy.

Optimizing control of a continuous stirred tank fermenter using a neural network

Feedforward neural networks are a general class of nonlinear models that can be used advantageously to model dynamic processes. In this investigation, a neural network was used to model the dynamic behaviour of a continuous stirred tank fermenter in view of using this model for predictive control. In this system, the control setpoint is not known explicitly but it is calculated in such a way to optimize an objective criterion. The results presented show that neural networks can model very accurately the dynamics of a continuous stirred tank fermenter and, the neural model, when used recursively, can predict the state variables over a long prediction horizon with sufficient accuracy. In addition, neural networks can adapt rapidly to changes in fermentation dynamics.

Optimizing control of a continuous stirred tank fermenter using a neural network

Optimizing control of a continuous stirred tank fermenter using a neural network

Optimization and control of a continuous stirred tank fermenter using learning system

A variable structure learning automaton is used as an optimization and control of a continuous stirred tank fermenter. The algorithm requires no modelling of the process. The use of appropriate learning rules enables to locate the optimum dilution rate in order to maximize an objective cost function. It is shown that a hierarchical structure of automata can adapt to environmental changes and can also modify efficiently the domain of variation of the control variable in order to encompass the optimum value.

Control of a bioreactor using a neural network

This paper describes an experimental investigation concerning the use of neural networks to achieve the non-linear control of a continuous stirred tank fermenter. The influent dilution rate and the substrate concentration have been selected as control variables. The backpropagation learning algorithm has been used for both off-line and on-line identification of the inverse model which provides the control action. Experimental results show the performance and the implementation simplicity of this control approach.

On‐line prediction of fermentation variables using neural networks

This article presents an introduction to the use of neural network computational algorithms for the dynamic modeling of bioprocesses. The dynamic neural model is used for the prediction of key fermentation variables. This relatively hew method is compared with a more traditional prediction technique to judge its performance for prediction. Illustrative simulation results of a continuous stirred tank fermentor are used for this comparison. It is shown that neural network models are accurate with a certain degree of noise immunity. They offer the distinctive ability over more traditional methods to learn very naturally complex relationships without requiring the knowledge of the model structure.

Improved Bioreaction Kinetics for the Simulation of Continuous Ethanol Fermentation by Saccharomyces cerevisiae

AbstractA kinetic model for the production of ethanol by Saccharomyces cerevisiae has been developed from semiempirical analysis. The values for the parameters in this model were then determined by nonlinear multiple regression using the data of Bazua and Wilke ( 1977). The final equations were μ=0.427s(1‐(p/101.6)1.95)/(0.245+s), YX/p=0.291, and YX/s=0.152(1‐p/302.3). This model was then used to simulate a continuous stirred tank fermentor (CSTF) and compared to other models using the same experimental data but different kinetics. The equations required to use these kinetics in a CSTF with recycle were then developed. From this simulation, it was found that, for a CSTF with recycle, the best configuration to operate is an external recycle, with a low bleed and recycle ratio.

Continuous alpha-amylase production using Bacillus amyloliquefaciens adsorbed on an ion exchange resin

A method for the continuous production of extracellular alpha amylase by surface immobilized cells of Bacillus amyloliquefaciens NRC 2147 has been developed. A large-pore, macroreticular anionic exchange resin was capable of initially immobilizing an effective cell concentration of 17.5 g DW/1 (based on a total reactor volume of 160 ml). The reactor was operated continuously with a nutrient medium containing 15 g/l soluble starch, as well as yeast extract and salts. Aeration was achieved by sparging oxygen enriched air into the column inlet. Fermentor plugging by cells was avoided by periodically substituting the nutrient medium with medium lacking in both soluble starch and yeast extract. This fermentor was operated for over 200 h and obtained a steady state enzyme concentration of 18700 amylase activity units per litre (18.7 kU/l), and an enzyme volumetric productivity of 9700 amylase activity units per litre per hour (9.7 kU/l-h). Parallel fermentations were performed using a 2 l stirred vessel fermentor capable of operation in batch and continuous mode. All fermentation conditions employed were identical to those of the immobilized cell experiments in order to assess the performance of the immobilized cell reactor. Batch stirred tank operation yielded a maximum amylase activity of 150 kU/l and a volumetric productivity of 2.45 kU/l-h. The maximum cell concentration obtained was 5.85 g DW/l. Continuous stirred tank fermentation obtained a maximum effluent amylase activity of 6.9 kU/l and a maximum enzyme volumetric productivity of 2.73 kU/l-h. Both of these maximum values were observed at a dilution rate of 0.345 l/h. The immobilized cell reactor was observed to achieve larger volumetric productivities than either mode of stirred tank fermentation, but achieved an enzyme activity concentration lower than that of the batch stirred tank fermentor.

Effect of dilution rates on the amount of wasted substrate during alcohol fermentation

Continuous ethanol production in a one-stage continuous stirred tank fermentor without recycle was carried out using a yeast strain Saccharomyces cerevisiae. Different dilution rates were used. Cell and ethanol concentrations in the culture medium decreased with increasing dilution rates, and the maximum value of 3.0 g l −1 h −1 was found at a dilution rate of 0.340 h −1. Specific ethanol productivities increased as dilution rates were increased, and the highest value appeared at about the same dilution rate as that for the maximum fermentor productivity. A material balance equation, which relates total amount of spent medium to cell synsthesis, ethanol production, and overall maintenance, was introduced. The cellular yield and overall maintenance coefficients increased with increasing dilution rates. The fraction of limiting substrate utilized for overall maintenance, which includes the limiting substrate spent for purposes other than cell synthesis and ethanol production, decreased with increasing dilution rates. The non-product associated substrate utilization can be minimized if correct dilution rate is chosen.

Extractive fermentation-integrated reaction and product recovery

Refinements have been made to a prototype process for the production of ethanol by extractive fermentation. The process is characterized by thein situ extraction of ethanol from a 7 L continuous stirred tank fermenter and the thermal recovery of ethanol from the extracting solvent, which is circulated in a closed loop through the process. Data are provided to show the efficacy and stability of the process under various operating conditions, and the near complete (>96%) continuous conversion of a 300 g/L glucose feed.

Ethanol production by extractive fermentation – solvent identification and prototype development

AbstractThe in situ removal and recovery of inhibitory fermentation products by solvent extraction has numerous beneficial effects (increased reaction rate, fermentation of concentrated feeds, decreased water usage, etc.) which have been confirmed on theoretical grounds. For the development of such an extractive fermentation process, the identification of solvents having desirable physical properties as well as complete biocompatibility with the microorganism is an absolute prerequisite, which, to this point, has not been adequately met. By means of a computer data base, we have systematically screened 1,361 solvents for their suitability for use in an extractive ethanol fermentation, and, through subsequent experimental evaluation of 70 of these solvents, have identified 19 as being appropriate for use in a continuous extractive fermentation process.Details of this screening procedure, and physico‐chemical data of the suitable extraction solvents are presented. A prototype extractive fermentation system, the first to employ a Continuous Stirred Tank Fermentor, is described. Results from mass transfer experiments in this prototype system, together with extractive fermentation experiments involving medium‐strength (ca. 150 g/L) glucose feeds are discussed.

A Mathematical model for ethanol production by extractive fermentation in a continuous stirred tank fermentor

Extractive fermentation is a technique that can be used to reduce the effect of end product inhibition through the use of a water-immiscible phase that removes fermentation products in situ. This has the beneficial effect of not only removing inhibitory products as they are formed (thus keeping reaction rates high) but also has the potential for reducing product recovery costs. We have chosen to examine the ethanol fermentation as a model system for end product inhibition and extractive fermentation and have developed a computer model predicting the productivity enhancement possible with this technique together with other key parameters such as extraction efficiency and residual glucose concentration. The model accommodates variable liquid flowrates entering and leaving the system, since it was found that the aqueous outlet flowrate could be up to 35% lower than the inlet flowrate during extractive fermentation of concentrated glucose feeds due to the continuous removal of ethanol from the fermentation broth by solvent extraction. The model predicts a total ethanol productivity of 82.6 g/L h if a glucose feed of 750 g/L is fermented with a solvent having a distribution coefficient of 0.5 at a solvent dilution rate of 5.0 h(-1). This is more than 10 times higher than for a conventional chemostat fermentation of a 250 g/L glucose feed. The model has furthermore illustrated the possible trade-offs that exist between obtaining a high extraction efficiency and a low residual glucose concentration.

Conditions for the phase–plane analysis of feedback control of chemostat

This article deals with the effect of P-control and Pl-control on the dynamic behavior of a continuous stirred tank fermentor (CSTF). Several conditions concerning the stability of steady states and the existence of limit cycles of the closed-loop system are derived. The application is made to the substrate inhibition model with variable yield coefficient. It is shown how the unfavorable phase-plane trajectories of the uncontrolled CSTF can be altered to favorable ones by the appropriate choice of control parameters based on the conditions derived.

ON THE PARAMETER-SPACE CLASSIFICATION OF THE DYNAMIC BEHAVIOR OF A CONTINUOUS MICROBIAL FLOW REACTOR

Recently Agrawal et al.1 classified the dynamic behavior of continuous stirred tank fermentor for the Monod's model and the two parameter hump function model with variable yield coefficient in the parameter space. We employed the more general three parameter substrate inhibition model which includes the Monod's model as a limiting case, derived the boundary equations which rigorously divide the parameter space of different dynamic behavior, and showed the interesting phenomenon that a limit cycle suddenly vanished for the slight change in the Damkohler number by computer simulation.

Controlling Morphological Instability of Zymomonas mobilis Strains in Continuous Culture

Growth of Zymomonas mobilis ATCC 29191 and CP4 in a continuous stirred tank fermentor resulted in the selection of stable flocculating variants. Factors responsible for enhancing the system pressures selective for the morphological variants were identified. By incorporating some modifications into the design of the fermentor, it was possible to achieve steady-state operation of the chemostat with both wild-type and flocculating strains. Biochemical and microscopic studies were performed to elucidate the mechanism of flocculation in Z. mobilis.

Continuous production of ethanol in a two-stage fermentation process using a protein — Phospholipid complex as a protective agent

A two-stage continuous fermentation process, using a continuous stirred tank fermenter (CSTF) and a tower fermenter (TF) connected in series, has been studied for ethanol production from d-glucose. The addition of a protein-phospholipid complex as a protective agent (PA) in the TF led to a three-fold increase in ethanol productivity and a 23.63% increase in final ethanol concentration in the tower effluent. The results are consistent with our previous findings on a cascade operation of CSTFs, namely, that the addition of PA to the tower increases cell tolerance towards ethanol at ethanol concentrations up to 70 gl −1. Both studies indicate that beyond this experimentally determined critical ethanol concentration, ethanol production is significantly inhibited. Mathematical modelling of the behaviour of a single flocculated yeast floc suggested that, for yeast flocs up to 1 mm diameter, neither internal nor external diffusion of substrate is limiting. Therefore, a simplified mathematical method was developed for the analysis of the TF system. By plotting the calculated values from the derived performance equation and the experimental values of substrate conversion vs. residence time, good agreement was obtained between these two for the addition of PA. However, a small deviation was observed for the PA-free system.